WELCOME

To
Training Session
On
Workplace Management System
5 S
5S RELAUNCH

5S at HZW - 1995-2003
New 5S model
5S basics
5S- Advance tools
5S- Road map
5Sat HZW
1995-2003
TQM Journey at L&T, Hazira Works.
EIS - Staff & Workmen
Speak-out Sessions
VOU Sessions
TQM Launch
5S
Self Development
OCS
Process Parameters
JQ I
TPM
IQRS Audit
Vendor Meet
CSS
LSIP
Aug 92
Jan 94
Jun 96
Jul 96
Jan 95
Apr 00
Improvement Teams Dec 99
Mar 95
Oct 95
Jul 97
Jan 99
Jun 93
TOC
TBW
IQRS Level-7
Dec 02
May 01
Apr 03
P
D
C
A
P-D-C-A Cycle
Aug 02
Manthan
Feb 95
Apr 93
Apr 95
Oct 95 Example Setting
Nov 03
CII Certi.
Mar 04
Mar 04
5S relaunch
6 Sigma
5 S
5S at HZW- 1995-2003
Introduced - Jan 1995
No. of employees trained - App.1000 (35 Sessions)
No. Area Committees - 48
No of zones - 5
No of categories - 5
Total no. of Participants - App.350
[Zone Owners, Area Owners, Area Committee
Members, Auditors]
No. of Announced Audits - 41
No. of Unannounced Audits - 20
No. of Night Audits - 03
5 S
ZONE - V (HTN)
ZONE -IV (PBS)
ZONE - III (PR)
ZONE - II (SHD)
ZONE - I (MMM)
OLD SYSTEM Master Plan
OLD
SYSTEM
5 S
Checklists used
AUDIT NO : UNANNOUNCED : ANNOUNCED : DATE :
SL.NO. CHECK
ZONE I
WQTC, A & I
BLOCKS
ZONE II
LFS
ZONE II
MFS
1 & 2
ZONE II
PPS &
PFS
ZONE II
LMS &
HMS
ZONE III
HFS-1
ZONE III
HFS-2
ZONE III
MAINT.
AREAS O/H
CRANES IN
HFS 1,2 & 3
ZONE III
HFS-3
A
1 2 3 4 5 6 7 8 9
1 Shop / Job layouts are displyed & followed
2 Visual Controls for safety ( SWL on handling
equipments, Warnings on electrical equipments/
Installations, Gangway painting, Safety statistics
display etc.)
3 Gas Cylinders - Safe storage & usage practice
4 Fire Extinguishers, First aid box, Stretcher - Visible
& Usable
5 All machines have proper protection (Guards, Wire
mesh etc.)
6 Standard Scrap bins / Dust bins placed at required
locations (Segregation at source for scrap) &
disposal schedule
7 DPP / TPM Boards updated
8 Tools & Accessories available in working condition
and in place
9 Standard color code followed ( Machines, Fixtures,
Pipe line, Lifting tackles etc.)
10 Last three months MOMs available - Participation
Level, Details of Improvement(s)
SUB TOTAL : ( OUT OF 60 )
B Overall impression of Shop Floor & Shop Office
SUB TOTAL : ( OUT OF 40 )
TOTAL : ( OUT OF 100 )
AUDIT GUIDELINE : Use compliance scale of 1 to 6 ( Poor - 1 to 2, Average - 3 to 4, Good - 5 to 6) againts each check point for each area
AUDITOR'S SIGNATURE :
FOCUS : Safety & Equipment Condition CATEGORY : PRODUCTION (SHOP)
"5S" AUDITOR'S CHECKLIST
5 S
'5S' CATEGORYWISE AVERAGE SCORE - YEARLY TREND
64.4
42.1
54.1
48
58
55.6
60.4
61.4
60.7
66.4
51.3
53.7
55.7
60.8
64.2
57.7
54.2
61.2
58.5
55.8
52.5
57.4
53.4
63
59.8
55.8
58.4
53.9
60.0
65.2
56.5
56.7
55.32
61.34
59.8
55.0
0
10
20
30
40
50
60
70
1998 1999 2000 2001 2002 2003
YEAR
A
V
E
R
A
G
E

