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It is a very effective approach to improving our work,environment and total quality. It becomes a base for continuous improvement in the organisation
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Summary
housekeeping.
It is today gaining strong support in most industries, especially in Japan and there are increasing number of companies which are implementing 5s with greater involvement of people within the organisation.
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Workplace becomes clean and better organised Shopfloor and office operations become easier and safer Results are visible to everyone insiders and outsiders Visible results enhance generation of more new ideas People are automatically disciplined People become proud of a clean and organised workplace Resultant good company image generates more business etc.
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Happier employees with high morale. Greater people involvement. Low employee turnover. Increased number of suggestions. Better use of floor space. Less work-in-progress and inventories. Better flow of work. Low machine breakdown rates. Low accident rates. High yield of materials. High product quality.
The assumption why 5S is becoming so popular in Japan in recent years and in other countries today is that it emphasizes a peopleoriented and also practice-oriented approach. 5S expects everyone-indeed everyone-to participate in it. It is based on the belief that every individual can contribute to improving his/her workplace where he/she spends one-third of his/her life.
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What is 5S?
The concept of good housekeeping has been with the Japanese for a very long time.At home and in school ,children are disciplined to adhere to good housekeeping practices.However, it was only in the early 1980s that good houskepping became a pertinent issue in Japanese industries as companies realised its powerful contribution to productivity and quality improvement. The basis for good housekeeping in Japanese companies is a concept popularly known as 5S.This stands for the five good housekeeping concepts in Japanese.
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Why a 5-Smovement
Human beings feel good if work place is clean and well organised. 2. Helps in reducing time a. For searching things b. For handling 3. Helps in reducing a. Waste, inconsistencies & strain b. Unnecessary items & reserve stock c. Space requirement d. Machine downtime e. Rejection / Rework f. Number of accidents Helps people a. In seeing things more clearly b. In changing mindsets-develop a proactive attitude
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Meaning of 5S
1. Segregation (SEIRI)
2. Arrangement (SEITON)
3. Cleaning (SEISO) 4. Maintenance of standards (SEIKETSU) 5. Discipline (SHITSUKE)
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What is 5S??
5S
1S 2S
Original Japanese
SEIRI SEITON
Meaning in English
Sort out unnecessary items in the workplace and discard them Arrange necessary items in good order so that they can be easily picked for use A place for everything Everything in its place Clean your workplace thoroughly so that there is no dust on floors,machines and equipments
3S
SEISO
4S 5S
SEIKETSU SHITSUKE
Maintain high standards of workplace at all times Train people to follow good housekeeping discipline automatically
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Segregation ---SEIRI
It helps to segregate necessary and unnecessary items and eliminate unnecessary items. It essentially means organising / putting things in order. ACTIVITIES 1. Go through what you have 2. Segregate/identify what you need 3. Categorise needed/not needed items 4. Discard What Is Unnecessary
INDICATOR OF SUCCESS 1. Decrease in unnecessary items and reserve stock 2. Percentage of area / space saved
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Putting in order
Things needed
Potentially usefull
No potential use
Cleaning ---SEISO
This step eliminates dirt, dust and other foreign matter to make workplace clean and polished. ACTIVITIES 1. Clean equipment, tools, furniture, records,etc. 2. Keep the workplace spotless 3. Sweeping, wiping, polishing, painting,etc. INDICATOR OF SUCCESS 1. Reduction in machine downtime 2. Increased life of the machine parts 3. Reduction in number of accidents 4. Reduction in rejection / rework
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What is an Abnormality ?
An abnormality is any gap between actual performance and the appropriate standard
EXAMPLES
Alert us to an abnormality Help us monitor quickly Promote adherance and prevention Enable successful self management
Reduce errors / waste by making problems visible Identify gap between standard and actual performance
Visual controls
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2. Danger alerts/cautions
3. Direction/locations
4. Equipment Designations
5. Planned programmes 6. Preventive maintenance/Calibration displays 7. Appeals
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The Elements of 5S
DISCIPLINE Adherance to standards developed through 4S steps by all employees of the workplace
ORGANISING/PUTTING CLEANING things in order sorting Keeping things clean and 1.Removing what is not needed polished,No trash or dirt 2.Keeping what is needed anywhere in the workplace
ARRANGEMENT MAINT.OF STANDARDS Placing things so that people Mainting cleanliness after can easily reach what they organisation ,arrangement need whwnever they need it and cleaning and establishing
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5 Levels of housekeeping
LEVELS 1. Horizontal surfaces/floor full of unwanted material. 2. Vertical surfaces / areas near walls having clutter. 3. Horizontal ,vertical surfaces clean and have no unwanted items.However,storage areas, record rooms disorganised. 4. Storage areas ,machines,offices are clean.All materials ,furtinuture,documents properly organised,labelled and numbered. 5. Factory/office is immaculate at all times.
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Level 1 of Housekeeping
Work area is in level 1 of housekeeping if, Cigarette butts/Gutkha pouches Scraps of paper Tools (Used or Unused) Packing and clamping materials Support structures Left -over raw material Obsolete documents Bulky files Unused equipment,machine etc are scattered around all over the workplace.
