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5S

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Hesham Awesh

on 25 November 2014

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Transcript of 5S

5S
THE SECRET TO JAPANESE
SUCCESS

Prepared by: Eng. Omar Aboul Dahab

Agenda
1. Introduction

1- Introduction to 5S

2- The 5S Process

3- Conclusion

4- Case Study

5- What to do?

Establish a Visual Workplace.
Main Objectives
Organized and Paperless Office
Save Money.
Save Space.
Boost productivity.
Easier to share info.
Minimize Waste.
Electronic Documentation.

Increase Productivity. (~15%)
Improve Safety.
Improve Quality.
Improve Employees Morals.
Minimize Waste.
Minimize Mistakes & Errors.
User Friendly Work Area.

Paperless Office
Visual Workplace
Benefits
A Visual Workplace and a Paperless office begins with implementing a

5S
Program

Housekeeping Technique.

Productivity and Safety Enhancement
Technique.

History The philosophy “5S” begins in the 5´s with the Toyota Production System (TPS).



Definition To create and maintain a method which assures to have
an organized, clean, safe and efficient workplace.


5S History & Definition
A Five S program is usually a part of, and the key component of establishing a Visual
Workplace and are both a part of Kaizen —
a system of continual improvement —
which is a component of lean manufacturing.

In order to achieve high levels of Quality,
Safety and Productivity Employees and/or Workers must have a Conducive* working environment.
…………………………………………………………..
*Conducive:

5S Concept
Is a workplace methodology that uses the list of five

Japanese words which are

(Seiri, Seiton, Seiso, Seiketsu and Shitsuke)

to describe how items are stored and how the new

order is maintained.

Provides a standard approach to Housekeeping.

Helps create a better working environment.

What is 5S?
The five Japanese words transliterated in English:

SEIRI………..….Sort.

SEITON………..Set in Order / Straighten.

SEISO…............Shine / Systematic Cleaning.

SEIKETSU........Standardize.

SHITSUKE…….Sustain.
5S Principles
The 5S Cycle
5S Benefits
Better Control on Work Area.

Improve Productivity.

Improve Quality.

Improve Efficiency.

Improve Safety.

Improve Morals.

Minimize Cost.

Minimize Waste.
Visual Workplace
refers to a workplace that uses a system of visual communication tools
(Visual Controls) that impart information visually at the time and place needed.


Paperless Office
is a work environment at which the use of paper is eliminated or wisely used.

Definitions
All types of business and everyone benefit from having a 5S program.

Manufacturing and industrial plants come to mind first, as those are

the business that can realize the greatest benefits.

However, any type of business, from a retail store to a power plant --

from hospitals to television stations --

all types of businesses, and all areas within a business,

will realize the benefits from implementing and maintaining a 5S program.
What Types of Businesses Benefit from 5S?
The shipyard industry is spending nearly a million dollars to develop a Five S program the industry can use, and to implement that program at two shipyards. On the other hand you can implement a Five S program without adding an extra dollar to your budget.
Your actual costs will depend on where you are :
- Condition of the facility.
- Training Time.
- Purchases.
- Man hour to get the facility cleaned up and organized.
- Time spent to sustain the system.

What will 5S Cost?
5S Target
- Dirtiness refers to untidy, messy and dusty.
- Cleanliness refers to tidy, organized and clean.

TOMORROW
I’ll start my work with cleanliness at my workplace
and I’ll leave it clean.

TODAY
I started my work with dirtiness at my workplace
and I’ll leave it clean.

YESTERDAY
I started my work with dirtiness at my workplace
and I left it dirty.
5S Methodology
2. The Process
1. Sort
1. Sort (Cont.)
2. Set in Order
3. Shine
Examples
Identified

Sorted

Examples (Cont.)
Recycling Identification
Examples (Cont.)
Color Coded Scrap Hoppers
Workshop
Tools
Examples (Cont.)
Notice Board
Folders Shelves
Examples (Cont.)
Shop Floor
Examples (Cont.)
Coffee Room
Identifying by Numbers
Identifying by Colors
Examples (Cont.)
Do…
Don’t…
Examples (Cont.)
Do…
Don’t…
Examples (Cont.)
Visual Communication
Examples (Cont.)
Examples (Cont.)
STOP

Both Visual & Audio Controls

Visual Controls

12

11

10

9

8

7

6

5

4

3

2

1

4. Standardize
5. Sustain
3. Conclusion
5S Circle
Neat & Clean Work Area.
No Obstruction.
Smooth Working.
Improved Productivity.
Improved Quality.
Improved Safety.
Minimized Waste.
Minimized Cost.
Employees Motivated.
Work Areas become Spacious.
Customers & Visitors Impressions. (Co. Image)
Better Control on Work Area. (Visual Control)
5S Outcomes

ONE MUST LOCATE THE ITEM WITHIN THIRTY (30) SECONDS IF 5S PROGRAM IS PROPERLY IMPLEMENTED.


ALSO APPLIES TO THE ELECTRONIC RECORDS RETRIEVAL.
5S Test (30 Seconds Rule)
5S Locations
4. Case Study
On May 26th,2010 Arabian Cement 5S Leader made a random tour to check Headquarters status and his camera captured the coming photos for incorrect situations, the outcomes were not very good. (All photos are real)

Before going through the photos kindly :
- Do not mention departments names or employees names.
- Do not take the photos personally.
- The purpose is to get the lessons learned behind each photo,
not to criticize or throw blames.
- Comments were added to some of the photos not to be
sarcastic but to highlight the negative situation.


The Tour
Narrow and obstacles…
Security kiosk or box…
The Tour (Sample Photos)
Cleaning tools…
Garage traffic…
The Tour (Sample Photos)
No comment…
No comment…
The Tour (Sample Photos)
Multi… desk
Filing or Piling…
The Tour (Sample Photos)
Domino filing…
Just fit in…
The Tour (Sample Photos)
New uniform boxes…
All in one…
The Tour (Sample Photos)
Old logo items…
Just left over…
The Tour (Sample Photos)
No comment…
No comment…
The Tour (Sample Photos)
Floor filing…
Waiting chair filing…
The Tour (Sample Photos)
Boxes, praying carpet…
Archive room…
The Tour (Sample Photos)
The step…
Empty notice board…
The Tour (Sample Photos)
No comment…
Wall not floor…
The Tour (Sample Photos)
Fix…
Discard or fix…
The Tour (Sample Photos)
Desktop filing…
Corner filing…
The Tour (Sample Photos)
This is a waste of time…
Don’t judge if you don’t know...

I don’t have the time for this...
Time management might help…

It’s not a priority…
No harm to set priorities…

We are still a growing company…
Till when…

In my previous job no one asked me to do that…
Welcome to Arabian Cement…

I wish to work in a multinational environment…
Why don’t we make our own…

Common Sayings & Answers
If you say this, then please…
OR ELSE…
5. What to do?
Your work area is your responsibility.


Follow the visual communications signs.


Feedback/Comments/ Suggestions.

“Don't waste time looking for barriers, perhaps there are none ”
Franz Kafka
Full transcript