S
C
O
R
E
PRODUCTION (SHOP) PRODUCTION (YARD) STORAGE OFFICE UTILI. & SERV. HZW
5S
NEW MODEL


New name
WORKPLACE MANAGEMENT SYSTEM
5 S
P. Ramesh - L
P.B. Shah
M.M. Makwana
H.T. Naik
S.H. Desai

Team
for
5S transformation
Workplace Management System

New Model
5 S
Divide complex into 46
geographical areas
Identify area managers &
teams. Select Model areas
Provide training to model area
teams & launch WMS
Provide training to all
other area teams.
Develop checklists
Identify & Train the
Trainers & Auditors
Provide training to all remaining
employees through trainers
Organise Red-tag day
Conduct internal / external
audits for all the areas
Conduct visits of model areas
with TQMC members
Recognition
of winners
5 S
Details of Categories & areas..
SHOPs
1. LFS
2. MACHINE SHOP
3. MFS-1
4. MFS-2
5. PPS & PFS
6. HFS 1
7. HFS 2
8. HFS 3A
9. HFS 3B
YARDs - LEMF
1. LEMF- SPECIAL PROJECTS
2. LEMF-PRESS
3. NEW LEMF
4. LEMF- CENTRAL
5. LEMF-GANTRY
6. LEMF-JETTY
YARDs - MFF
1. MFF INFRASTRUCTURE 1
2. MFF INFRASTRUCTURE 2
3. MFF JETTY AREA
4. MFF-PAINTSHOP &
BLASTING
5. MFF-GANTRY
6. MFF-II A
7. MFF-II B
8. MFF-II C
5 S
Details of Categories & areas..
OFFICES
1. ADMN BLOCK GROUND FLOOR
2. ADMN BLOCK FIRST FLOOR
3. ADMN BLOCK SECOND FLOOR
4. SBU GROUND FLOOR(RIGHT
WING)
5. SBU GROUND FLOOR(LEFT
WING)
6. SBU FIRST FLOOR
7. QA OFFICE
8. LEMF & LOGISTIC CELL
OFFICE
9. MFF BLOCK 1
10. MFF BLOCK 2
11. MFF BLOCK 3
UTILITIES
1. MEDICAL CENTER
2. CANTEEN
3. MAIN STORE
4. PLATE & STRUCTURAL YARD
5. WQTC
6. SHOT BLASTING AREA
7. TRANSPORT & SECURITY
8. DG ROOM & ELECTRICAL
SUBSTATION
9. ADMN &SBU AC PLANTS
10. GARDENS & ESTATE AREAS
11. TRAINING CENTER
12. MFF STORES

5 S
NEW 5S MASTER PLAN
5 Categories
OFFICES
YARD-LEMF
SHOPS
UTILITIES
YARD-MFF
5 S
Category - SHOPS
5 S
Category - LEMF_YARDS
5 S
Category - MFF_YARDS
Training
For
5S
5 S
Meaning of 5S

It is a series of steps
taken for ensuring
proper organization,
neatness, cleanliness,
standardization and
discipline in companys
housekeeping and
workplace management
practices.

5 S
Why the name 5S?

Because the Japanese term of
organisation, neatness, cleanliness,
standardization and discipline start
with a letter S which are
1S - Seiri - Sort - suiv-ajn
2S - Seiton - Straighten - suVyvS9a
3S - Seiso - Scrub - SvC2ta
4S - Seiketsu - Systamize - Str iny8
5S - Shitsuke - Standardize - i=St
5 S
Now, let us
further
understand
each 5 S
5 S
Seiri
The literal meaning of the
Japanese word SEIRI is
to straighten and contain.
It can be understood as
discard of unnecessary
things.
Seiri
5 S
Seiri


It sorts
between
unwanted
and
wanted
things in a
selected
area,
region or
domain.
Chotu, I want you to remove all the unwanted things
from your cupboard by this evening.
5 S
in a shop floor,
Seiri
Can be
applied
hospital,
a house,or
an office.
5 S
Seiton
While SEIRI helps us to
decide what are the items
needed, SEITON helps to
decide the way they are to be
placed so that our working is
smooth.
Seiton
5 S
Practicing Seiton ensures that there is
an assigned place for every wanted thing
and that a particular thing is always kept
in its assigned place.
Seiton
A PLACE
FOR
EVERYTHING
AND
EVERYTHING
IN ITS
PLACE.

