5S Implementation - A Snapshot

Confederation of Indian Industry
CII-AVANTHA Centre for Competitiveness for SMEs 1

20 February 2007
CII AVANTHA Centre for Competitiveness
5 S
( Work Place Improvement )

Implementation & Monitoring
of
5S is a basic, fundamental,
systematic approach for
productivity, quality and safety
improvement in all types of
business.

Who will Benefit by 5S
Any type of business, from a retail store to a power plant
-- from hospitals to television stations - all types of
businesses, and all areas within a business, will realize
benefits from implementing a Five S program.

What will it cost me?
Improved
Profitability
Efficiency
Service
Safety
Sort
Set in Order
Shine
Standardise
Sustain
Seiri
Seiton
Seiso
Seiketsu
Shitsuke

Elements of

5 S
Objective

To bring a cultural change in the
organization...

.Achieve through

Total Employee Involvement.
1Sorting out :
Sort & Out
What to Sort & What to
send Out ( REMOVE ) ?
1Sorting out :

Sorting:

Identify,Segregate
Wanted & Unwanted things

ORGANIZATION CHART FOR '5S' TEAM
CEO
5S' COMITTEE
COORDINATOR
DEPUTY
COORDINATOR
ZONE-1 ZONE-2 ZONE-3 ZONE-4 ZONE-5 ZONE-6 ZONE-7
TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
1Sorting out :

Team members
are operators
A Five S program is usually a part of, and the
key component of Visual Factory and
(Workplace) Management. And 5S and VFM
are both a part of Kaizen -- a system of
continual improvement -- which is a
component of lean manufacturing.

Make zones by allocating a reasonable area to each leader
RED TAG :-
A Card containing detailed
information of unwanted things
with a given time limit for
further action to be taken.

To be used based on following
questions:
What is required ?
How much is required ?
When is it required ?
Where is it required?
Section / Area :-

Name of Item : Quantity :

Reason :-
1. Obsolete 5. Unnecessary
2. Defective 6. Mix - up
3. Scrap 7. Unidentified
4. Not in place 8. Others

Action :-
1. Move to Scrap Yard 4. Rectify
2. Locate properly 5. Return to Supplier
3.Segregate 6. Others
Target date of disposition:

Remarks :-

1Sorting out :
5 S RED TAG
CII-L M Thapar Centre for Competitiveness
Removing Red Tagged stuff
What Stuff would you Red Tag in these pictures ?

Think Break
1 Sorting out

RED
TAG AREA
Removal of unwanted things
Methodology to Implement 1S: ( Contd.)
Fix a date and time for Red Tag Campaign & carry out the
audit across all Zones.
Search & Identify unwanted things and tie them with a RED
TAG.
Other than product scrap, Red Tagged items should be
moved to respective RED TAG AREA.
All those items which are finally identified unwanted ones
should be reviewed by the review committee and decision
for disposing off should be taken within a fixed time(
Maximum Time Limit is 15 days).
1Sorting out :

Zonal Leader & Members Photos
Photo
Current month view
Date : 11.01.08 Date :11.01.08
ZONAL MEMBERS ZONAL LEADER: MR. ANAND KUMAR

ZONE: 2

RED TAG CAMPAIGN
RED TAG CAMPAIGN
Unused Raw Material due
to excess Inventory.
Created Free Space.
RED TAG TARGETS
Types of items
Red-tag
targets
Physical areas
Inventory
Equipment
Floors, walkways, operation areas,
well, shelves, warehouses
Raw materials, procured
parts, processing parts, in-
process inventory, assembly
parts, semifinished products,
finished products
Machines, equipment, Jigs,
Tools, cutting bits, gauges, dies,
carts, conveyance tools,
worktables, cabinets, desks,
chairs, supplies
Identifying Red-Tag Targets
1S
DISPATCH DEPARTMENT

BEFORE AFTER
RACKS TO BE
REMOVED
Rack Removal
6x8 feet space released
Example of 1 S
Before
After
Habit of accumulating unwanted things
Example of 1Sat Office Area

Before After
CII-AVANTHA Centre for Competitiveness for SMEs
BEFORE AFTER
Before After
HP LP
Water
pump
House
Fly Ash
Silo
Operatio
n Panel
NO LEAKAGE
AFTER
BEFORE
BALCO POWER PALNT
2 S
Systematic
Arrangement
Objective
Place for Every Useful Thing & Every Useful Thing is
on its place .
Arranging them in a Systematic manner.
Result: Reduces Search Time
(Systematic Arrangement)
2 S
SEITON is important because it helps eliminate
many kinds of waste in the workplace

Motion Waste Person sent to find cart searched
full factory
Searching Waste No one can find the key to
the tool cabinet
Waste of Human Energy Frustrated worker
gives up searching for template after two hours
2 S

Waste of Excess Inventory Desk drawers are
full of papers and stationary supplies
Waste of defective products Items not kept
back in the same location so worker picks up
wrong piece for assembly
Waste of unsafe condition Boxes of material
kept in the walkway, causing someone to trip
and get injured

2 S
Steps to do SEITON
Step A Deciding Appropriate location
1.Principles of Storing jigs, tools, dies to eliminate
waste
2.Principles of motion economy to eliminate waste
3.5 S Map to decide location
Step B Identifying location
1.Signboard Strategy
2.Painting Strategy
3.Colour coding Strategy
4.Outlining strategy
Step 2 - SEITON
2 S
Methodology to Implement 2S
Check What (Item Identification)?, Where ( Location)?
& How Much ( Quantity)? When ( Time limit)? Before
actually practicing 2S.
Decide appropriate location for every thing.
Display identification mark for every location.
Items stored should have the Identification Mark including
purpose of storage & its review date.