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Look at all horizontal surfaces Examine the entire work floor.Eliminate all garbage and non- essential items on floor,shelves,tabletops etc Remove unnecessary papers from files Discard old files,stationery etc Make a definite place for all tools/documents,files and parts that are lying on the floor tabletops
Do not put anything directly on the floor As much as possible, throw/dispose off things that have no clear foreseeable use.
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Level 2 of housekeeping
Work area is in level 2 of housekeeping if there is no litter or unused material on the floor/horizontal surface, but
Look at vertical surfaces Examine walls and columns Eliminate all garbage and non- essential items leaning against the walls/columns Paint all walls and columns that can be reached by hand
Level 3 of housekeeping
Work area is in level 3 of housekeeping if the walkways are clear and the factory/office is clean,but the tools,materials,papers and files are still disorganised in the storage areas,record rooms,drawers,filing racks etc. Tools ,parts,clamps are all mixed together Gloves,shoes etc are thrown in with tools in the toolbox Drawers,shelves are disorganised All tools are in locked storage units Drawers,shelves are locked and keys are missing Unused and worthless items found inside closed cabinets
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Look inside the shelves and sort the papers, material ,parts and tools Get rid of locked cabinets Make separate storages for tools,parts,clamps, documents etc. Make the above area distinct and clear
HINT FOR IMPROVEMENT Remove the back and sides of all the storage cabinets
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Level 4 of housekeeping
At level 4,the work area will have, Machines,equipment,furnitures spotlessly clean Storage areas clearly marked and distinguished
Level 5 of Housekeeping
At level 5,the work place is immaculate at all times.It witnesses, Constant and continual cleaning by all employees Origins of rubbish are removed so that dirt,clutter and garbage are eliminated at source Tools,items and materials can be found at a glance Inventory levels can be found visually Production runs smoothly High product quality achieved
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Workplace rating
In third rate workplace ,people leave trash and no one stops to pick it up In second rate workplace, people leave trash but others pick it up In first rate workplace, no one leaves trash,but people would pick it up, if they saw it.
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A clean workplace is high in PRODUCTIVITY A clean workplace has high QUALITY A clean workplace keeps COST down A clean workplace ensures DELIVERY on time A clean workplace is SAFE for people to work A clean workplace is high in MORALE
The programme would be more effective when it is included in the small group activities like Quality Circles.34
The programme should be practised during working hours as an authorized programme,but should not be treated as casual or extra activity during overtime or off duty hours.
Everyone should be officially informed of the significance of the programme. The CEO should personally make an official announcement of the launching of the programme at an information sharing meeting attended by all people of the organisation.
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The CEO himself should be keen and committed and have a vested interest in the programme. The CEO should not delegate the leadership to other people. The CEO should exercise his leadership in 5S steering committee.
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Each committee member should keep everyone informed of the current progress of 5S implementation on a departmental level.
Each committee member should encourage and guide his people for involvement in 5S implementation activities.
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Banners,slogans,posters and newsletters should be fully utilized to draw attention of everyone to this programme An easy handbook or a pamphlet illustrating Why 5S What is 5S and How to implement 5S should be printed and distributed to everyone. Periodic 5S implementation review should be conducted by CEO or an external expert for comments and updating the status quo. Basic in-house training and introduction to model companies that have successfully implemented 5S practices would not only provide the necessary skills but also give an insight into how other companies implement 5S. After the company has attained a certain level of implementation,participation in Inter- company 5S competition should provide greater motivation for further 38 improvement.
The CEO should tour the factory from time to time and point out strengths and weaknesses of 5S implementation in each workplace. The CEO should advise 5S steering committee to take corrective action in the areas identified. The CEO should check the progress of the implementation. The CEO should give recognition to improved or better practice.
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5S especially at SEITON requires certain Kaizen principles and skills which can be acquired via external or well organised in-house training programmes. SEITON requires logical problem-solving approaches.In this sense,it can well be a good theme for Quality Circle activities.
SEITON also requires creative ideas from everyone.Therefore,it can be tied in with and employee suggestion scheme.
Successful implementation of 5S will,by itself,bring about various tangible results.It is also a necessary step for a company to go through before implementing advanced management technologies such as TQC,JIT and TPM because 5S buildsup a solid foundation for SHITSUKE.
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Greater team spirit and co-operation can be built up through involvement of all within an organisation. Employees will be disciplined to follow safer and better ways of work,resulting in lesser risks to accidents. Employees would be more conscious of improvement which leads to greater efficiency and effectiveness.
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Machine troubles can be detected at an earlier stage to prevent a major breakdown, when machines are cleaned daily by people operating them. Daily cleaning of measuring instruments will ensure accuracy and reliability. Life of machines and tools can be extended significantly when they are handled with care and placed in the designated locations.
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Clean workplace will ensure that final products will be free from dust.
Sales people will be eager to show customers the plant as a marketing tool.
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Housekeeping to Happiness
Housekeeping means Orderliness Orderliness leads to Cleanliness Cleanliness leads to Quality Quality leads to Productivity Productivity leads to Prosperity Prosperity means Happiness
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