5S

HOUSE KEEPING
HOUSE KEEPING IS A PROCESS WHEREIN EVERYONE IN THE COMPANY IS COMMITTED AND INVOLVED IN UPKEEPING OF THE WORK PLACE AND CLEANLINESS OF MACHINE, MATERIAL, ETC., SUCH THAT ONLY NEEDED MATERIAL IS KEPT AND ITS FASTEST ACCESSIBILITY IS ENSURED.

5 S - PRINCIPLES OF HOUSE KEEPING

SEIRI SEITON SEISO SEIKETSU SEGREGATION ARRANGEMENT CLEANING MAINTANCE OF STANDARDS/ STANDARDIZATION DISCIPLINE

SHITSUKE

WHAT IS 5S ?
SEIRE Sort out unnecessary items in the workplace and discard them

SEITON Arrange necessary items in good order so that they can be easily picked for use  A place for everything  Everything in its place

SHITSUKE
Train people to follow good house keeping discipline autonomously

SEISO Clean your work place completely so that there is no dust on the floor, machines and equipment.

SEIKETSU

Always maintain high standard of house keeping at work place in the organization

IMPORTANCE OF 5S

PRODUCTIVITY A CLEAN WORKPLACE HAS HIGH QUALITY A CLEAN WORK PLACE KEEPS COST DOWN A CLEAN WORK PLACE ENSURES DELIVERY ON TIME A CLEAN WORK PLACE IS SAFE FOR PEOPLE TO WORK A CLEAN WORK PLACE ENHANCES MORALE
A CLEAN WORKPLACE IS HIGH IN

5 S is BASICS to PRODUCTIVITY & IMPROVEMENT

PRODUCTIVITY QUALITY COST DELIVERY Safety MORALE

: Quality work life : No defect : No waste : No delay : No accident : Good team work

STEPS OF HOUSE KEEPING A PICTORIAL VIEW

SEIRE (SEGREGATION)
TAKE OUT UNNECESSARY ITEMS AND THROW THEM AWAY

THIS STEP DISTUINGUISHES WANTED AND UNWANTED ITEMS AND ELIMINATES UNWANTED ITEMS ACTIVITIES: a ) SORT THROUGH AND THEN SORT OUT. b) SORT THROUGH WHAT YOU HAVE IDENTIFIED, WHAT YOU NEED AND DISCARD WHATS UNNECESSARY. INDICATOR OF SUCCESS AREA OR PERCENTAGE OF SPACE SAVED

HOW TO PRACTICE SEIRE ? (SEGREGATION)

DEVIDE INTO GROUPS THINK ABOUT HOUSE KEEPING IN YOUR WORKPLACE FOLLOW STEPS GIVEN BELOW TO PRACTICE SEIRE ?

HOW TO PRACTICE SEIRE (SEGREGATION)

STEP I
- LOOK AROUND YOU -SEPARATE OUT THINGS YOU DO NOT NEED

STEP II
- ARE THERE THINGS BELONGING TO OTHER PEOPLE / COMPANY WHICH SEEMS UNNECESSARY ? - PASTE A DISPOSAL NOTICE ON THE OBJECT

STEP III
- CHECK DISPOSAL NOTICE AFTER SCHEDULE DATE - ACT ACCORDING TO REPLY

STEP IV - SET OBJECTIVES AND STANDARDS ON THE CRITERIA

TO RETAIN AND THROW AWAY THING.

