Lean Tools | 5S | 4th S Seiketsu or Standardizing | Definition and Technique For Implementation.

In my last three articles I have discussed the first three apparatus or tools of the Lean fundamental & most essential tools 5S. Seiri is sorting or organization, which includes putting away things that are not needed, and keeping close those that used frequently. Seiton or set in order or meatiness, insure that the things you are used smartly so they can be quickly & easily recovered.  Seiso is not just cleaning, but a whole approach that includes ensuring everything in perfect circumstance.

 

Definition: Involves creating or updating SOPS (KSAT – Level of Detail) for keeping the area organized, orderly, clean and make the workplace more visual and obvious.

Seiketsu is the 4^th stage of 5S 5S method. It means “Standardize Cleanup”. It makes from the one-time Seiso step which made the factory Shine & Set the Standard for cleanliness. Seiketsu makes it possible and efficient to live up to that level.

5S is the methodical way to reduce the seven wastes of Lean with the processes as well as the wastes of Mura and Muri.

The 4^th S is Seiketsu which means Standardization or Sanitizing. Seiketsu is not simply a brief state of cleanliness. It is an attitude of cleanliness and reliable behavior for keeping things clean. Not just clean but actively clean. But not just clean, actively clean. The clean and unclean are separated. Dirty equipments should not be introduced to dirty areas. Frequent checks are made to find and remove dirty equipments.

The true purpose of 5S is not so much about maintenance, but in achieving standard work, ensuring that the most well-organized, and less wasteful ways of doing things are acted in a repeatable approach, either through having no other options or through documented work instructions or standard operating procedures (SOPs).

The Standard Operating Procedure Should Be a detailed work cycle of each and every step undertaken, it should be written in the operators own words. Use digital cameras to record each step and take closeups of any difficult thorough work.

By having the operators identify and write the instructions you avoid any issues with them not understanding the work directions or not retail into the methods described. They are also more motivated as they greater be in charge of over their own working technique etc.

This is only an initial point, if you have never had SOPs and 5S is your first step on the road to be taught then this is where to start with your directions. As you become more concerned with your Lean programs we will need to be adding ideas such as Takt time, Kanban and work in progress information to these directions also.

To make possible constant development, we must have steadiness, stable processes are attained by standard ways of operating as accomplished through this fourth stage of 5S Seiketsu.

Continuous development is affecting from one standard to a better standard, it is up to your teams to carry on purifying their 5S implementation and improving on their work instructions and other standards.

_Motivation:

Seiketsu enables and make sure compliance with the new standards of sanitation.

1.      Maintaining the higher confidence gained during Seiso.

(i)                 Satisfaction in the Workplace.

(ii)               Relapsing into grimy or muddled circumstances means that the Seiso effort was wasted.

2.      Least assets in time: the goal is 5 minutes per worker per shift.

(i)                 No immense cleanup before a visit from customers or executives.

3.      Fewer downtimes for tools.

Learn from the 4^th 5S – Seiketsu:

One output from the Seiso step was a list describing the cleanup process:

1.      Everyday jobs

2.      Apparatus essential for each job.

3.      Sequence of responsibilities.

4.      Time is essential for each assignment.

We also found repair and maintenance issues, and began to ask “where does the grime come from”?

How can we keep up sanitation?

As an overview, four main questions will present the answer:

1.      What sources of grime can be gotten rid of?

2.      What cleanup should be performed daily?

3.      What cleanup should be performed weekly?

4.      What cleanup should be performed less frequently, and how do we make sure it happens?

Separation of clean and dirty:

Hard works are made to inhibit grime from the outside from arriving the home. To evade following dust into the house, people take off their shoes, without exclusion, before arriving. Even ambulance staffs slip off their shoes before running into a home to save lives. Many people also swab their hands and faces and may even change clothes after they reach home. A Japanese home is thought to be a haven of ease and cleanliness to those returning from outside. By comparing, public areas in Japan, such as toilets at railway stations, may not be above all clean. Railway stations that thousands pass over each day are not estimated to be Seiketsu. Private areas, such as homes and workstations, are.

Developing Standard Routine:

In a 5S Workstation, Seiketsu search for to find prime methods for each specific assignment, state and determination. After the primary 5S steps- the establishing and cleaning of Seiri, Seiton and Seiso, Seiketsu progresses a reliable methodology for chores and actions. How often do they need to be implemented? And by whom? How methodically? Seiketsu is a method for retaining and assisting fragmentary and stable Seiri, Seiton and Seiso deeds.

Integrated into daily work:

Seiketsu generates the job lists, projects and forecasting for the other 5S actions. Job lists name responsibilities, define events, name the person or persons responsible as well as the time the job is to be done. Job lists are made for the comparatively honest chores to be performed daily. Lists are also created for more complex weekly and monthly reviews. Just as in Seiri (Sorting) and Seiton (Organizing), all tools and materials are their proper place, in Seiketsu 5S duties are scheduled for their proper times and integrated with other job actions. 5S isn’t something additional to jobs, it is a primary and essential part of everyone’s job.

Visual Clues:

A 5S Workstation can be straightaway documented by its orderly and well systematized form, and also for its bright visual statement. Color coding, tape lines and other visual hints make it easy to separate objects. Colors are connected with categories so that items can be instantly documented, even from a distance, less time is spent pursuing objects, since colors make them easy to catch. Employees first control what categories these consistent colors will define. Then a legend of the standardized color coding method should be drawn up and dispatched around the work area.

Checking:

Every single acting a precarious role in the successful operation of 5S. All employees are asked to observe circumstances in their own work areas and in neighboring areas on a systematic roster. Where probable, responsibilities should be rotated among all the work area employees so that all are familiar with both acting the chore and appraising its efficiency. This reflects a Japanese “team” ethic, where there is no task that is exactly “my job” nor are there jobs that are “not my job”.

Seiketsu and Safety:

Dust is retained from arriving sanitary areas. Also grime that has somehow originate its way into the sanitary area must be detached. Seiketsu includes intermittent safety sweeps finding out-of-date, venomous or other hazardous resources and eliminating them from the work area.

Taking Standardization Beyond Sanitation:

There are good motives for companies to spend major time and money on “image” to design a logo, a color scheme, and the font(s) which area used in promoting and on letterhead. One intention in “brand recognition” –the customer should directly identify the brand.

Consider developing standardized labels for implementing and apparatus storage:

Use the same font and color

For all apparatuses, everywhere?

For all the apparatuses in one department?

For all the metric wrenches, but use a altered color for the magnificent wrenches?

Always brand the implement itself on a side that is displayed when stored on its rack.

Use the same help designate where it should be stored (in which department’s tool rack). Or for what purpose (metric or imperial products).

Use reliable signage-all “departure” signs look the same, but are different from “entry” signs or “washroom” signs – to make the message easy to understand quickly. Some of this has been built into society: the red circle with a reducer to indicate “do spread the use of standard colors and images to express important information quickly and steadily. The main benefit here is increased workshop safety. 

 Written By:
Md. Farid Ahmed
IE Officer
Fakir Apparels Ltd.
BSCIC Industrial Area, Enayet Nagar,
Fatulla, Narayangonj, Bangladesh.
Mobile: 8801814220987
E-mail: farid.ieconcern@gmail.com