Professional Documents
Culture Documents
BY:
ERWAN KARTIKA
INTRODUCTION
OF 5 S
Together, we CARE 1
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.
Together, we CARE 2
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.
Together, we CARE 3
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
Together, we CARE 5
1. Forming 5S Committee.
a. Steering Committee
Who are the 5 S steering committee?
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
1. Forming 5S Committee.
Audit Committee Roles & Responsibilities
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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
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
Together, we CARE 8
2. SET-UP 5S ZONES
3. TRAINING
5 S awareness training to everybody
5 S implementations
5 S Internal audit to Audit committee
4. 5 S KICK OFF
Kick-off
Explain
Declare
the activity
the policy
Together, we CARE 9
5 S IMPLEMENTATION - DO
SORT
SORT
PRIORITY FREQUENCY OF USE HOW TO USE
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SORT
SORTING
Rework Discard Repairable Unrepairable No Potential Use Potentially Useful Req Spl Disposal
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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
Together, we CARE 13
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?
Together, we CARE 14
SHINE / SWEEP / SCRUB
CLEANING STATION
STANDARDIZE
To maintain a high standard of workplace
organisation by keeping everything clean
and orderly at all times.
Together, we CARE 15
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
Together, we CARE 16
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
Together, we CARE 17
5S Internal Audit
sample of criteria
5S Internal Audit
sample of criteria
5S Internal Audit
sample of criteria
Together, we CARE 18
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.
Together, we CARE 20
THANK YOU
Together, we CARE 21