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5S THE SECRET TO JAPANESE SUCCESS
5S THE SECRET TO JAPANESE SUCCESS
WHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACE HIGH
WHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACE HIGH
THE SOLUTION TO ALL THESE PROBLEMS IS 5S
THE SOLUTION TO ALL THESE PROBLEMS IS 5S
5S HOUSEKEEPING TECHNIQUE PRODUCTIVITY AND SAFETY ENHANCEMENT
5S HOUSEKEEPING TECHNIQUE PRODUCTIVITY AND SAFETY ENHANCEMENT
IDEA BEHIND 5S
IDEA BEHIND 5S
WHAT IS 5S
WHAT IS 5S
THE 5S PRINCIPLES
THE 5S PRINCIPLES
DISCOVERY OF 5S
DISCOVERY OF 5S
DISCOVERY OF 5S
DISCOVERY OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
ADVANTAGES OF 5S
Lean Production
Lean Production
It’s a mindset & commitment to achieve a totally waste-free operation
It’s a mindset & commitment to achieve a totally waste-free operation
From the operations perspective
From the operations perspective
From the operations perspective
From the operations perspective
KINERGARTEN OF ALL THE QC TOOLS
KINERGARTEN OF ALL THE QC TOOLS
METHODOLOGY OF 5S
METHODOLOGY OF 5S
1. ORGANISATION(SEIRI)
1. ORGANISATION(SEIRI)
RED TAG TECHNIQUE
RED TAG TECHNIQUE
For wavering items
For wavering items
ORGANISATION
ORGANISATION
2. ORDERLINESS(SEITON)
2. ORDERLINESS(SEITON)
Organise layout of tools and equipment Designated locations Use tapes
Organise layout of tools and equipment Designated locations Use tapes
ORDERLINESS(SEITON)
ORDERLINESS(SEITON)
3. SEISO (CLEAN/SHINE)
3. SEISO (CLEAN/SHINE)
SEISO (CLEAN/SHINE)
SEISO (CLEAN/SHINE)
4. SEIKETSU (STANDARDISE)
4. SEIKETSU (STANDARDISE)
5. SHITSUKE (SUSTAIN / DISCIPLINE)
5. SHITSUKE (SUSTAIN / DISCIPLINE)
LITMUS TEST FOR 5S
LITMUS TEST FOR 5S
WHAT U HAVE COME ACROSS AT THE END OF DAY
WHAT U HAVE COME ACROSS AT THE END OF DAY
Cont
Cont

Презентация на тему: «THE SECRET TO JAPANESE SUCCESS». Автор: . Файл: «THE SECRET TO JAPANESE SUCCESS.ppt». Размер zip-архива: 166 КБ.

THE SECRET TO JAPANESE SUCCESS

содержание презентации «THE SECRET TO JAPANESE SUCCESS.ppt»
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1 5S THE SECRET TO JAPANESE SUCCESS

5S THE SECRET TO JAPANESE SUCCESS

2 WHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACE HIGH

WHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACE HIGH

ABSENTEEISM HIGH TURNOVER DEMOTIVATED EMPLOYEES DISORDERED/ CLUTTERED ENVIRONMENT MISTAKES/ERRORS

3 THE SOLUTION TO ALL THESE PROBLEMS IS 5S

THE SOLUTION TO ALL THESE PROBLEMS IS 5S

4 5S HOUSEKEEPING TECHNIQUE PRODUCTIVITY AND SAFETY ENHANCEMENT

5S HOUSEKEEPING TECHNIQUE PRODUCTIVITY AND SAFETY ENHANCEMENT

TECHNIQUE

5 IDEA BEHIND 5S

IDEA BEHIND 5S

IN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENT

6 WHAT IS 5S

WHAT IS 5S

Developed by the Japanese Housekeeping System Helps Create a Better Working Environment and a Consistently High Quality Process

7 THE 5S PRINCIPLES

THE 5S PRINCIPLES

SEIRI – Organisation/Sort out SEITON – Orderliness/Systemize SEISO – The Cleaning/Shining SEIKETSU – STANDARDIZE SHITSUKE - Sustain/Discipline

8 DISCOVERY OF 5S

DISCOVERY OF 5S

Thirty years ago researchers started studying the secret of success of Japanese manufacturing companies 5S turned out to be the most impressive "secret" The factories were so well organized that abnormal situations were readily apparent

9 DISCOVERY OF 5S

DISCOVERY OF 5S

Equipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seen This passion of cleanliness and orderliness became a hallmark of Japanese organizations

10 ADVANTAGES OF 5S

ADVANTAGES OF 5S

If tools and materials are conveniently located in uncluttered work areas Operators spend less time looking for items This leads to higher workstation efficiency, a fundamental goal in mass production

11 ADVANTAGES OF 5S

ADVANTAGES OF 5S

A clean and tidy workplace leads to greater well being and increased motivation Company image improves

12 ADVANTAGES OF 5S

ADVANTAGES OF 5S

Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing

13 ADVANTAGES OF 5S

ADVANTAGES OF 5S

RESULTS IN A PLACE EASIER TO MANAGE SMOOTH WORKING NO OBSTRUCTION NO DEVIATION, NO PROBLEMS B/C EVERYONE KNOWS WHERE THE THINGS ARE SPPOSEDF TO BE

