5S modul[1]

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1.T5S Activ ity (Overview)

Basically refers to overall 5S activities in a field. This activity is to improve

and maintain not only the existing 5S activity but also 3R and visual control

parts.

This activity shall satisfy the followings in comfortable circumstances:

To create an exciting company atmosphere, To make a business easy based upon above conditions, and To increase productivity and quality.

Also,

The most important points are improvement and maintenance which not

returned to the original condition.

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2. 5S Activi ty (Conc ept)

This refers to a basic activity for creating an exciting and

comfortable atmosphere for the production activity, and means

a breathing movement of a factory as a basic stage for an

improvement, and a movement carried out by 3 I & 3 C principle.

Shitsuke

Environmental improvementin factory, improvement ofproduction and quality

1. Quality Obtainment2. Reduction of cost3. Improvement of

productivity4. Increase of Innovation Mind

Seiri

Seiton

Seisoh

Seiketsu

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2. 5S Activi ty (Conc ept)

1. Be sure to maintain Seiri and Seitonto allow everyone to identify easilynecessary things.

2. Propel 5S through participation in of

all Members.

3. 5S is a foundation for discoveringtrouble or loss.

Be sure to unify 5S with improvementActivity.

One of the most basic tools for living of field quality innovation

Seiri

Seiton

Seisoh

Seiketsu

Shitsuke

To dispose unnecessary things immediately by

classifying necessary and unnecessary things.

To show necessary things in designated

place for allowing that to be identified and

used easily by everyone.

To make a work field clear by removing dust,

contamination, foreign materials, etc.

To maintain and improve 3S activities of Seiri,

Seiton and Seisoh.

To make oneself familiar with an attitude to

obey learned matters and designated matters.

Improvement Point

Yes! This is the

first step for obeying

the basis.

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Material

Environment/

Product Quality

Work

Method of Work

Office Division

OfficeConference table,passage,conferenceroom,scrubbing things,Window,wall,ceiling,

lighting, dressing room,toilet,welding room

Office SuppliesOffice machine, desk, drawer, chair, telephone,

cabinet, clock, blackboard, waste basket

DocumentFile,drawings,regulation,standard,

various standards, various forms

Field Division

FieldWork table,passage,desk,cabinet,lighting,Window,entrance,wall,pillar,scrubbing things,dressing room,toilet

Equipment

Jig and FixtureConveyor,machinery,mold,equipment,

jig and fixture,tool box,truck,forklift

Material Parts,

DocumentMaterial,part,product,document,drawings,

work standard,file

Etiquette,Observance of

Regulation, Rule

Bow,costume,designation marking,telephone response,vending machineuse,Document preparation,factory guide for visitor

Observance ofSafety & Work

Standards

Safety rule,putting on safety device,workStandard,work instruction observance,smoking place observance

PunctualityAttending and leaving the office,conference time,break time,time of opening and closing of office

2. 5S (Object o f Ac tivity )

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2. 5S (Activ ity Order)

Seiri

Seiton

Seisoh

Classification of necessary and

unnecessary materials

Removal of unnecessary material

Exclusion of surplus holding

material

Designation of depot for

nonconforming product

Arrangement of processing tools

(Mold included)

Arrangement of cutting tool

Arrangement of measuring

instrument and measuring jig

Arrangement of work in-process

Arrangement of raw material

and part

Arrangement of lubricant

Cleaning

Isolation of dust cause

Cleaning and Inspection of

equipment

Clean

Maintenance

ImprovementShitsuke Settlement

5S

Object

Scope

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2. 5S (Requirements fo r Success of Act iv i ty

Total Participation

Seek control, leadership ofsupervisor and total participation

bottom-up for importance of 5S.

Autonomous Performance

Attempt the complete performance

for planned things by means

of role play clarification and

formalization.

Creativity

Create the creativity of workshop

such as QC, IE, VE, etc. based on

5S.

Shitsuke

Seek settlement of 5S by making a

point of observing the regulated

things.

Responsibility

Seek an increase of workshop

control level by acting with overall

responsibility.

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2. 5S (Ro le (Manager / Supervi so r)

Behavior

Instructions

Take the initiative and set an example for others.

If others failed to observe the rule, take corrective action to have them

observe it for them on the spot. - It is important to make them observethe rule on the spot even though the subsequent work stops.

