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5 S IMPLEMENTATION

BY:
ERWAN KARTIKA

INTRODUCTION

OF 5 S

There are 3 different types of


workplace
a. 3rd class workplace
with people throwing rubbish around but none to
clean up.
b. 2nd class workplace
with people throwing rubbish around and another
group of people cleaning up.
c. 1st class workplace
without anybody throwing any rubbish and yet
everybody is cleaning up.

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Do these points describe your
company work areas?
Space is crowded with parts and tools
Unneeded items are stacked between workers
Excess inventory on the floor
Excess items and machines make it difficult to
improve process flow
Equipment is dirty and a collection point for
miscellaneous materials
Needed equipment such as tools are difficult to
find

5S GOOD HOUSEKEEPING

WHAT IS 5S ?

5S is a set of TECHNIQUES
providing a standard approach
to GOOD HOUSEKEEPING
within the ORGANIZATION

About 5S

A cornerstone of 5S is that
untidy, cluttered work/study areas
are not productive.

People are happier


in a clean and tidy environment
and hence are inclined to work hard with
due care and attention.

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WHY DO IT?

QUALITY EFFICIENCY

5S
SAFETY ELIMINATING
BREAKDOWNS

QUALITY
Defects reduced by mistake proofing.
Clear methods and standards are established
Visible results enhance the generation of more
and better ideas
Customer complaints are reduced

EFFICIENCY
Time is wasted looking for tools, equipment and
paperwork, etc
A clean and tidy workplace leads to greater well
being and increased motivation
Team working makes unexciting work more
rewarding
Changeover time reduced by streamlining
operations.

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ELIMINATE BREAKDOWNS
Breakdowns and minor stops eliminated
on production lines
Clear labelling and routine maintenance
are essential disciplines
A clean workplace highlights problems
early

SAFETY
Dirty cluttered workplaces are not safe
Safety depends on good care and
organisation
Workplace becomes cleaner, better
organised and safer

THE 5S PRINCIPLES

SEIRI SORT
SEITON SYSTEMATIZE
SEISO SWEEP, SHINE, SCRUB
SEIKETSU STANDARDIZE
SHITSUKE SELF-DISCIPLINE

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THE 5S PRINCIPLES

5S IMPLEMENTATION BY
PDCA

5 S PREPARATION - PLAN

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1. Forming 5S Committee.
a. Steering Committee
Who are the 5 S steering committee?

Comprise of top management e.g.


1. MD/CEO as a advisor
2. GM as a chairman
3. HoD as a facilitator.

1. Forming 5S Committee.
What are the Roles & Responsibilities of Steering
Committee
To decide on the overall direction for the
implementation of the 5S Programme.
To form the implementation plan.
To decide on budget and financial resources.
To set policies, regulations as well as guidelines.
To identify committee members and team
leaders.
To set reward system.

1. Forming 5S Committee.
b. To appoint 5 S committee members:

i. Promotional committee
ii. Audit committee
iii. Leader on each department/zone/area/

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5S COMMITTEE CHART

1. Forming 5S Committee.
Promotional Committee Roles & Responsibilities

Promote 5S campaigns including training


Identify and recommend promotional activities.
Recommend and grant rewards or recognition
to individuals / groups who have participated
or won in the promotional activities.

1. Forming 5S Committee.
Audit Committee Roles & Responsibilities

Develop 5S evaluation criteria & guidelines


To conduct 5S Internal Audit.
Submit audit summary report to top management

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1. Forming 5S Committee.
Facilitator Roles & Responsibilities

Support 5S implementation.
Communicate with everyone involved.
Motivate work groups.
Ensure employee implementation plan.
Monitor measurement systems.

