5S & TPM System Training

Business Excellence
 7 Type of Abnormalities

1. Minor Flaws

2. Unfulfilled Basic Conditions

3. Inaccessible Places

4. Contamination Sources

5. Quality Defect Sources

6. Unnecessary and Non-Urgent Items

7. Unsafe Places
 1. Minor Flaws

Contamination Dust, dirt, oil, grease, rust, paint

Damage Cracking, crushing, deformation, chipping, bending

Play Shaking, falling out, tilting, eccentricity wear, distortion, corrosion

Slackness Belts, chains

Abnormal Unusual, noise, overheating, vibration, strange, smells ,discoloration,

Phenomenon incorrect, pressure ,current

Adhesion Hardening, accumulation of debris, peeling, malfunction

 2.Unfulfilled Basic Conditions

Lubrication Insufficient, Dirty , Unidentified unsuitable, Leaking

Lubrication Supply Dirty, damaged or deformed lubricant, inlets, faulty lubricant pipes

Oil level Gauges Dirty, Damaged, leaking, No indication of correct level

Nuts and bolts slackness, Missing, cross- threaded, Too long, crushed,
Tightening
corroded, Unsuitable washers, wing nuts on backward
 3.Inaccessible Places

Machine construction , covers, Layout, footholds, Space behind

Cleaning
machine

Construction, Covers, foothold, Instrument position and orientation,

Checking
operating- Range display
Position of lubricant inlet, construction, height, footholds , lubricant,
Lubricating
outlet size, space

Tightening Covers, Construction, Layout Size, Space

Operation Machine layout, Position of valves , Switches and Leavers, Footholds

Position of Pressure gauges, thermometers, flow meters, moisture

Adjustment
gauges, vacuum gauges etc.
 4.Contamination sources

Product Leaks, Spills, Scattering, Overflow

Leaks, Spills, Scattering, Overflow

Raw materials

Lubricants Leaking Spills, Seeping Oils, Hydraulic fluids fuel oils etc.

Gases Leaking Compressed air, Gases ,steam, vapors.

Leaking Water, Hot, cold, half-finished products, wastewater,
Liquids
Leaking ,supply lines etc.
Flashes, Cuttings Packaging Materials and nonconforming
Scrap
products.

Contaminants by people & Forklifts, Infiltration thought cracked

Others
walls, broken windows etc.
 5.Quality Defect Sources

Dust, Rust, Powder, Chips ,Moisture, Wire, Scraps, Wood Pieces, Paper
Foreign Matter
Pieces, Stones, etc.

Shock Dropping, Jolting, Collision, Vibration etc.

Moisture Too little or too much infiltration.

Inadequate warming heating compounding mixing evaporation stirring

Concentration
etc.

Inadequate warming, heating, compounding, mixing, evaporation,

Viscosity
stirring etc .
 6.Unnecessary and Non-urgent items

Machinery Pumps, fans, compressors, columns, tanks etc.

Piping equipments Pipes hoses ducts valves dampers vacuum etc.

Measuring instruments Temperatures ,pressure, gauges, vacuum ,gauges, ammeters, etc.

Electrical equipment Wiring, piping, power leads, plugs, switches, sensors, loose wires etc

Jigs& Tools General tools ,cutting tools, jigs molds dies frames etc.

Standby equipment, spares, permanent stocks, auxiliary materials,

Spare parts
etc.

Makeshift repairs Tape, string wire, metal plates etc.

 7.Unsafe places

Unevenness, cracked holes, projections, peeling ,wear of steel chucker

Floors
plates, slipping.

Steps Too steep, irregular slipping, missing, handrails, etc.

Lights Dim ,out of position, dirty or broken covers, no explosion proofing etc.

Rotating Displaced, fallen oil or broken covers, not safe for emergency ,missing,
machinery emergency ,stop devices

Lifting devices Wires,hooks ,brakes and other parts of cranes and hoists etc

Special substances, solvents ,toxic gases insulating materials, danger signs,

Others
protective clothing etc.
5 “S”
 5S Description
Original in Meaning in
Activity Detailed Meaning
Japanese English

Removal of all items that are not needed within the scope of
Seiri Sort Clearing current production.
E-bay is your friend

Every tool, bin, pallet should have a place.

