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THE SECRET TO JAPANESE SUCCESS

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15S THE SECRET TO JAPANESE SUCCESS. 20From the operations perspective. For
2WHAT PROBLEMS DO U COMMONLY ENCOUNTER example, lean production frees office and
AT YOUR WORKPLACE HIGH ABSENTEEISM HIGH plant space and increases capacity so
TURNOVER DEMOTIVATED EMPLOYEES DISORDERED/ companies can Add product lines In-source
CLUTTERED ENVIRONMENT MISTAKES/ERRORS. component production Increase output of
3THE SOLUTION TO ALL THESE PROBLEMS IS existing products without acquiring new
5S. facilities.
45S HOUSEKEEPING TECHNIQUE PRODUCTIVITY 21KINERGARTEN OF ALL THE QC TOOLS. 5S IS
AND SAFETY ENHANCEMENT TECHNIQUE. THE STARTING POINT OF ALL THE QC TOOLS
5IDEA BEHIND 5S. IN ORDER TO ACHIEVE COULD BE SAID AS THE PRE- REQUISITE OF ALL
HIGH LEVELS OF QUALITY, SAFETY,AND QC TOOLS.
PRODUCTIVITY, WORKERS MUST HAVE A 22METHODOLOGY OF 5S.
CONDUCIVE WORKING ENVIRONMENT. 231. ORGANISATION(SEIRI). Decide what
6WHAT IS 5S? Developed by the Japanese you need Remove unnecessary clutter All
Housekeeping System Helps Create a Better tools, gauges, materials, classified and
Working Environment and a Consistently then stored Remove items which are broken,
High Quality Process. unusable or only occasionally used.
7THE 5S PRINCIPLES. SEIRI – 24RED TAG TECHNIQUE. RED TAG. GIVE STAFF
Organisation/Sort out SEITON – RED LABELS ASK STAFF TO GO THROUGH EVERY
Orderliness/Systemize SEISO – The ITEM IN THE WORK PLACE ASK IF NEEDED &
Cleaning/Shining SEIKETSU – STANDARDIZE THOSE THAT ARE NEEDED,IN WHAT QUANTITY NOT
SHITSUKE - Sustain/Discipline. NEEDED RED TAG IT STORE IN THE RED TAG
8DISCOVERY OF 5S. Thirty years ago AREA.
researchers started studying the secret of 25For wavering items. PLACE THE
success of Japanese manufacturing SUSPECTED ITEMS IN THE RED TAG AREA FOR
companies 5S turned out to be the most ONE WEEK ALLOW THE STAFF TO REEVALUATE THE
impressive "secret" The NEEDED ITEMS AT THE END OF WEEK THOSE WHO
factories were so well organized that NEED ITEMS SHOULD BE RETURNED. RED TAG.
abnormal situations were readily apparent. 26ORGANISATION. Low. Less than once per
9DISCOVERY OF 5S. Equipments were so year Once per year. Throw away Store away
clean and well maintained that any problem from the workplace. Avg. Once per month
such as a loose bolt or leaking oil could Once per week. Store together but offline.
be easily seen This passion of cleanliness High. Once Per Day. Locate at the
and orderliness became a hallmark of workplace. PRIORITY. FREQUENCY OF USE. HOW
Japanese organizations. TO USE.
10ADVANTAGES OF 5S. If tools and 272. ORDERLINESS(SEITON). ONCE YOU HAVE
materials are conveniently located in ELIMINATED ALL THE UNNEEDED ITEMS NOW TURN
uncluttered work areas Operators spend TO THE LEFT OVER ITEMS.
less time looking for items This leads to 28Organise layout of tools and equipment
higher workstation efficiency, a Designated locations Use tapes and labels
fundamental goal in mass production. Ensure everything is available as it is
11ADVANTAGES OF 5S. A clean and tidy needed and at the “point of use”.
workplace leads to greater well being and ORDERLINESS(SEITON).
increased motivation Company image 29ORDERLINESS(SEITON). Workplace
improves. Checkpoints:- Positions of aisles and
12ADVANTAGES OF 5S. Health and Safety is storage places clearly marked? Tools
ensured Machine maintenance Quality classified and stored by frequency of use?