Expose problems by going around every corner of a work field everyday.

Determination for 5S propelling

Establishment of 5S propelling plan

Obtainment and determination of time of 5S activity

Obtainment and determination of space required to a minimumfor 5S propelling

Preparation of overall rules and check list related to 5S

Preparation and determination of classification standards for acceptableproduct, not-required product, unacceptable product by going around

Carrying out 5S related training and guidance to worker

Coordination of department concerned(Role Play)

Key Roles

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2. 5S Role (Work er)

Be sure to observe the regulated rule.

Understand, in connection with waste of production,

why do that should be observed.

If required, immediately report to a superior official to takesuitable actions.

Carrying out of 5S activity in a district(facility) assigned

Recommendation of practical problems improvement

Field improvement for 5S can not be achieved so easily.

Important thing is a tops strong will of must do it and certain

practice ability in a field of lets do it in advance.

For this, a company must propel it in a body.

Thus, improvement(team) activity is required.

Discovery of problems and improvement review for that

Improvement review and performance

Behavior

Instructions

Key Roles

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2. 5S (Necess ity o f 5S and Its Effect)

In general, a factory of higher level has good conditions of arrangement, cleaning and order.5S is a means to make comfortable factory.

Also this is a technique to isolate sources generating a lot of troubles caused by unnecessary,non-uniform and unreasonable matters in a factory.

Trouble occurs to accuracy control.

30 minutes to find anything are not important for wait time taking several hours of the day, but3 minutes can be fatal for production of supplied product .

It is impossible to take concurrent operating multi processes if a lot of troubles occurs to

equipment.

Surplus tenement still exists in a place where can not be seen.

Various wastes (stock, quality deterioration, efficiency deterioration, cost rising) can not be seen in

a factory where does not carry out 5S activity well.

Necessity of 5S

Improvement in Quality

Reduction of Ready Time

Equipment Protection

Minimization of Inventory

Increase of Waste

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2. 5S (Necess ity o f 5S and Its Effect)

Effect of 5SIt takes much time to carry out 5S activity. It is required to take preventive actions

for preventing comparatively relative large waste or loss. Various effects such as

improvement in quality and productivity, removal of waste, stock control, safety

control, etc. can be taken by carrying out 5S activity in cases that it takes much time

to find out product or part caused that 1 minute was saved to arrange the product and

the part, and product gets rusty caused that anti-corrosion process was not be taken,

and so forth. Also, clean and comfortable work circumstances can give effects asFollows:

To die down unrest caused by even small defects and minor failures, To ensure good feeling, low fatigue and increased efficiency by means of clean

and comfortable workshop where you spend most of the time of the day in,

To form high reliability between customers and job seekers, and To assure company development and personnel growth.

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2. 5S ( What is ou r ch anged figu res? )

Shitsuke

Seiri Seiton

Seiketsu Seisoh

Classify clearly

necessary and

unnecessary things

and throw away

unnecessary

things.

Store the necessarythings properly tobe used and seen easilyby everyone.

Keep 3S activity of

Seiri, Seiton andSeisoh.

Always keep work

circumstances clean.

Accustom yourself

to observe the specified

things at all times.

DevelopmentIn Quality

ReductionOf Cost

DeliveryDate

Observance

Development

In

Safety

Batch

Production

DevelopmentIn

Operating

Rate

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3. 3R

This refers to a tool to ensure that Right amounts can be stored in Right container in

Right location at all times.

RightLocation

Right

Container

Right

Amounts

Allocation of

Location

Signboard

Attachment

Size Classification

by Parts

Classification by

Part Features

Box

Standardization

Packaging Form

Classification by

Container

Determination of

Max/Min

Allocation by classification forms (part, product)

Allocation by using interval (store,depot)

Subsequent process information share(Visual Stock Control)

Presentation of Classification Move(First-in First-out)

Iron Basket,Plastic,Adhesive Pallet

Large, Medium, Small parts

Carrier Box

Logistics moving amounts

Worker Usability

Box: Indication of quantity by Bundle and bag,

and total quantities of boxes Carrier: Indication of piece quantity

Large Part: Quantity required for 10~30 min.

Small Part: Quantity required for 2~4 hr.

Time required for minimum movementconsidered

Quantity allocation by area unit

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4. Visual Contr ol

This is to allow trouble to be identified visually by everyone.