SEITON ( ARRANGEMENT )
ARRANGE REQUIRED ITEMS IN ORDER SO THAT THEY CAN BE EASILY PICKED UP FOR USE

A PLACE FOR EVERY THING AND EVERYTHING IN ITS PLACE

SEITON (ARRANGEMENT) THESE STEPS ENABLES DETERMINATION OF THE TYPE OF STORAGE SYSTEM AND LAYOUT, THAT ACCOMODATES REQUIRED ITEMS FOR EASY ACCESSIBLITY

ACTIVITIES
1) SET THINGS IN ORDER BY CREATING PLACE FOR EVERYTHING 2) KEEP EVERY THING IN ITS PLACE 3) KEEP ACCESSIBILITY AS EASY AS POSSIBLE 4) USE THE PRINCIPLEE OF WIDE RANGE AND SHALLOW DEPTH FOR STORAGE SUCCESS INDICATOR 1) TIME SAVED IN SEARCHING 2) TIME SAVED IN HANDLING THE MATERIAL

SEITON (ARRANGEMENT)

DEVIDE INTO GROUPS AFTER SEGREGATION, FOLLOW THE STEPS GIVEN BELOW, TO ARRANGE ITEMS / PRACTICE SEITON.

HOW TO PRACTICE SEITON

STEP I
- LOOK THE WAY THINGS ARE ARRANGED - REMEMBER EVERYTHING SHOULD BE IN ITS PLACE - DECIDE WHICH THING SHOULD BE WHERE

STEP II

- THE MORE YOU USE - CLOSER YOU KEEP

- LEAST USED MATERIAL SHOULD ALSO HAVE A PROPER PLACE FOR EASY LOCATION

STEP III

- ASSUME YOU WILL FORGET WHERE YOU

PLACED A CERTAIN OBJECT - RECORD THINGS WITH LOCATIONS

SEISO (CLEANING)
CLEAN YOUR WORKPLACE COMPLETELY SO THAT THERE IS NO DUST ANYWHERE

ACTIVITIES : 1) CLEAN EQUIPMENT AND TOOLS

2) KEEP THE WORKPLACE SPOTLESS 3) SWEEPING, WIPING, POLISHING, PAINTING ETC.

SUCCESS INDICATOR:
REDUCTION IN MACHINE DOWNTIME INCREASED LIFE OF THE MACHINE PARTS REDUCTION IN NUMBER OF ACCIDENTS REDUCTION IN REJECTION

HOW TO PRACTICE SEISO ?

- DO NOT ALLOW THINGS & PLACE TO GET DIRTY - CLEAN / SWEEP REGULARLY - PUT ASIDE 3 MINUTES EVERY DAY FOR CLEANING - YOU ARE RESPONSIBLE FOR CLEANING WORKPLACE AROUND YOU - DONOT THROW / LITTER ANYTHING - DO NOT ASSUME THERE IS SOMEONE TO CLEAN UP THE MESS YOU MAKE - SEISO ALSO INCLUDES REGULAR CLEANING OF MACHINES & TOOLS YOU USE

WHAT THE MACHINE SAYS WITH HIS MASTER ? My dear master, I Love you because: You care for me. You wash my body & joints regularly, before I become dirty and feel itchy. You hear to my whisper, when I feel uncomfortable & become seriously ill. I like to work hard for you master, I also like to live longtime. Please understand me a bit more, so that, I can enjoy working with you . Thank you for your kind consideration.

Yours faithfully Machine - X

BEGIN THE DAY WITH CLEANING THE MACHINE AND TOOLS ON WHICH YOU WORK SO THAT IT WILL FUNCTION GOOD

SEIKETSU
(MAINTAINANCE OF STANDARD/ STANDARDIZATION)
ALWAYS MAINTAIN A HIGH STANDARD OF HOUSE KEEPING IN THE ORGANISATION.

ACTIVITIES:
1) CREATE VISUAL CONTROL SYSTEM 2) CREATE STANDARDS AND MAINTAIN STRUCTURE FOR CONTROL OF STANDARDS 3) DEVIDE WAYS TO EXPOSE HIDDEN PROBLEMS INTO THE OPEN

SUCCESS INDICATOR:
NUMBER OF NEW PROBLEMS EXPOSED AND SOLVED

HOW TO PRACTICE SEIKETSU ?

