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 | 3rd S Seiso or Shine | Definition and Technique For Implementation.

After completion Seiri and Seiton (that are the 1^st two steps of Lean tools 5S), Now the next step is to implement the third Seiso or Shine.

Seiso is the third stage of 5S (Lean’s Most effective tools) method. Seiso (to make everything shiny clean) is a term that suggests you a highly productive work environment should be clean. Seiso is a Japanese word which means shiny, sweeping or cleaning or systematic cleaning, when using 5S refers relates to cleaning workplace and all equipment and keeps it clean, neat and systematized.  Seiso means remove dust and dirt from a workplace. This 5S (Seiso) is being an operative Lean Manufacturing apparatus which helps with not just your housekeeping, but with enhancing your efficiencies, improving  safety, and ensuring standardized ways of working. 5s benefits are based around the fact that it will help to remove the S7even wastes of Lean engineering from the manners. It has also an advantage to inspecting the apparatuses during the cleaning period, whereby leakage problems, breakdowns, failures, or any type of leakage are identified.

Seiso has 2 most important goals. Those are:

1. To set the new Level for cleanliness.

2. To learn how to keep up that level of cleanliness.

Cleaning is thoroughly related to the proper functioning of the apparatus and the ability to produce quality goods.

Implementation:

For Implementing Seiso, it requires,

1. At 1^st we need to identify the source of dirt and contagion to take root shares for throwing away. Otherwise it would be impossible to keep clean and in good working area.

2. Add cleaning as a part of daily work. A regular cleaning process can be used as a visual inspection of apparatus or the workshop capability. Just as you might notice corrosion or a scrape when washing your car – and not notice it if you just get in and drive – so the workers will have opportunities to catch problems in their early stages. As an example: we had to clean a small puddle of hydraulic fluid – what does this mean about the state of the apparatus?

Even this one-time activity links in with the previous steps of Seiri and Seiton. While acting the one-time "shiny clean" activity, the work teams should ask themselves questions and note the answers:

1.      Does dirt cause problems in operating the apparatus?

2.      Is gravel causing the machinery to wear rashly?

3.      Is the work station clean enough for safety and comfort?

4.      What does the "grime" tell us about the apparatus (like the leaking hydraulic fluid example)?

5.      Is the "mud" – especially powder, gas or liquid – harmful or toxic?

6.      What apparatuses, chemicals or procedures are appropriate?

7.      Could uncaring scrubbing actually damage the apparatus?

8.      Could we implement routine maintenance – like checking the engine oil when washing your car – be executed while cleaning?

9.      Was "clay" hiding any problems, such as decomposing apparatus or uneven floors?

This Seiso steps should be functional before a factory setting and before physical cleanliness. For example guess an office partition. Is dirt adding on a picket of papers? Why are the papers sitting there, relatively than being filed appropriately? Are the computer’s air outlets congested? Are outmoded booklets stored on the computer relatively than on a network backup?

We know that the Seiso step is one time assignment. So it must be documented.

The benefits from The Third 5s-Seiso:

1.      Setting the standard for future cleanliness.

2.      Less lost time for maintenances, since apparatus will be inspected concisely but frequently, and because there will be less grime clogging the apparatus.

3.      Reduce potential risk of accidents.

4.      Improving the physical and mental welfare worker.

5.      The useful life of the apparatus is increased to inhibit any decline from pollution and dirt.

6.      The cleaning leads to a significant increase, in overall apparatus are in top form cleaning.

7.      Wastage of materials and energy due to the abolition of leaks and leaks are reduced.

8.      The quality of Productions is upgraded and losses are avoided by dirt and contagion of the product and packaging.

Main benefits of a Seiso stage come with what is learned:

1.      Actually acting the work validates what was planned – or extends the planning with reality.

2.      Lists of.

3.      Tasks.

4.      Tools, apparatus, detergents or cleansers required for each task;

5.      Series of tasks – wash the machinery before swabbing the floor.

6.      Actual times required by the various chores.

7.      Maintenances required, as noted during the inspections.

8.      Ideas for development – when you do the cleaning yourself you will acquire ideas on how to make the work easier in the future

9.      Employee buy-in: they did the work and therefore they know it can be done and how long it took to do it the first time.

    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