5 S
Seiso
SEISO means
clean up i.e take up
the job of cleaning
all places
Seiso
5 S
Seiso deals
with the job
of
completely
cleaning the
workplace
Seiso


The cleaning operation should
encompass the entire surroundings
and should not be restricted to
machines, equipment, tables etc.

5 S
Seiketsu
Seiri, Seiton and Seiso are
easy to be done once, but
difficult to maintain. To
maintain we have to
standardise the system.
Seiketsu is nothing but
standardisation.
Seiketsu
5 S
Systemising the
practices of
Seiri, Seiton and
Seiso by making
them an integral
part of the
working system
of an
organization.
Seiketsu
Seiketsu
ensures
cleanliness
on a
permanent
basis.
5 S
Shitsuke
Shitsuke means discipline.
Discipline calls for strict
adherence to a system by
changing from our present
unsystematic way
Shitsuke
5 S
Setting up
standards in
order to ensure
that 5S becomes
a discipline and
a way of life for
everyone in an
organization

Shitsuke

Discipline
5 S
5 S
This comprises of the following steps

Planning: in 5W and 1H framework
Which area should we organise?
Why are we organising ?
Where will we organise it ?
When will we organise it?
Who will be responsible?
How will we do it?


Seiri


Seiri
5 S
Seiton




Seiton
This comprises of the following steps
Study the work area critically
Clear planning of passages
indicating entry and exit
Prepare storage areas for storing
the items
Put a tag/sign/label for each
location of an item
Place one type of items at one
place
5 S
Seiso


Seiso
This comprises of the following steps
Educate people on the importance
of cleaning
Clean environment
Divide the work area into distinct
categories
Allocate individual responsibility
for each area

5 S
Seiketsu


Seiketsu
This comprises of the following steps

Systemize the practices of
Seiri,Seiton and Seiso taking
the opinion of the entire group
Register standard practices
Visual Management

5 S
Shitsuke


Shitsuke
This comprises of the following steps
Pay attention to the minutest
aspect of an operation
Make the training program simple
Clearly allocate jobs
Clear instructions
Prepare a checklist
5 S
RELATIONSHIP BETWEEN 5S
SEIRI
PROPER SELECTION
SEITON
PROPER ARRANGEMENT
SEISO
CLEAN
SEIKETSU
CLEANLINESS
SHITSUKE
WELL DISPLINE MANNER
5 S
BENEFITS OF 5-S
5S
REDUCTION IN
ERRORS/DEFECTS DUE
TO STANDARDISATION
CONSISTANT
IMPROVED QUALITY
HIGHER
PRODUCTIVITY
LESSER ACCIDENT
MORE USABLE
SPACE
REDUCTION IN
M/C DOWN TIME
NICE TO WORK IN CLEAN /
ORGANIZED & BEAUTIFUL
WORK PLACE
LESSER TIME TO
RETRIEVE THINGS
WHEN REQUIRED
IMPROVED
COMMUNICATION AMONG
EMPLOYEES
IMPROVED MORALE
OF EMPLOYEES
SENSE OF OWNERSHIP
OF WORKPLACE
POSITIVE IMPACT ON
THE CUSTOMER
5 S
GEMBA KAIZEN
PROFIT
TARGET
ELEMENT
FOUNDATION
HABIT
5 S
PROFIT