YOU HAVE - THROWN AWAY UN-NECESSARY ITEMS - ARRANGED NECESSARY ITEMS - CLEANED YOUR WORKPLACE NEXT STEP IS TO MAINTAIN THE GOOD WORK YOU HAVE DONE - CONSCIOUSLY TRY TO MAINTAIN THE CLEAN ENVIRONMENT OR ELSE IT WILL BE DIRTY AGAIN - CREATE A MAINTENANCE SYSTEM FOR HOUSEKEEPING - MAY EVEN HAVE INTER - DEPARTMENTAL COMPETITION

VISUAL CONTROL
Visual control communicates improvement information
to people who need it when they need it. It grabs one or more of our senses in order to alert us to an abnormality (A gap between actual performance and the appropriate standard) for e.g. defective goods, scrap, equipment failure, over production, lateness, waiting, etc. Help us recover quickly Promote adherence and prevention Enable successful self management

SHARING

INFORMATION;

NO

SEARCHING

What information can help employees work more efficiently and independently ? How can it be made easy to see and understand ?

Share all the information and avoid unnecessary searching. Mark items and containers with delivery dates and destination, lot size, re-order information, etc. so that they are visible at a glance . Share routine standards, procedures and tolerances in ways that are easy to see and follow

SHITSUKE (DISCIPLINE)
TRAIN PEOPLE TO FOLLOW GOOD HOUSEKEEPING DISCIPLINE INDEPENDENTLY SEIRE - SEGREGATION
SEITON SEISO SEIKETSU SHITSUKE ARRANGEMENT CLEANING MAINTENANCE OF STANDARDS/STANDARDIZATION DISCIPLINE

ACTIVITIES:
1) CREATE GENERAL AWARENESS ON 5 S 2) TRAINING TO EVERYONE 3) SHARE SUCCESS TO GENERATE MORE ENTHUSIASM

SUCCESS INDICATOR:
HIGH EMPLOYEE MORALE INVOLVEMENT OF PEOPLE IN THE MOVEMENT FOR PROFIT FOR THE COMPANY

HOW TO PRACTICE SHITSUKE ?

DECIDE IN A GROUP AND MAKE A PRESENTATION

MOST DIFFICULT PART OF HOUSE KEEPING : MANAGEMENT RESPONSIBILITY TO TRAIN STAFF & EMPLOYEES TO DEVELOP A GOOD HOUSE KEEPING HABIT THE IMPRESSION YOU MAKE : TREAT YOUR WORKPLACE AS YOUR SECOND HOUSE BEWARE OF YOUR OWN ATTITUDES & HABITS

5 LEVELS OF HOUSE KEEPINGIN IN THE COMPANY LEVEL 1: FLOOR IS FULL OF UNWANTED MATERIALS LEVEL 2: CLUTTER FOUND BY THE WALLS LEVEL 3: WORKPLACE IS CLEAN BUT TOOLS AND MATERIALS ARE DISORGANISED LEVEL 4: STORAGE AREA, MACHINE ARE CLEAN AND MATERIALS ARE ORGANISEED LEVEL 5: FACTORY IS IMMACULATE / SPOTLESS

LEVEL 1: HOUSE KEEPING CIGARETTES /BUTTS SCRAPS OF PAPER TOOLS (UNDER USE) TOOLS (NOT IN USE) OLD DOCUMENTS Unused M/c s & Equip. Etc. are scattered around all over the place

CORRECTIVE ACTION Look at the horizontal surface Examine the shop floor and eliminate all garbage and non essential tools and storage Examine the floor - corner to corner and wall to wall and eliminate unwanted things Make a definite place for all tools and parts that are on the floor

HINTS FOR IMPROVEMENT

DO NOT PUT ANY UNWANTED MATERIAL ON THE FLOOR

LEVEL 2: HOUSE KEEPING

CORRECTIVE ACTION

Clutter is found by the walls passage ways are not clear unused items are lying against the walls or pillars unused tools and equipment left beneath or beside the equipment