Productivity Lean Manufacturing. Pallets stacked correctly? Safety
13ADVANTAGES OF 5S. RESULTS IN A PLACE equipment easily accessible? Floors in
EASIER TO MANAGE SMOOTH WORKING NO good condition?
OBSTRUCTION NO DEVIATION, NO PROBLEMS B/C 303. SEISO (CLEAN/SHINE). Create a
EVERYONE KNOWS WHERE THE THINGS ARE spotless workplace Identify and eliminate
SPPOSEDF TO BE. causes of dirt and grime – remove the need
14ADVANTAGES OF 5S. TIME SAVING QUICK to clean Sweep, dust, polish and paint.
RETRIEVAL ACCIDENTS & MISTAKES 31SEISO (CLEAN/SHINE). Divide areas into
MINIMIZED INCREASES SPACE CREATES zones Define responsibilities for cleaning
WORKPLACE OWNERSHIP. Tools and equipment must be owned by an
15ADVANTAGES OF 5S. FOUNDATION OF ALL QC individual Focus on removing the need to
TOOLS CONTINUOUS QUALITY IMPROVEMENT LEAN clean.
MANUFACTURING KINDERGARTEN OF QUALITY 324. SEIKETSU (STANDARDISE). Generate a
TOOLS & TECHNIQUES. maintenance system for the first three
16ADVANTAGES OF 5S. VISUAL MANAGEMENT Develop procedures, schedules, practices
SYSTEM VISUAL CONTROL TO SEE THE Continue to assess the use and disposal of
ABNORMALITIES SIMPLE SIGNALS THAT PROVIDE items Regularly audit using checklists and
AN UNDERSTANDING OF THE CONDITION( NORMAL/ measures of housekeeping Real challenge is
ABNORMAL) A LOOK AT THE PROCESS REVEALS to keep it clean.
ITS DIRECTION (RIGHT/WRONG). 335. SHITSUKE (SUSTAIN / DISCIPLINE).
17Lean Production. The latest Means inoculate courtesy & good habits
incarnation of JIT Based on Toyota Driving force behind all 5S Deming’s point
Production System. Waste elimination number 1: Constancy of purpose Make it a
Widely used in automotive manufacturing way of life Part of health and safety
& other repetitive mfg. Involve the whole workforce* Develop and
18It’s a mindset & commitment to keep good habits.
achieve a totally waste-free operation 34LITMUS TEST FOR 5S. 30 SECOND RULE ONE
that’s focused on your customer’s success… MUST LOCATE THE ITEM WITH IN 30 SECOND IF
achieved by simplifying and continuously 5S IS PROPERLY IMPLEMENTED ALSO APPLIES TO
improving all processes. It’s the THE ELECTRONIC RECORDS RETRIEVAL.
elimination of waste Everywhere – while 35WHAT U HAVE COME ACROSS AT THE END OF
adding customer value… DAY. Followings can be harnessed form the
19From the operations perspective. Lean 5S NEAT & CLEAN WORKPLACE SMOOTH
production cuts costs & inventories WORKING NO OBSTRUCTION SAFETY INCREASES
rapidly to free cash, which is critical It PRODUCTIVITY IMPROVES.
also supports growth by improving 36Cont. 6. QUALITY IMPROVES WASTAGE
productivity & quality, reducing lead DECREASE MACHINE MAINTENANCE VISUAL
times, and freeing huge amounts of CONTROL SYSTEM EMPLOYEES MOTIVATED
resources. WORKSTATIONS BECOME SPACIOUS.
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THE SECRET TO JAPANESE SUCCESS

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