The 5S housekeeping environment

Summary of the unit

This unit addresses the competencies needed to facilitate and increase the 5S housekeeping environment. In an average scenario, an organisation is putting into action or training a 5S method of housekeeping. While 5S places a lot of the duty on associates, team market leaders need to support, encourage and help effective 5S in the workplace. The creation environment for 5S may include the warehouse, tool shop, office, etc.

Key Learning points

5S or the 5 pillars of the aesthetic work area (Hirano 1995) is a systematic process of work area organisation. Whenever we ask developing people about the 5S's, the majority of them say they don't think the 5S's are relevant. "That's only a system of keeping things organised and clean? The 5S's are not simply getting rid of toolboxes and cleaning up.

While the principles are easy to comprehend, most companies have never implemented them. Implementation of the 5S's create benefits such as top quality, lower costs, reliable deliveries, and improved securityto name a few. These benefits are obviously relevant to any manufacturer, and they are not had simply by reducing toolboxes and cleaning up.

The intent of 5S is to possess only what you need available in the workplace, a specified place for everything, a standard way to do things, and the discipline to keep it. Created in Japan, the 5S's are: Seiri, Seiton, Seiso, Seiketsu, and shitsuke.

Translated to British, we've:

• Sort - remove all items from the place of work that aren't needed for current development.
• Set in Order - organizing needed items in order that they are no problem finding and set aside. Items used often are placed closer to employees.
• Shine - making sure everything is clean, functioning, and ready to go.
• Standardise - the method you use to keep up the first 3S's.
• Sustain - making a behavior of properly maintaining correct procedures.

The pursuing is a set of the essential information that the learner must know and apply when they complete this unit. 5S is the foundation of lean making. It specializes in eliminating waste products and bettering overall productivity, safety and customer satisfaction.

Sort needed from unneeded

• Identify all items in the task area
• Distinguish between essential and non-essential items
• Place any non-essential item in a appropriate place, not in the task area
• Regularly be sure only essential items are in the work area

Set the workplace in order

• Identify the best location for every single essential item
• Place each essential item in its designated location
• After use immediately come back each essential item to its allocated location
• Regularly check that each essential item is at its assigned location

Shine the task area

• Keep the task area clean and tidy in any way times
• Conduct regular housekeeping activities during shift
• Ensure the work area is cool, clean and tidy at both beginning and end of shift

Standardise activities

• Follow procedures
• Follow checklists for activities where available
• Keep the work area to given standard

Sustain the 5S system

• Clean up after completion of job and before commencing next job or end of shift
• Identify situations where conformity to requirements is unlikely and take activities specified in procedures
• Inspect work area regularly for conformity to given standard
• Recommend improvements to lift the level of compliance in the workplace

5S Implementation

As many organisations try to become truly "World Class", the first question facing management. Can often be where to get started their lean journey. The answer is easy - the 5S program. The 5s's are: sort, set in order, shine, standardize, and sustain. Based on a company's situation, the 5S's can be integrated in various ways.

However, many companies have found success using the following 7 steps:

1. MCj03039030000[1]Organise this program committee.
2. Develop an idea for each S.
3. Publicly announce the start of the program.
4. Provide training and education to employees.
5. Select a day in which everyone cleans up his/her own working area.
6. Evaluate the results of 5S.
7. Perform Self-Examination and Take Corrective Activities.

5S, like all other quality and prevention initiatives, requires determination from top management and involvement by everyone in the company. Requiring plans tailored to each facility, a 5S program cannot be implemented using a "one-size-fits-all" procedure. 5S is best implemented very gradually over a period. Because implementing five S can be this overwhelming activity, some companies decide to institute it department-by-department.

SORT

Sometimes the hardest part about 5S is actually starting out! The first step, "Sorting", methods to evaluate everything in each workshop and keep only what is necessary for current creation.

Materials, tools, equipment and resources that aren't frequently used should be transferred to another, common storage area. Items that aren't used any more should be discarded or recycled. Don't keep things around because they could be used someday. Sorting is the first step in making a workshop tidy. It makes it better to find the things you need and frees up additional space.

As a result of the sorting process you will eliminate (or repair) cracked equipment and tools. Outdated fittings, moulds, jigs, scrap materials, misuse and other unused items.

The goal and process of the first "S" is organisation. The type process distinguishes needed items from unneeded items and takes out the latter.

We also need to use a tool known as "Red-tagging. " This involves the team going right through all items (tools, equipment, material, etc. ) and requesting the question: "Do I need this to do my job frequently?" Items that are being used very infrequently or not used should be red-tagged. After identifying what is actually needed, update all documentation to reflect the needed parts.