( 3G )
( 5 S )
GEMBA KAIZEN
Man Machine Method Material
Muda / Mura / Muri
( 3M )
5 S
P D C A
PLAN
DO
CHECK ACTION
5 S
S D C A
STANDARDISE
DO
CHECK ACTION
5 S
PDCA TO SDCA
S D
C
A
S
D
C
A
P D
C A
TIME
IMPROVEMENT
5S
Advance tools
5 S
ELIMINATE COMBINEREARRANGESIMPLIFY
E.C.R.S
HIGH
PRODUCTIVITY
TYPICAL EXAMPLES
MUDA OF MOTION
MUDAOF WAITING
MUDA OF DEFECTS
TYPICAL EXAMPLES
REPAIR WELDING
FETTLING
INSPECTION
TRANSPORTATION
CONDUCT KAIZEN TO REMOVE MUDA
FROM EACH VALUE ADDED OPERATION
CONDUCT KAIZEN TO ELIMINATE NON
VALUE ADDED OPERATIONS
OPERATION WHICH DO NOT ADD VALUE OPERATION WHICH DO NOT ADD VALUE
ARRANGEMENT TO PERFORM OPERATIONS THAT PRODUCE GOODS & SERVICES
DECIDED BY CONVENTIONAL SYSTEM
MFG.
COST
MATERIAL
COST
PROCESS-
ING COST
OVER-
HEAD
5 S
3k
KIMERAREA
KOTO A
KIHONDORI
KICHINTO
MAMORU
WHAT HAS
BEEN DECIDED
MUST BE
FOLLOWED
AS PER
STANDARD

5 S
3G
GENBA

GENBUTSU

GENJITSU
GO TO THE SPOT


SEE THE ACTUAL
PROBLEM

TAKE APPROPRIATE
COUNTER MEASURE
5 S
3M
MUDA

MURA

MURI




WASTAGE


INCONSISTANCY


INCONVENIENCE


5 S
4M + 1E
MAN
MACHINE
METHOD
MATERIAL
ENVIRONMENT
5 S
7W
WASTAGE BY OVER PRODUCTION
WASTAGE BY WAITING TIME
WASTAGE BY OVER CONVEYANCE
WASTAGE BY OVER PROCESSING
WASTAGE BY OVER INVENTORY
WASTAGE BY OVER MOTION
WASTAGE BY OVER
REPAIR/REJECTS
5 S
Group Exercise
Developing 5s Checklist for your
area
5 S
5S Trophy- Details
Material - Wood, Glass , MS
& Stainless steel

Height - 20

Wood Quality- Sycamore wood, white
in shade & PU coating.
Protective layer of any
color for aesthetics &
looks.
5 S
All Ss of red colour
painted MS with Powder
coating & DUKO painted,
Edges to be made blunt

5 Glass plates cut & put
one behind other(Flush)
1st glass pane-12mm thk,
Rest all glass panes- 6
mm thk
*Base of Sycamore
wood
Trophy having
S-shaped curves
on top of each
other ,
Supported by
Cut glass sheets
put b/h each
other(Flush).
L&T logo & name tag
of recipient area
2 1/2x4, SS plate with
Black anodized letters
2
0

7
3
4-1/2
*Bottom of Base
dark vinear
5 S
And the winner is.
5 S
RED TAG DAY
Unit wide event
Participation by all
Tagging of all unwanted items
from your area
Removal of all tagged items to a
designated place
Reissue of these items to other
users
Disposal of these items
5 S
RED TAG- FRONT SIDE
RED TAG- REVERSE SIDE
Area : Category:
Date of tagging:
Tagged by:
Possible Users:
Item / Material description:
5
Thread for
tagging
4
3
Red Tag Day ! Date:___________
Participate enthusisatically !!
What can I do with this tag?
1. Identify any item in my area, which is not being
used by anyone since past six months
2. Attach this tag on such items - fill up the details
as shown over leaf .. and
CONTRUBUTE to the movement called 5S !!!
Thread for
tagging
5 S
Internal & External Audits For 2005-06
Audit No Internal / External Month
Ext 02 External Apr,2005
Int 05 Internal May,2005
Int 06 Internal July,2005
Ext 03 External Aug,2005
Int 07 Internal Sept,05
Int 08 Internal Nov,05
Ext 04 External Dec,05
Int 09 Internal Jan,06
Int 10 Internal Mar,06
Ext 05 External Apr,06