2 S
Every thing should be cleaned thoroughly before they
are stored at its pre fixed location.
Location and storage of the items should be easily
accessible to all.
Clear identification and visibility for the location.
Training and information to all.
FIFO should be ensured.
Methodology to Implement 2SContd..
2 S
Availability of pre fixed locations for everything.
Locations are appropriate (Near to use).
Presence of identification for every thing.
Containerization- No touching/ damage between two
parts.
Accessibility is easy and known to every one.
Locations for fire extinguishers is adequate.
Gang ways are clearly marked.
Presence of Good 2S
2 S
Direction for Respective Departments, Shops, Reception,
Canteen , Visitor Rooms, Meeting Halls . is clearly
marked and displayed.
Direction for Toilets and Water Coolers is self informative.
Display boards are available for Safety / Fire Prone Areas.
Display of Speed Control of the vehicle inside the factory
premises is adequate.

Presence of Good 2SContd..
2 S
Direction for Dispensary is clearly marked & displayed.
Serial numbers on Fans , Machines, Tube Lights, .are
present & visible.
Important / emergency Telephone Numbers are displayed
at appropriate locations.
Instructions for Safety / Quality Standards are clearly
visible.
Shadow Boards are available at the appropriate locations.
Presence of Good 2S( Contd.)
2 S
Benefits of 2S
Faster retrieval of things, result in Elimination of
Search Time.
Opportunity to correct the abnormalities faster as
visibility improves by system itself.
Space Saving by systematic arrangements.
Efficiency of work improves as things are available
when they are actually needed.
2 S
Kaizen No. 1
Kaizen Theme: Easy identification of pipeline
Problem: There was no
identification on the pipeline with
respect to the pump
Benifits:
Reduction of time for identifying the
pipeline with respect to pump.
0
5
10
15
20
25
30
35
Before After
Time in min
Min
Right Things in the Right Place.
2 S
Before
After
(Systematic Arrangements)
Pre-Fixed
Locations
2 S
Shadow Boards
2 S
Only shadows on board .. Empty board
Shadow board with tools
Kaizen 3

Zone No.2 BOILER
Theme COLOUR CODING OF ALL
PRESSURE GAUGES IN MILL AREA
Problem EARLIER THERE WAS NO
COLOR-CODING OF PRESSURE GAUGES
IN MILL AREA.OPERATORS ARE NOT
ABLE TO PREDICT THE SAFE WORKING
CONDITION OF THE RUNNING
EQUIPMENTS.NOW COLOUR CODING OF
96 NOS,. OF GAUGES HAVE BEEN DONE
Benefits
IDENTIFICATION TIME REDUCED.
SAFE WORKING RANGE OF HYD. PUMP WAS
PREDICTED RESULTING IN LESS FAILURE.

Cost of Implementing : RS.10/- PER
GAUGE.
Zone no:2
BEFORE
AFTER
BALCO POWER PLANT
Identification
of the
valve ON-OFF
position

EASY IDENTIFICATION
BALCO POWER PLANT
Kaizen No. 1
Kaizen Theme: Easy inspection of water pr. gauge
Problem: Pressure gauge was at 25
mtr height .The pressure has to
check twice in a shift.
Benifits:
Movement reduced.
CPP-1/zone-4sz-5
Before
After
50
0
0
10
20
30
40
50
60
Before After
MTR
Example of 2S at office area
2 S
Solution / Benefit:
All the Pipe Lines were labeled, it
help the operators to operate in
safer atmosphere and it also
reduce time of operation
Problem:
Earlier, Pipe Lines were not
labeled due to which operation
was not understood
Kaizen No. 5
Kaizen Theme: LABELING OF PIPES
Benefits -
Benefit:

It help local operator in proper
identification which save time.
(5 mins approx.)
Problem:
Earlier there was no proper
indication of pneumatic valve
open or close
Kaizen No. 1
Kaizen Theme: Valve open and close visual indication.
C D
3 S
Shine
Everything
Definition
Seiso means that

You need to keep everything swept and clean

This is done with the objective of inspecting
for problems and taking faster corrective
actions
3 S
Objectives and Benefits of Practicing
3S
Provides dust free environment.
Creates safe & healthy work place.
Ensures higher quality of work & products.
Increases the efficiency & life of equipment .
Improves Visibility to identify abnormalities.
3 S Shine everything
7 types of
Abnormalities
Unfulfilled
basic
conditions
Inaccessible
places
Unsafe places
Unnecessary
and Non-
urgent items
Quality defect
sources
Contaminated
sources
Minor Flaws
7 Types of Abnormalities
Example of 3Sat Shop Floor
3 S Shine everything
Before
After
Problems:
View before thermography showing a
header looks externally well insulated,
with no Thermal Loss
If survey done through IR gun gives
satisfactory result

Solution: Oil stand, color coding of oil drums
& Equipments, Oil measuring can

Kaizen Theme: Finding abnormalities through Thermography
BHARAT ALUMINIUM COMPANY LIMITED

Before
A
F
T
E
R
Cost of Implementing : Nil
Benefits
The maximum observed temperature
is very high.
The loss on evaluation = 0.04
KCal/kWhr (Approx)
Revenue loss = 5000 Rs PA
Thermography shows the hot spot at various
locations

BALCO
Solution / Benefit:
Gives visual identification of location of
leakage
Loss in terms of heat & cost is known
Creates awareness of the employee
Gives the commitment towards work.

Problem:
Earlier leakages were noted down in
the defect lists, also the losses in
term heat & cost were not
evaluated.
Kaizen No.1
Kaizen Theme: To create awareness about the leakages with proper quantification
-(Harshal Ambulkar)
Kaizen at Turbine area

5S Implementation - A Snapshot

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Confederation of Indian Industry

CII-AVANTHA Centre for Competitiveness for SMEs 1

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