Tool for

Visual

Control

Indication of Location and Goods Depot

(Place to go to take goods)

T/Time Indication

Productivity Control Table Per Time

(Status of Production and Input)

Notice of Standard Work Instruction(Work Order, Inspection Contents, Standard Quantity

In-Process)

Signboard(Right Position Signboard, Part Table)

Alarm Lamp for Abnormal Conditions

Identification Marking

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4. Visual Contr ol

Are there any tools to identify the troubles as seen by naked eyesin your field?

Are those tools structured to be identified easily by everyone(includingpersonnel who is not concerned in the matter).

Can everyone visually identify the production status if approaching to theproduction line right now?

Is a system structured so that the contents and corrective actions forquality defectives can be identified by everyone if the quality defectives

are occurred?

Can personnel in charge of clean-up be identified if it fails to cleanevery corner in a factory?

Is a monthly improvement plan established and operated, and also is theprogressive status controlled with a method of color marking, etc.?

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5S - Image by step

Image

Step Step Step Step Step

Sequence

conditions

5 S 3 C Visual management

Seiri Seiton Seisoh Seiketsu ShitsukeCorrect

positionCorrect

container

Correct

volume

Remove partition,

In a straight Line

Current production

state boardError

alarm

Organizing of

needed items is

performed

- Cleaning rules

(objection to be

cleaned, a person in

charge, time, cycle,

check points) are

regulated, and

autonomous check and

evaluation are

performed

- Public facilities (toilet,

lounge, dressing room)

are kept in clean state

- Floor and outer of

factory are kept/

managed in clean state

- Cleaning tools are

provided

- Cleaning is performed

with cleaning cycle

and object not clear

- Jig & Fixture kit is

open and arranged in

place easier to use

- Needed items and

unneeded items

divided and the latter

is removed

- Ceiling or steam pipe

of wall face is

preserved in clean

state

- Even hidden places

are being cleaned

- Workplace Image is

smart, continuous

environmental

improvement activitiesAre performed

- Cover is transparent

enough to see the

inside, and cleaned

- The results of actions,

associated with

improvement activities

are appeared gradually

- Events are held

regularly to promote

attitude of activities

- The whole employees

are satisfied with work

environment, and haveself-confidence

- There is long term

environment plan, and it

is carried out as

scheduled

Person in charge of

cleaning is designated

and individual autonomy

management isperformed

Periodical management

is performed,

even though hidden place

The entire of factory is

maintained cleanly by

habituation of all

employees

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3C Image by s tep

Organized so that

Workers can

handle easily

Passage/Depot

are divided

Organized to be able

to see what is in

where

Organized to allow

first-in first-outImage

Step Step Step Step Step

Order

Conditions

Operated according to

3C operation basis;

- continuous version up is

performed

- There is operation basis

so that 3 C can be

obeyed

- There are Correct

position markings of

workbench or parts

mounts by line process

- Being marked in order to

be able to things (parts)

that is under the control

within district

- Basis of division per

district is set up

- Places for lay

parts(things) on are

set and divided

- Basis that controls the

height of storage

presents

- Be organized to be

able to use parts in the

order of their

warehousing

- L/No is specified and

organized to be able to

handle easily

- Correct part/ defective

part/ remains are

classified and

controlled

- Organized to be able to

store Jig/tools as open

type

- 3C has habituated and

maintained

- Continuous improvement

Activities, connected with

material handling

Improvement proceeded,

and effect of improvement

realized

- Standardization/ using

in common of

container are

proceeded

- Be managed to be able

to see the change of

inventory

- Container becomes

Standardization/

common in use and is

made of usable

structure



positionCorrect

container

Correct

volumeRemove partition,

In a straight Line

Current production

state boardError

alarm

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Visual management - Image by step

Visual marking is madeto parts/equipment/

districts

Attachments such as

Current state board is

replaced andcontrolled regularly

Organized to be able to

see the abnormal

conditions

Organized to be able to

share production/ quality

situation

Image

step step step step step

- Current state board is

controlled regularly

- Attachments are

replaced regularly,

and shared by

employees

- Able to see work

guide, sequential

inspection, and

production plan by

time zone to actual

result loss

- There is marker that

allows visual

management

- Nameplate

recorded/controlled

regularly.