Look at vertical surface Examine the walls and pillars eliminate all garbage and non essential tools leaning against the wall Paint the walls and pillars that can be reached by hand

HINTS FOR IMPROVEMENT

DIVIDE RESPONSIBILITIES FOR AREAS AND WALLS

LEVEL 3: HOUSE KEEPING

CORRECTIVE ACTION

Tools, parts,clamps are all mixed together in the storage cabinet. Gloves, shoes, etc., are thrown in with the tools in the tools box. All tools are in locked storage units. Unused and worthless items found inside closed cabinets

Look inside the shelves and sort the materials, parts and tools. Get rid of locked cabinets. Make separate storage for tools, parts, gauges, clamps, documents etc. Make the above area distinct and clear.

HINTS FOR IMPROVEMENT

ROMOVE THE BACK AND SIDES OF ALL THE STORAGE CABINETS

LEVEL 4: HOUSE KEEPING

CORRECTIVE ACTION

Clean machine and equipment Storage area cleanly distinguished Storage area shows many parallel lines and right angles Tools are color coded

Clean, strengthen, tidy and organize automatically Develop visual control

HINTS FOR IMPROVEMENT

1) Scrap and chips should fall directly into waste containers.

2) Make a model line with super market type displays of parts and tools.

LEVEL 5: HOUSE KEEPING

AT LEVEL 5 THE WORKPLACE WILL WITNESS
Constant and continual cleaning from wall to wall. Work area is immaculate / spotless Tools well laid out Origins of rubbish are removed so that dirt, clutter and garbage are eliminated at the source Tools, parts and materials can be found at a glance Inventory levels can be found visually Production runs smoothly High product quality achieved

HOUSE KEEPING VISION

Systems would exist for housekeeping, waste collection and disposal There would be conscious efforts to keep furniture, equipment and surrounding areas clean There would be a defined place for everything & everything in its place Roads, passages, gangways and aisles would be kept free of any material, equipment or furniture Gangways and scrap, rework and storage areas would be cleanly marked Railings, fences, racks, equipment if dirty would be cleaned and painted if necessary

HOUSE KEEPING SCHEME

1) Plant is divided into different zones 2) Different zones are sub dived 3) Each sub zone has a check sheet 4) Audit is done each month or as convenient 5) Best house kept area is recognized 6) Cumulative of six months also recognized

ACTION PLAN
Where we are ?
Visualize the state of housekeeping in your Division / Workplace and write down describing the status. Compare the housekeeping with 5 levels and decide the level

Work in the group and conclude.

5 S PLEDGE
IT SHALL BE MY ENDAVOUR TO DELIGHT OUR CUSTOMER BY ADHERING TO THE STANDARDS OF:

PUTTING THINGS IN ORDER MAINTAINING CLEANLINESS AT OUR WORKPLACE

STANDARD FOR GOOD 5S PRACTICE

P E T S STEP -1 SEIRI SEITON SEIRI: Only needed items SEITON: A place for everything and everything in its place Dispose items not needed Nothing directly Assign a place placed on floor for everything Use space more No searching effectively Extensive Start daily cleaning by Effect 'FIFO' retrieval stocks everybody Implement KAIZEN activities cleaning Remove causes of problems Standardise good practices Observe various standards fully STEP - 2 SEIRI SEITON SEISO SEISO: machines and equipment STEP - 3 SEITON SEISO SEIKETSU SEIKETSU: and organised workplace STEP - 4 SEISO SEIKETSU SHITSUKE SHITSUKE: maintain achieved standard of 5'S' all times

T A R G E T S

No dust on floor Creation of clean Good habit to

A C T I O N S

Separate passages for people from vehicles

Checklist for House Keeping

Check points
Safety Shop floor Common areas Gate / Security / Horticulture Scrap yard Administration / office X - Y Setting Visual Dispalys