Seiton Set in Order Arranging
Shadow boards, tape and paint

Ensuring everything in the factory stays clean

Seiso Shine Neatness
Both prevention & cleaning routines apply

Seiketsu The methods used to maintain the gains, not only standard
Standardise Discipline ops, best current practice and actively using ISO are
applicable

Ongoing Ensuring that the gains are held and continue to be made.
Shitsuke Sustain
Improvements Removal of friction and waste
 1 S - Discarding Unwanted Material

• It is about identifying the necessary (what is really needed

to do the job?) and the unnecessary things.

• The necessary ones must be put in order , while the

unnecessary ones must be disposed immediately
 1 S - Discarding Unwanted Material
Proposed steps
• Make cross-functional teams

• Review everything: tools, dies, work instructions , materials

• Organize required items in a permanent place

• Put seldom used items in an organized area away from the workplace

• When in doubt, put it in a quarantine area: when it’s not used within
30days, remove it
 1 S - Discarding Unwanted Material

Initially Afterwards

Employees collecting unwanted material at one place during TPM time

14
 2S - Set in Order

• It means having things in the right places or right layout so

that they are easily accessible and can be used conveniently

• Here items are clearly identified and labeled them properly

• It determines the rate at which things can be located or

placed
 2S - Set in Order
Proposed steps
• Painting / color coding floors

• Zoning and placement marks

• Removal of old and obsolete notes on notice boards

• Creating shadow boards for tools (drawers are waste of time to open
and close them)

• Creating cabinets for storing cleaning supplies and materials used

occasionally
 2S - Set in Order
NEI JAIPUR PLANT ATTAINS EXCELLENCE IN 5S
SAVING IN SPACE & REDUCTION IN SEARCH TIME

Standard room-QA Dv. Keeping of Nuts Screw in Tool Room Store

Tool Room-BB Div. M/C wise sorting of tools BB Div.

 2S - Set in Order
Some evidence of set work areas

Clear, shiny machines

Color coded areas

No work-in-
process ( WIP )
One-place for easy
retrievability
Standardized
Drawers
 3S - Neat & Clean Workplace

• It means keeping machines and work areas clean

• Cleanliness involves cleaning every aspect of the Organization and the

removal of dirt, dust , oil , coolant leakages , splits, garbage, process
material on the floor, etc.
 3S - Neat & Clean Workplace
Proposed steps
• Increase the lighting in the work area

• Divide the area into zones

• Define responsibilities for cleaning

• Identify proper methods and tools for cleaning

• Provide protection for the persons doing cleaning(gloves, face- masks)

• Identify the sources of dirt

• Inspect machines and tools while cleaning

• If possible, perform some preventive maintenance while cleaning and inspecting

 4S - Standardization
• By maintaining the gains made from sort, set and shine, we have effectively standardised them.

• The main goal is to avoid going back to the bad old days by ensuring that daily activities are sufficient to
maintain the status quo.

• Effectively turn the first 3Ss into a habit

 5S - Discipline

• Without discipline to sustain 5S, the previous status

will appear more fast

• Discipline is a bad description, making 5S a habit is

more accurate
5 ‘S’ Improvement in Offices
TOTAL PRODUCTIVE
MAINTENANCE
( TPM)
 • ZERO ACCIDENT
Goals: • ZERO DEFECT
• ZERO BREAKDOWN
 What is TPM?

TPM is a technique whereby small teams of employees, company

wide are responsible for maintaining their own production equipment
. The target is zero breakdown and zero defects.
WHY DID WE GO FOR TPM ?
TPM IS PROFITABLE

P - PRODUCTIVITY IMPROVEMENTS
Q - QUALITY IMPROVEMENTS
C - COST REDUCTIONS
D - ON TIME DELIVERY
S - SAFETY IMPROVEMENTS
M - INCREASE IN MORALE
27
 8 PILLAR APPROACH

TPM
8 PILLARS
NATIONAL ENGINEERING INDUSTRIES LTD.

1S 2S 3S 4S 5S
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