1、 5STHE SECRET TO JAPANESE SUCCESS nWHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACEnHIGH ABSENTEEISMnHIGH TURNOVERnDEMOTIVATED EMPLOYEESnDISORDERED/ CLUTTERED ENVIRONMENTnMISTAKES/ERRORSnTHE SOLUTION TO ALL THESE PROBLEMS IS 5S 5S HOUSEKEEPING TECHNIQUEPRODUCTIVITY AND SAFETY ENHANCEMENT TECH

2、NIQUEIDEA BEHIND 5SnIN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENTWHAT IS 5S?nDeveloped by the JapanesenHousekeeping SystemnHelps Create a Better Working Environment and a Consistently High Quality ProcessTHE 5S PRINCIPLESnSEIRI

3、 Organisation/Sort outnSEITON Orderliness/SystemizenSEISO The Cleaning/ShiningnSEIKETSU STANDARDIZEnSHITSUKE - Sustain/DisciplineDISCOVERY OF 5SnThirty years ago researchers started studying the secret of success of Japanese manufacturing companies n5S turned out to be the most impressive secretnThe

4、 factories were so well organized that abnormal situations were readily apparent DISCOVERY OF 5SnEquipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seennThis passion of cleanliness and orderliness became a hallmark of Japanese organizati

5、onsADVANTAGES OF 5SnIf tools and materials are conveniently located in uncluttered work areasnOperators spend less time looking for items nThis leads to higher workstation efficiency, a fundamental goal in mass production ADVANTAGES OF 5SnA clean and tidy workplace leads to greater well being and in

6、creased motivationnCompany image improvesADVANTAGES OF 5SnHealth and Safety is ensurednMachine maintenancenQuality nProductivitynLean ManufacturingADVANTAGES OF 5SnRESULTS IN A PLACE EASIER TO MANAGEnSMOOTH WORKING NO OBSTRUCTIONnNO DEVIATION, NO PROBLEMSnB/C EVERYONE KNOWS WHERE THE THINGS ARE SPPO

7、SEDF TO BEADVANTAGES OF 5SnTIME SAVING nQUICK RETRIEVALnACCIDENTS & MISTAKES MINIMIZEDnINCREASES SPACEnCREATES WORKPLACE OWNERSHIPADVANTAGES OF 5SnFOUNDATION OF ALL QC TOOLSnCONTINUOUS QUALITY IMPROVEMENTnLEAN MANUFACTURINGnKINDERGARTEN OF QUALITY TOOLS & TECHNIQUESADVANTAGES OF 5SnVISUAL MA

8、NAGEMENT SYSTEMnVISUAL CONTROL TO SEE THE ABNORMALITIESnSIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE CONDITION( NORMAL/ ABNORMAL)nA LOOK AT THE PROCESS REVEALS ITS DIRECTION (RIGHT/WRONG)Lean ProductionnThe latest incarnation of JITnBased on Toyota Production System.nWaste eliminationnWidely

9、used in automotive manufacturing & other repetitive mfg.Its a mindset & commitment to achieve a totally waste-free operation thats focused on your customers success achieved by simplifying and continuously improving all processesIts the elimination of waste Everywhere while adding customer v

10、alueLean production cuts costs & inventories rapidly to free cash, which is criticalIt also supports growth by improving productivity & quality, reducing lead times, and freeing huge amounts of resources.For example, lean production frees office and plant space and increases capacity so comp

11、anies can1.Add product lines 2.In-source component production3.Increase output of existing products without acquiring new facilities. KINERGARTEN OF ALL THE QC TOOLSn5S IS THE STARTING POINT OF ALL THE QC TOOLSnCOULD BE SAID AS THE PRE- REQUISITE OF ALL QC TOOLSMETHODOLOGY OF 5S1. ORGANISATION(SEIRI

12、)nDecide what you neednRemove unnecessary clutternAll tools, gauges, materials, classified and then storednRemove items which are broken, unusable or only occasionally usedRED TAG TECHNIQUEnGIVE STAFF RED LABELSnASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACEnASK IF NEEDED & THOSE THAT ARE

13、NEEDED,IN WHAT QUANTITYnNOT NEEDED RED TAG IT nSTORE IN THE RED TAG AREA RED TAGFor wavering itemsnPLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEKnALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMSnAT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNEDREDTAGORGANISATIONPRIORITYFREQUENCY O

14、F USEHOW TO USELowLess than once per yearOnce per yearThrow awayStore away from the workplaceAvg.Once per monthOnce per weekStore together but offlineHighOnce Per DayLocate at the workplace2. ORDERLINESS(SEITON)nONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMSnNOW TURN TO THE LEFT OVER ITEMSORDERLINE

15、SS(SEITON)Organise layout of tools and equipmentDesignated locationsUse tapes and labels Ensure everything is available as it is needed and at the “point of use”O(jiān)RDERLINESS(SEITON)Workplace Checkpoints:-nPositions of aisles and storage places clearly marked?nTools classified and stored by frequency

16、of use?nPallets stacked correctly?nSafety equipment easily accessible?nFloors in good condition?3. SEISO (CLEAN/SHINE)nCreate a spotless workplacenIdentify and eliminate causes of dirt and grime remove the need to cleannSweep, dust, polish and paintSEISO (CLEAN/SHINE)nDivide areas into zonesnDefine

17、responsibilities for cleaningnTools and equipment must be owned by an individualnFocus on removing the need to clean4. SEIKETSU (STANDARDISE)nGenerate a maintenance system for the first threenDevelop procedures, schedules, practicesnContinue to assess the use and disposal of itemsnRegularly audit us

18、ing checklists and measures of housekeepingnReal challenge is to keep it clean5. SHITSUKE (SUSTAIN / DISCIPLINE)nMeans inoculate courtesy & good habitsnDriving force behind all 5SnDemings point number 1: Constancy of purposenMake it a way of lifenPart of health and safetynInvolve the whole workforce*nDevelop and keep good habitsLITMUS TEST FOR 5Sn30 SECOND RULEnONE MUST LOCATE THE ITEM WITH IN 30 SECOND IF 5S IS PROPERLY IMPLEMENTEDnALSO APPLIES TO THE ELECTRONIC RECORDS RETRIEVALWHAT U HAVE COME ACROSS A