Power Distribution

panel, S/W/

equipment name CTQ

process, Time Check

- Alarm lamp is

installed and used

- Be operated so that

upon changing 4M,

anyone can know it

(Process signboard

etc.)

- Rules about 4M

change are

managed, especially

changed process is

managed

preponderantly

- Production/quality

situation shared, and

current Mfg. state

board is operated

- Rreconsideration

meeting

reconsideration

meeting is held

regularly, and

situation of abnormal

symptoms is shared

- RTY system is

established, and data

upgraded regularly

Order

Conditions

R/time of information on

abnormal conditions

is shared and processedquickly

- R/time on Error is shared

and linked to

Improvement Activities

- Be systematized so that,upon abnormal conditions

occurring, anyone can

realize it and it shall be

not reoccurred



positionCorrect

container

Correct

volumeRemove partition,

In a straight Line

Current production

state board

Error

alarm

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1 5 S Seiri:To dispose unnecessary

things immediately byclassifying necessary and

unnecessary things.

1) Objects : JIG and molded mount Tool kit,cleaning tool kit Indoor and floor

Original/subsidiary materials warehouse Factory outer office2) Progress activities according to a management basis by

section Division/item name/department/reason should bespecified

- Red Card(division, item name,department, attachmentreason, attachment date)

Seiton:To show necessary things indesignated place for allowingthat to be identified and usedeasily by everyone.

1) Organizes needed things2) Checks storage place3) Determines storage place: using easier method to follow4) Marks storage place: position, item name5) Maintains/checks: marking visibly

(marks in thing itself or classifying using color)

- Designates storage placefor defective products

- Performs 3C

Seisoh:To make a work field clearby removing dust,contamination, foreignmaterials, etc.

1) Uses a broom(prepare cleaning tools)2) Arranges section line: passages, floor lines of correct position Passages: straight lines,passing direction marking Entrance:dotted linesPosition lines:place designation Designation of line thickness and color3) Remove and improve the causes of dust or dirt: oil leaks, piping

leaks, particle blowing4) Thorough cleaning: cleaning of oil soaked into floor, painting,

wall, stepped area

- 5S MAP- Signboard to divide 5S area- Cleaning rules :

Designating a person incharge of cleaning,method, tool, location,period (time)

Seiketsu:To maintain and improve3S activities of Seiri,Seiton and Seisoh.

1) Periodic check and evaluation of clearing-up, organizing orcleaning status

2) Selects and executes continuously a month key theme ex) floorcleaning

3) Checks the causes of dilapidation : is it too complicated ?Is it too distant?Does not it move back against work action?

4) Filming of the pictures or VTR of dilapidated place.

- 5S evaluation

Shitsuke:To make oneself familiarwith an attitude toobey learned matters anddesignated matters.

1) Leaders leadership2) Proceeds activity on a principle that total personnel attend

NO. Purposes Remarks

T5Smethods

Items Contents

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2 3 C Standardization of howto place things

Where Correct

positionWhat Correct thing

(Correct container)

How much Correct

volume

1) Uses signboard so as to be able to know place and amount of

parts correctly

2) Regulates amount of stock: marking of load height, amount

(max,min)3) Attaches item name and ID card to each part and thing

4) Standardization of used container (size,amount etc)

5) Clears up of JIG tool Piling table open/drawer-in

arrangement

6) Storage place is marked with line, positioned so as to be able

to search easily like supermarket

- Signboard- Standardization of

container- Connected with materialhandling improvementactivity

To perceive abnormal

conditions of working field

quickly, to restore in normalconditions and to minimizeloss

1) Indication light

Call indication : Demand of parts

Abnormality indication : Indicates situation of assemblyline, abnormal assembly state etc.

running indication : Indicates production situation/

machine running

Progress indication : Indicates work progress

2) Signboard : Attaches and manages signboard periodically in

order to be able to know 4M change etc.

3) Defects indication : Attaches/positions markers in a such way

that positive/negative distribution within process is definite

4) Production management : Indicates productive situation of line

Plan/result management

5) Attaches and manages the signboard about how to work

equipment

- Error Alarm

- Current state board- Work guide/new process/

sequential inspection cardetc.

- OS&D Table,TAGDistrict division indication

- Current state board ofProduction management

- Plant check table (lubricationrecord table etc.)

3 Visual

management

NO Purposes RemarksItems Contents

T5Smethods

Documents

5S modul[1]