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    The Secret To: Japanese Success

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    rezanur rahat
    The document discusses the 5S methodology, which originated in Japan as a housekeeping technique to improve productivity, quality, and safety. The 5S principles are: Sort, Set in Order, Shine, Standardize, and Sustain. Implementing a 5S program leads to a cleaner, more organized workplace where tools and materials are easily accessible, allowing workers to work more efficiently with fewer mistakes and less wasted time. Overall, 5S creates a more productive, safer work environment.

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    The Secret To: Japanese Success

    Uploaded by

    rezanur rahat
    29 views41 pages
    The document discusses the 5S methodology, which originated in Japan as a housekeeping technique to improve productivity, quality, and safety. The 5S principles are: Sort, Set in Order, Shine, Standardize, and Sustain. Implementing a 5S program leads to a cleaner, more organized workplace where tools and materials are easily accessible, allowing workers to work more efficiently with fewer mistakes and less wasted time. Overall, 5S creates a more productive, safer work environment.

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    5S

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    The document discusses the 5S methodology, which originated in Japan as a housekeeping technique to improve productivity, quality, and safety. The 5S principles are: Sort, Set in Order, Shine, Standardize, and Sustain. Implementing a 5S program leads to a cleaner, more organized workplace where tools and materials are easily accessible, allowing workers to work more efficiently with fewer mistakes and less wasted time. Overall, 5S creates a more productive, safer work environment.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    29 views41 pages

    The Secret To: Japanese Success

    Uploaded by

    rezanur rahat
    The document discusses the 5S methodology, which originated in Japan as a housekeeping technique to improve productivity, quality, and safety. The 5S principles are: Sort, Set in Order, Shine, Standardize, and Sustain. Implementing a 5S program leads to a cleaner, more organized workplace where tools and materials are easily accessible, allowing workers to work more efficiently with fewer mistakes and less wasted time. Overall, 5S creates a more productive, safer work environment.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 41

    5S

    THE SECRET TO
    JAPANESE SUCCESS
     WHAT PROBLEMS DO U COMMONLY
    ENCOUNTER AT YOUR WORKPLACE

     HIGH ABSENTEEISM
     HIGH TURNOVER
     DEMOTIVATED EMPLOYEES
     DISORDERED/ CLUTTERED
    ENVIRONMENT
     MISTAKES/ERRORS
     THE SOLUTION TO ALL THESE
    PROBLEMS IS

    5S
    5S

    HOUSEKEEPING TECHNIQUE

    PRODUCTIVITY AND SAFETY


    ENHANCEMENT TECHNIQUE
    IDEA BEHIND 5S
     IN ORDER TO ACHIEVE HIGH
    LEVELS OF QUALITY, SAFETY,AND
    PRODUCTIVITY, WORKERS MUST
    HAVE A CONDUCIVE WORKING
    ENVIRONMENT
    WHAT IS 5S?
     Developed by the Japanese
     Housekeeping System
     Helps Create a Better Working
    Environment and a Consistently
    High Quality Process
    THE 5S PRINCIPLES
     SEIRI – Organisation/Sort out
     SEITON – Orderliness/Systemize
     SEISO – The Cleaning/Shining
     SEIKETSU – STANDARDIZE
     SHITSUKE - Sustain/Discipline
    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
    ADVANTAGES OF 5S
     A clean and tidy workplace leads
    to greater well being and increased
    motivation

     Company image improves


    ADVANTAGES OF 5S

     Health and Safety is ensured


     Machine maintenance
     Quality
     Productivity
     Lean Manufacturing
    ADVANTAGES OF 5S
     TIME SAVING
     QUICK RETRIEVAL
     ACCIDENTS & MISTAKES
    MINIMIZED
     INCREASES SPACE
     CREATES WORKPLACE
    OWNERSHIP
    METHODOLOGY
    OF 5S
    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
    2. ORDERLINESS(SEITON)
     ONCE YOU HAVE ELIMINATED ALL
    THE UNNEEDED ITEMS

     NOW TURN TO THE LEFT OVER


    ITEMS
    ORDERLINESS(SEITON)

    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)
    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?
    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


    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


    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
    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
    WHAT U HAVE COME ACROSS
    AT THE END OF DAY

    Followings can be harnessed form the


    5S
    1. NEAT & CLEAN WORKPLACE
    2. SMOOTH WORKING
    3. NO OBSTRUCTION
    4. SAFETY INCREASES
    5. PRODUCTIVITY IMPROVES
    Cont.
    6. QUALITY IMPROVES
    7. WASTAGE DECREASE
    8. MACHINE MAINTENANCE
    9. VISUAL CONTROL SYSTEM
    10. EMPLOYEES MOTIVATED
    11. WORKSTATIONS BECOME
    SPACIOUS
    Deming’s 14 Principles

    W. Edwards Deming
    Create constancy of purpose for
    the improvement of product an
    service.
    Adopt the new philosophy.
    Cease dependence on mass
    inspection.
    End the practice of awarding
    business on price tag alone.
    Improve constantly and forever
    the system of production and
    service.
    Institute training and retraining
    Institute leadership
    Drive out fear.
    Break down barriers between
    staff areas.
    Eliminate slogans, exhortations,
    and targets for the workforce.
    Eliminate numerical quoatas.
    Remove barriers to pride of
    workmanship..
    Institute a vigorous program of
    education and retraining.
    Take action to accomplish the
    transformation.
    Benchmarking
    Benchmarking is a process of improving one’s performance by
    locating Benchmark/standards and replicating them is one’s
    own organization.
    It helps in appraising the firm’s position as against the best in
    the industry.

    Why benchmarking:
    1.Increase efficiency
    2.Create awareness
    3.Make continuous improvement
    4.Gain commitment to corporate goals
    5.Improve profitability
    Types of benchmarking:
    1. Internal Benchmarking (Comparison within
    Organization)
    2. Functional Benchmarking (Comparison of
    specific functional performance of competitor
    firms)
    3. Competitive Benchmarking (Comparison with
    competitors – within the country and outside the
    country)
    4. Generic Benchmarking (Comparison across
    companies / industries – Universal)
    Steps in Benchmarking

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