14 ADVANTAGES OF 5S

ADVANTAGES OF 5S

TIME SAVING QUICK RETRIEVAL ACCIDENTS & MISTAKES MINIMIZED INCREASES SPACE CREATES WORKPLACE OWNERSHIP

15 ADVANTAGES OF 5S

ADVANTAGES OF 5S

FOUNDATION OF ALL QC TOOLS CONTINUOUS QUALITY IMPROVEMENT LEAN MANUFACTURING KINDERGARTEN OF QUALITY TOOLS & TECHNIQUES

16 ADVANTAGES OF 5S

ADVANTAGES OF 5S

VISUAL MANAGEMENT SYSTEM VISUAL CONTROL TO SEE THE ABNORMALITIES SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE CONDITION( NORMAL/ ABNORMAL) A LOOK AT THE PROCESS REVEALS ITS DIRECTION (RIGHT/WRONG)

17 Lean Production

Lean Production

The latest incarnation of JIT Based on Toyota Production System. Waste elimination Widely used in automotive manufacturing & other repetitive mfg.

18 It’s a mindset & commitment to achieve a totally waste-free operation

It’s a mindset & commitment to achieve a totally waste-free operation

that’s focused on your customer’s success… achieved by simplifying and continuously improving all processes

It’s the elimination of waste Everywhere – while adding customer value…

19 From the operations perspective

From the operations perspective

Lean production cuts costs & inventories rapidly to free cash, which is critical It also supports growth by improving productivity & quality, reducing lead times, and freeing huge amounts of resources.

20 From the operations perspective

From the operations perspective

For example, lean production frees office and plant space and increases capacity so companies can Add product lines In-source component production Increase output of existing products without acquiring new facilities.

21 KINERGARTEN OF ALL THE QC TOOLS

KINERGARTEN OF ALL THE QC TOOLS

5S IS THE STARTING POINT OF ALL THE QC TOOLS COULD BE SAID AS THE PRE- REQUISITE OF ALL QC TOOLS

22 METHODOLOGY OF 5S

METHODOLOGY OF 5S

23 1. ORGANISATION(SEIRI)

1. ORGANISATION(SEIRI)

Decide what you need Remove unnecessary clutter All tools, gauges, materials, classified and then stored Remove items which are broken, unusable or only occasionally used

24 RED TAG TECHNIQUE

RED TAG TECHNIQUE

RED TAG

GIVE STAFF RED LABELS ASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THAT ARE NEEDED,IN WHAT QUANTITY NOT NEEDED RED TAG IT STORE IN THE RED TAG AREA

25 For wavering items

For wavering items

PLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEK ALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMS AT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNED

RED TAG

26 ORGANISATION

ORGANISATION

Low

Less than once per year Once per year

Throw away Store away from the workplace

Avg.

Once per month Once per week

Store together but offline

High

Once Per Day

Locate at the workplace

PRIORITY

FREQUENCY OF USE

HOW TO USE

27 2. ORDERLINESS(SEITON)

2. ORDERLINESS(SEITON)

ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS NOW TURN TO THE LEFT OVER ITEMS

28 Organise layout of tools and equipment Designated locations Use tapes

Organise layout of tools and equipment Designated locations Use tapes

and labels Ensure everything is available as it is needed and at the “point of use”

ORDERLINESS(SEITON)

29 ORDERLINESS(SEITON)

ORDERLINESS(SEITON)

Workplace Checkpoints:- Positions of aisles and storage places clearly marked? Tools classified and stored by frequency of use? Pallets stacked correctly? Safety equipment easily accessible? Floors in good condition?

30 3. SEISO (CLEAN/SHINE)

3. SEISO (CLEAN/SHINE)

Create a spotless workplace Identify and eliminate causes of dirt and grime – remove the need to clean Sweep, dust, polish and paint

31 SEISO (CLEAN/SHINE)

SEISO (CLEAN/SHINE)

Divide areas into zones Define responsibilities for cleaning Tools and equipment must be owned by an individual Focus on removing the need to clean

32 4. SEIKETSU (STANDARDISE)

4. SEIKETSU (STANDARDISE)

Generate a maintenance system for the first three Develop procedures, schedules, practices Continue to assess the use and disposal of items Regularly audit using checklists and measures of housekeeping Real challenge is to keep it clean

33 5. SHITSUKE (SUSTAIN / DISCIPLINE)

5. SHITSUKE (SUSTAIN / DISCIPLINE)

Means inoculate courtesy & good habits Driving force behind all 5S Deming’s point number 1: Constancy of purpose Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits

34 LITMUS TEST FOR 5S

LITMUS TEST FOR 5S

30 SECOND RULE ONE MUST LOCATE THE ITEM WITH IN 30 SECOND IF 5S IS PROPERLY IMPLEMENTED ALSO APPLIES TO THE ELECTRONIC RECORDS RETRIEVAL

35 WHAT U HAVE COME ACROSS AT THE END OF DAY

WHAT U HAVE COME ACROSS AT THE END OF DAY

Followings can be harnessed form the 5S NEAT & CLEAN WORKPLACE SMOOTH WORKING NO OBSTRUCTION SAFETY INCREASES PRODUCTIVITY IMPROVES

36 Cont

Cont

6. QUALITY IMPROVES WASTAGE DECREASE MACHINE MAINTENANCE VISUAL CONTROL SYSTEM EMPLOYEES MOTIVATED WORKSTATIONS BECOME SPACIOUS

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