Lean Initiatives The 5S Methodoloty and Practice of 5S

5S is the first in a continuous series of Lean Manufacturing and the component of 5S to give a framework of Efficiency and continuous improvement methodically make your work more efficient, as well as            originating better methods and influencing both worker complacency, and finally your subordinates.

While we are practicing Lean Six Sigma (LSS) and according to Lean Six Sigma we are considering 5S as a tool, it is more than that. The abbreviation of 5S from the Japanese words Seiri, Seiton, Seiso, Seiketsu, Shitsuke, is not just a system, it is a culture that has to be implemented into any Organization which’s goals are too spontaneous and successive implementation of working environment and working states. 

Lean initiatives mean the exclusion of all waste in any Manufacturing, Work Staton, Store room, Warehouse, and Third Party Logistics (3PL) provider. It can be implemented at office with permission of top management.

Once upon a time when Henry Ford was building automobiles, there was tools hanging on a board outlined by the tool shape, so one took the tool off the board and used it, and he had to bring it back to the same identical spot. It was not called a Lean initiative, 5S or even “shadow boarding” back then. It was called a good, old common sense approach to tool management.

That is, place like tools and equipment in the same area. All the tools are must be visual and  keep everything within reach. The workplace must be organized and use the KISS method; Keep it Simple and Stupid so anyone can find and use tools readily and know immediately where to return them for re-use.

[Note That: 5S is only the start to implementing all Lean initiatives, by using basic organizational  skills first, 5S is only one of many LEAN Methods.]

The Japanese developed this simple and easily understandable words and religiously followed the philosophy of 5S in every aspect of their life and spread it worldwide. Today these 5S’s are world wide recognizable system.

If the 5S philosophy is confined to one classroom training season or, at best, used as a one-time implementation methodology that then dies its own death due to negligence. 5S is not a list of action items that has to be reviewed at some interval of time. It has to be practiced as a daily routine, which needs concentration, dedication and devotion for sustaining it and it and ultimately making it a company as well as a worldwide culture.

An appropriate and frequent process has to be followed to make 5S a practice and a success.

PDCA or Plan-Do-Check-Act:

The PDCA (Plan, do, check, act), or “De ming cycle,” of implementing 5S is effective. This is a Never dying  process has to be followed willingly.

Basically 5S mean having visual order. The 5 components of 5S are: Sort, Set In Order, Shine, Standardize and Sustain. First, sort everything out, set it in order, clear it all up, so it shine, make sure everything is standardized, and the toughest part is of 5S is to sustain and control the 5S administrative systems, with negative and positive reinforcement, so it takes In place permanently. After Implementations are being successful, then it needs to be written or documented. These Standard operating Procedures (S. O. P.s) are useful to ensure that,

When new persons or new employees joining in the company, he/she must have to educate in 5S before they work.

Benefits of 5S:

Improve safety,decrease NPT or Non Productive Time, raise employee morale, identify problems more quickly, develop control through visibility, establish convenient  work practice, increase product and process quality, strengthen employees, pride in their work, promote stronger communication among staff, and empower employees to sustain their work area, 5S can increase morale, create positive impressions on customers, and increase efficiency and organization. 

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

Lean Tools | 5S | 5th S Shitsuke or Sustaining | Definition and Technique For Implementation.

In 5S System achieving the 1^st 4our S; Seiri or Sorting, Seiton or Set in order, Seiso or Shining & Seiketsu or Standardizing is comparatively easy than the 5^th S; Shitsuke.   Shitsuke is the 5^th and the final step of the 5S method. It means “Sustain” or “Sustained discipline”, or “Sustaining through discipline”.

Maintaining exact discipline in the workstation so that all rules and actions distinct from the first, next, third and fourth S are followed until they are enhanced, the fifth S of 5S, actual meaning in Japanese is “Discipline”.

It is a Japanese word that carries an asset of culturing importance:

Discipline and training compulsory upon a person:

Children are trained by their parents to brush their teeth after each meal.

Self-discipline:

Children grow into adults who brush their teeth after each meal.

Shared cultural self-discipline:

Everyone is expected to brush their teeth after each meal.

Personal discipline to continually practice and improve:

Golfers follow putts and drives - they do not merely play one round on the weekend without practicing in between.

The responsibility for Shitsuke is shared between management and the workforce.

Managers should remind the employees of the 5S ethics, and support them through regular messages and behaviors.

In the Japanese language the 5^th S – Shitsuke is written as:

躾

The final stage is 5S - Shitsuke or Sustain, ensuring that the company continues to continually progress using the previous stage of 5S. Keep up housekeeping, and accomplish audits and so onward.

5S should become part of the culture of the business and the liability of everyone in the organization.

In the first four methods of 5S Series, we have been looking at the heredity of 5S practices. Shitsuke is typically written with Japanese hiragana syllables rather than the kanji characters consequent from Chinese. The kanji  has the symbol for “body, self, soul or mind” on the left side, and the symbol for “beauty” on the right. It means “self-discipline,” or internalized, self-motivated discipline. Discipline from the outside should step by step and naturally transform into self-discipline as a person matures. A Discipline, then becomes a continuous practice or a state of being.

5S has some principles. Such as:

1.       Introduce and support audit and certification programs, to formally ensure that the new standards are sustained and implemented.

2.       Develop Seiketsu (Standardized Cleanup) procedures and appraisal the criteria from time to time Conduct inspections to ensure the standards are met.

3.       Devote time and resources to the less-frequent cleanups.

4.       Provide training, storage space, cleaning supplies replacement parts and other resources as required to enable the standards to be met.

5.       Train new employees in the 5S methods, as well as explain  the principles.

6.       Communicate the 5S principles to the workers on a regular basis-perhaps by installing and updating posters that emphasize one or another aspect of the 5S program.

Visual Communication:

Communicating with other’s or understanding to someone is not an easy process. Here, sometimes language is not enough to understand anything. Guess, in a garments industry sewing floor, there in front of the machine a notice is hanged. Where a safety instruction says, “sit in your chair for working from the 2 inch away of machine.” The sentence itself is clear, but everyone has not a sense of 2 inches. Therefore, if there a visual explanation and notice, a tape marking is located on the floor 2 inches from the machine, letting everyone know what areas are unsafe. Communication discipline means using language that is clear, and checking that people have understood properly. It means using visual communication as well as verbal.

Leaders Behavior:

Leaders behavior should be a role model for the others. In Japan, after the earthquake of Stunami, Prime Minister Kon and the members of the Japanese cabinet changed from their usual business suits to the work uniforms usually seen in factories. This expressed their determination to work to get the situation under control. Government spokesman Yukio Edano gave a statement in the television was an apparent constant state of exhaustion. Similarly, in a Japanese workplace, everyone, even executive are expected to pull together and do what needs to be done in an emergency.

Self Control or Composure:

During the critical moment, bars and restaurants saw a severe drop in their business. Even Japanese who were not directly affected felt that they couldn’t feel good about themselves while others were suffering. Most people practicing voluntary as controlled from the buying of staples such as toilet paper, even though many were anxious about those items becoming short supply.

Shitsuke means that once procedures and approaches are affected, workers voluntarily carry out the 5S activities without having to be noticed. It should not be necessary to reward workers to perform their assigned tasks, or discipline workers for not doing them. Workers should continue to practice the activities even after moving to different workstations. Shitsuke means not just following the rules, but exhausting the common sense to recognize and react properly to 5S encounters. It means using your Brain.

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

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