1. Forming 5S Committee.
Zone Leader Roles & Responsibilities

Participate in work group implementation


process.
Communicate with everyone involved.
Monitor progress of group activities.
Ensure every employees participate with full
commitment

2. SET-UP 5S ZONES
Obtaining the layout of the entire work area and
dividing each section into small zones
Assigning one team to each section, identify the
number of people per team, and displaying the
names of team members, leader and their areas
Ensuring that section size and team strength are
uniform

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2. SET-UP 5S ZONES

Facilitators divide each section into zones

3. TRAINING
5 S awareness training to everybody
5 S implementations
5 S Internal audit to Audit committee

4. 5 S KICK OFF

Inform all Assemble all


employees employees
of kick-off

Kick-off
Explain
Declare
the activity
the policy

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5 S IMPLEMENTATION - DO

SORT

Decide what you need

Remove unnecessary clutter

All tools, gauges, materials, classified and stored

Remove items which are broken, unusable or


only occasionally used

SORT
PRIORITY FREQUENCY OF USE HOW TO USE

Low Less than once per year Throw away


Once per year Store away from
the workplace
Average At least 2/6 months Store together but
Once per month offline
Once per week
High Once Per Day Locate at the
workplace

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SORT
SORTING

SCRAP NOT IN WORKING ORDER IN WORKING ORDER

Reworkable Rejected Necessary Unnecessary Usable Item

Rework Discard Repairable Unrepairable No Potential Use Potentially Useful Req Spl Disposal

Usable Item Repair Discard Discard Move to Req Arrange


Location Disposal

Usable Item Usable Item Discard

Red tag strategy

Before sort after sort

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Before sort after sort

SET IN ORDER
To arrange necessary items in a neat
and systematic manner so that they can
be easily retrieved for use and to return
after use.

SET IN ORDER
1. Painting strategy
Is a method for identifying locations on floors
and walk ways

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SET IN ORDER
2. Color-Coding strategy

SET IN ORDER
4. Outlining strategy

SET IN ORDER
5. Signboard strategy
Signboards are used to identify what, where
and how many e.g.
Location indicator
Item indicator
Amount indicator

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SET IN ORDER

Workplace Checkpoints:-
Walkways and storage places clearly marked?
Tools classified and stored by frequency of use?
Pallets stacked correctly?
Safety equipment easily accessible?
Floors in good condition?
Lights / Reflectors clean?

SHINE / SWEEP / SCRUB


Create a spotless/clean workplace
Identify and eliminate causes of dirt and
grime remove the need to clean
Sweep, dust, polish and paint

SHINE / SWEEP / SCRUB


1. Divide areas into zones
2. Delegate Cleaning Assignments
3. What is to be Cleaned.
4. Methods to be Used.
5. Prepare the Cleaning Tools and
Materials.

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SHINE / SWEEP / SCRUB
CLEANING STATION

Before shine after shine

STANDARDIZE
To maintain a high standard of workplace
organisation by keeping everything clean
and orderly at all times.

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STANDARDIZE
Standardize activities by:
Sustaining five-minute daily clean up habit
Keeping a balance between personal
cleanliness and the cleanliness of the
environment / work place
Avoiding littering. Learning to pick-up tiny pieces
of waste around
Regularly audit using checklists and measures
of housekeeping

SUSTAIN
To train people to practise the 5S system
continuously so that it becomes habitual
and ingrained in the culture of the
organisation.

SUSTAIN
Instilling the ability of doing things
the way they are supposed to be done
Becoming a role model by treating
your work place as your second home
Influencing others to join in keeping
a well-maintained work place.
Aiming for constant improvement

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SUSTAIN
Example Techniques to sustain
5S Slogan
5S poster
5S newsletter and kaizen board
5S audit
awarding systems
Big cleaning day
5S month
Benchmarking tour

5 S AUDIT CHECK

5S Internal Audit
Audit Committee to determine:
a. Audit criteria
b. Internal auditor
c. Audit frequency audit plan & schedule
d. Audit checklist & report
e. Display report at 5S Corner of every
department

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5S Internal Audit
sample of criteria

5S Internal Audit
sample of criteria

5S Internal Audit
sample of criteria

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Sample of Audit Report

5 S IMPROVEMENT ACT

IMPROVEMENT
Audit finding contribute to the
improvement process by evaluating
the conformance to the 5 S criteria.
Correction and corrective action shall
be responded by the department
concern to improve the 5 S status.

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GAP ANALYSIS
WORKING IN GROUP
Determine the gaps between your
organizations practices
and
the identified criteria that you have
learnt above.

GAP ANALYSIS

KEYS TO 5S SUCCESS
In order for the 5S system to be successful,
the most important factor is the commitment,
participation and involvement of
EVERYONE and strong visible support from
top management.

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THANK YOU

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