5S - Lean Manufacturing Methodology

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Information about 5S - Lean Manufacturing Methodology
Business & Mgmt

Published on February 22, 2014

Author: MastermindIndia2010



5s – A simple, but effective, lean manufacturing methodology that helps organizations to simplify, clean, and sustain a productive work environment

Consulting | Training | Staff Training | Placement Services

Presented By Dhaval Modi.

To make audience awareness about 5S’s. How to use in our organization.

5s – A simple, but effective, lean manufacturing methodology that helps organizations to simplify, clean, and sustain a productive work environment Originated in Japan Based on the simple idea - clean and safe work environment

Sort (Seiri) Sustain (Shitsuke) 5s Standardize (Seiketsu) Straighten Set in order (Seiton) Shine (Seiso)

Sort focuses on eliminating unnecessary items from the workplace that are not needed for current operations. Ask yourself: Does it have a function in this area? Is it needed? How often? By whom? Is it in the way? Does it take too much space?

A red tag is placed on all items that are not important for operations or that are not in the proper location or quantity. Once the red tag items are identified, these items are then moved to a central holding area (Red Tag Area) for subsequent disposal, recycling, or reassignment.

Set In Order focuses on creating efficient and effective storage methods to arrange items so that they are easy to use and to label them so that they are easy to find and put away. Set in order- a place for everything, and everything in its place identify best locations Relocate out-of-place items Set height and size limits Focus on safety install temporary location indicators

Shine is next step which imply thoroughly cleaning of the work area. Working in a clean environment enables workers to notice malfunctions in equipment such as leaks, vibrations, breakages, and misalignments. These changes, if left unattended, could lead to equipment failure and loss of production. Clean everything inside and out Inspect through cleaning Prevent dirt, grime, and contamination from occurring Inspect equipment by cleaning

Standardize is the method to maintain the first three steps, creates a consistent approach with which tasks and procedures are done. Standardize is prevention – preventing accumulation of unneeded items, preventing procedures from breaking down, and preventing equipment and materials from getting dirty.

identified: who is responsible? What actions must be taken to maintain the desired conditions? When should those actions be taken? Where do they apply? What are the procedures for the application of standards?

Sustain, making a habit of properly maintaining correct procedures, is often the most difficult S to implement and achieve. Sustain focuses on defining a new standard of work place organization, Without the Sustain pillar the achievements of the other pillars will not last long. Tools far sustaining 5S include signs and posters, newsletters, pocket manuals, team and management check-ins, performance reviews, and department tours.

Space is crowded with parts and tools. Unnecessary items are stacked between workers. Excess inventory. Excess items and machines make it difficult to improve process flow. Equipment is dirty and a collection point for miscellaneous materials. Tools and equipment are difficult to find.

Practice the old slogan, “a place for everything and everything in its place.” Place tools and instruction manuals close to the point of use. Design storage areas with a wide entrance and a shallow depth. Lay out the storage area along the wall to save space. Place items so that they are easy to access. Store similar items together and different items in separate rows. Do not stack items together. Use racks or shelves when possible.

Use small bins to organize small items. Use color for quickly identifying items. Clearly label items and storage areas to improve visibility. Use see-through/transparent covers and doors for visibility. Remove unnecessary doors, walls, and other barriers to visibility, movement, and travel. Use carts to organize, move, and store tools, jigs, measuring devices.

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