Specifications
Loose electrical cables, exposed switches, oil leakage's , etc . New look , materials on the floor, lubricant spillage's, etc.. Toilet upkeep, pantry front office/ reception / canteen Marked parking spaces for cars/ scooters/ visitors entry, massive greenery, etc.. Fencing/ boundary File storage, noise pollution, wall clocks on time Symmetry in everything sign / identity boards with standardization

EVALUATION STANDARD FOR GOOD PRACTICE OF 5 S

Sr. No. CHECK POINTS RATING
1 5S Activity bulletin board is well organised and data is updated 2 Locations for material, components and work in process are labelled for easy retrieval 3 Dies, jigs, fixtures and tools are located conviniently for use without searching 4 Bolts, nuts, components and other materials are not found on floor 5 Passges and operations areas are clearly separated by distinct lines and indications 6 Failures found are immediately fixed (uneven floor, projections, machine failures etc.) 7 Problems for spots difficult to clean are solved from time to time 8 Tools or documents can be retrieved in les than one minute without searching 9 Rules for 5 S practice are implenented and observed autonomously 10 5S patrol is regularly conducted by supervisors for continued improvement

Continued

EVALUATION STANDARD FOR GOOD PRACTICE OF 5 S

Sr. No.
11 12 13 14 15

CHECK POINTS
Inspections at starting and closing time are practised and recorded Jigs and tools are easy to return to designated locations Dirt and stain on machines are removed on the spot immedietly Causes for dirt and stain are removed for perfect solution Pnuematic devices are regularly cleaned and inspected and failures are repaired immedietly People are active in implementing KAIZEN on safety, quality and cost and achieving good results Voilators of rules are warned each other among colleagues Components, tools and documents are labelled and easy to retrive Rules are strictly observed ( punctual in time, cleaning, etc) 5S is well maintained and upgraded by creative activities

RATING

16

17 18 19 20

Rating:Satisfactory-5, Tackled-3, Not-tackled-1

K.F. I. L BEVINAHALLI SBU PARAMETER

HOUSE KEEPING ( 5 S EVALUATION )

DEPARTMENT / SECTION CRITERIA MARKS MARKS ALLOTTED ACTUAL 5

PAGE 2 OF 2 MONTH : WEEK OBSERVATIONS

Are the areas free of trash & dust ? Has the floor been cleaned ? Are clean up responsibilities assigned ? Are trash cans empty ? Marks Obtained Are apparels as per guidelines / regulations ? Are private belonging kept away ? Does everyone retain from eating & drinking from the work place ? Does everyone avoid private conversations during work time ? Marks Obtained TOTAL MARKS

5 5 20 5 5

5 20 100

TEAM LEADER 5 S HOUSE KEEPING COMMITTEE

Date :

K.F .I.L BEVINAHALLI SBU

HOUSE KEEPING ( 5 S EVALUATION )

DEPARTMENT / SECTION

PAGE 1 OF 2 MONTH : WEEK

PARAMETER

CRITERIA Have unwanted things been removed ? Is the reason for presence of unauthorised items known ? Are gangways and work areas clearly marked ? Are the things properly arranged ? Marks Obtained Does each item have an earmarked place ? Is each item in its place when not in use ? Are things kept away after use ? Are work areas uncluttered ? Are shelves & tables kept in orderly fashion ? Marks Obtained

MARKS
ALLOTTED

MARKS
ACTUAL

OBSERVATIONS

5 5 20 4

4 4 4

4 20

Are apparels neat & clean ? Is ventilation adequate ? Are work areas clean ? Are equipments including machines including Jigs, Fixtures,instruments kept clean ? Marks Obtained

5 5 5

5 20
P.T.O

TQM -IMPLEMENTATION HOUSE KEEPING AND VISUAL CONTROLS ARE THE FIRST STEPS FOR TOTAL QUALITY MANAGENENT IMPLEMENTATION