Red Tagging

Red tagging is an essential method for reducing clutter at work. Use your team to recognize and establish requirements for what to remove and where you can place it. Assign a team head who is accountable for deciding to keep or get rid of items you aren't sure about. For each item discovered ask three simple questions:

1. Why is this item here?
2. Why in this volume?
3. Why in this place?

Red-tagging items allow staff to set apart and evaluate items and information in terms of their usefulness and frequency of use. The things and information are returned, stored anywhere else, sold, distributed, or disposed of. When red tagging is completed, problems and annoyances in the workflow are reduced, communication between employees is better, product quality is increased, and efficiency is enhanced.

Activity 1 Sort checklist

Use the checklist in the workbook for activity 1 to recognize the current situation in your projects area:

10 steps to employing Sort

1. Train the team in Sort out - What is necessary for current development,
2. Agree on the rules of inventory,
3. Assign regions of responsibility,
4. Create a Red Tag Area,
5. Schedule a time for the Red Tagging to be achieved,
6. Conduct the Red Tagging,
7. Dispose of items of plainly no value,
8. Move Tagged items to the Red Label Area
9. Record Tagged Items on the Log and inform others of the tagged items,
10. Dispose of unclaimed items after an agreed period has lapsed.

Sort in Summary

• 5S is a social change activity so entail the complete crew
• Define ongoing responsibilities
• Use the RED TAG program to eliminate the chaos throughout the factory
• Review inventory levels right over the value chain - can they be reduced?
• Create maximum impact - success breeds success.

SET IN ORDER

The second "S" (Set in Order) requires you to definitely organise things so that they are easy to use and label them so that anyone can find, use, and go back them to the right place easily. Visible controls should be utilized where practicable in this activity; a aesthetic control is any communication device used in the task environment that lets you know at a glance how work should be achieved.

"Occur order" organises a workshop for the maximum possible efficiency.

Organisation and orderliness work best when they are applied together. Set in order means that there is a place for everything and everything is in its place. Labelling is mainly for others who need what is in the area, when the areas "owner" is away. The benefit is economy of time and motion. When orderliness is applied, there is absolutely no wasted human energy or extra inventory.

The Eight Wastes

To eliminate development waste, it's important to understand exactly what waste products is and where it is out there. While there are always a great variety of products being produced in several facilities, the typical wastes found in manufacturing environments are very similar. For every type of misuse, there's a technique to reduce or eliminate its results, and improve efficiency and quality.

One of the first steps in reaching the purpose of learning to be a competitive company is to recognize and attack the Eight Wastes.

1. Defective Products - rejects, rework and customer complaints re products
2. Overproduction - making more products than what customer needs right now & storing
3. Waiting - Parts are not available, missing information for job, equipment break down.
4. Not making use of your people Waste of individuals potential or expertise.
5. Transport Waste materials- unnecessary movement of work/goods/products. eg. Twin handling
6. Inventory/ Stock - any source in excess of process requirements to provide JIT
7. Motion Throw away- unnecessary motion by people eg. Searching for tools
8. Extra control - extra finishing of any polished surface, palm finishing scheduled to poor established up

Eight steps to follow when setting in order

There are eight steps to follow when setting to be able:

Using visual controls organise equipment, tools, and material storage. Use product labels on storage area areas, living area, cabinets and shelves. Labelling areas will make sure that no one will neglect where things are stored and equipment will be returned to the right location.

The eight steps are as follows

1. The item can be discovered when missing
2. Equipment and tools used most regularly are placed closest to the relevant employee
3. Work channels are to have a place for each tool and toolboxes and drawers should be noticeable and easy to get at.
4. Use tape on the floor to indicate regions of operations, parts, walkways, stored materials and hazards
5. Each work stop to show work instructions
6. Follow ergonomic guidelines for work place design
7. Use sign planks to point workstations, production targets and progress
8. Arrange area information planks eg, Bindery, Sheet Fed Press, Digital, Pre Press.

Set to be able in Summary

At its simplest it is "A place for everything and everything in its place"

At more technical levels, it involves

• Visual order to accomplish visual control
• Ergonomic considerations
• Layout considerations

Ensure people are content with the layout before marking the floor for inventory bays, etc.

SHINE

The third "S" (Glimmer) involves getting the workspace back again to proper order by the end of each day. It needs periodic (at least one time daily) cleanup, responsible people are identified for cleanup, establishment of cleanup/restocking methods (tools, checklists etc), and regular supervisor inspection.

If your garage floor is protected in oil spots then how can you tell if your car has an petrol leak?

Once you have everything, from each individual workshop up to your complete facility, sorted (cleaned out up) and organised, you need to keep it doing this. This involves regular cleaning, or to go with our third S, "shining" things up.

This could also be regarded as inspecting. While cleaning it's simpler to also inspect the machines, tools, equipment and materials you work with.

Regular cleaning and inspection helps it be easy to identify lubricant leakages, equipment misalignment, damage, absent tools and low levels of resources. Problems can be discovered and fixed when they are small. If these slight problems are not resolved while small, they could lead to equipment inability, unplanned outages or long unproductive waits while new supplies are supplied. The 'Sparkle' S can be thought of as an important aspect of preventative maintenance.

When done on a regular, consistent basis, cleaning and inspecting generally will not take a whole lot of the time, and in the long run will likely save time.

Nine steps to check out when Shining

1. Establish methods for keeping everything clean, assign cleaning responsibilities.

Implement daily 5-10-minute cleaning routines

1. Clean floors, wall space, ceilings, equipment and furniture
2. Check for leakages, frayed chords, clogged filters, missing guards
3. When cleaning take the opportunity to inspect more frequently so flaws and problems are discovered earlier.
4. Promptly repair the flower and equipment to make it more reliable.
5. Check you use correct cleaning agents
6. When it's clean, PAINT, SIGN, LABEL
7. Have a painting plan which is regular over the site (same colours etc).
8. Paint for control - what goes where.

Activity 4 Housekeeping Schedule

Develop a straightforward housekeeping schedule see Activity 4 of your Workbook

Shine in Summary

The initial Glow step is most beneficial organised as a particular event to get the region to a standard of sanitation & a representation of how we plan to work to any extent further. Shine is about creating a workplace environment which has a positive impact on those who work there.

Nine steps to check out when Standardising

1. Identify jobs to be carried out in the area
2. Identify the occurrence of every task
3. Identify enough time each task will take
4. Identify who'll carry out the task and how
5. Create an activity schedule
6. Assign responsibility to make certain that the slated is adhered to and signed off daily
7. Record actions necessary to keep up with the schedule
8. Outline methods to be implemented to remain compliant
9. Create a standard operating method outlining the above

Activity 5 Do a 5S Audit

Conduct an audit of your neighborhood using the 5S audit tool on your mother board. Attach a copy to your workbook under activity 5

Standardise in Summary

• Developing the "One easiest way" to reduce method variance so that process effects tend to be more predictable.
• Use Schedules to specify frequencies and duties to make 5S responsibilities habitual.
• For more complex jobs, such as Cleaning / Inspection / Lubrication / Maintenance use Standard Operating Steps.

The previous "S, " support, requires discipline. Without self-control, it is impossible to maintain consistent requirements of quality, safety, clean production, and process operation. The more closely people have the ability to follow manufacturing expectations, procedures, and guidelines, the less possibility there is of errors, defects, waste, and injuries. However, seeking to impose discipline within an authoritarian manner won't get far generally in most organisations today. Alternatively, people should be determined to want to follow the rules because the workplace rules are in reality a set of shared worth.

Shared prices are attained by training and team involvement, not by orders and penalties. Execution of 5S provides training by getting the visitors to do the simple things right. "Buying in" to these basic values is the essential starting point to developing a "World Class" organisation. Empowering people to take control of their daily activities and their work place is the unifying principle of 5S. By taking an active role in making and preserving their office, people take more take great pride in in their work, resulting in higher satisfaction and higher efficiency.

Many think that 5S is a must-have tool. For just about any of the tools in the toolkit for becoming slim -- quick changeover, total beneficial maintenance, mistake proofing, etc -- 5S significantly assists with both the execution and sustaining of advancements. The Yellow metal Standard for 5S is that anyone should be able to find anything in their own work environment in less than 30 seconds, and somewhere else in the workplace in less than 5 minutes without talking to anyone, beginning a e book, or turning on a computer. 5S is the building blocks for successful low fat execution. 5S is the tool to begin with, support, and support the lean trip.

Sustaining 5S

There are three tips to efficiently sustaining 5S:

• Commitment
• Top management support,
• Performance dimension.

Activity 6 Identify any Non conformance when doing the audit

Use your 5S audit checklist to recognize non conformance and list them in a separate correction action form

Sustain in Summary

• Leadership is most significant.
• Maintain the interest through auditing or regular reporting.
• A visual place of work supports detecting non complaining behaviour
• Can one does the 30 second rule