5s Student Guide

8/3/2019 5s Student Guide

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CONTENTS

INTRODUCTION ................................................................................1

5S BENEFITS.....................................................................................3

WHATS 5S?...................................................................................4

SORT (ORGANAZATION) ............................................................................. 4

STABILIZE (ORDERLINESS) ........................................................................ 5

SHINE (CLEANLINESS)..................................................................................5

STANDARDIZE (ADHERENCE) ...................................................................... 6

SUSTAIN (SELF-DISCIPLINE) ........................................................................6

5S IMPREMENTATION PROCEDURE ..............................................7

1. CURRENT SITUATION ANALYSIS ............................................................ 8

...............................................................................................10

2. IMPLEMENTATION OF SPECIAL 4S............................................................ 11

Sort .............................................................................................................11

Shine...........................................................................................................12

Stabilize.......................................................................................................13

Standardize .................................................................................................14

Bad and improved situation after special 4S ............................................... 15

3. IMPLEMENTATION OF SUSTAIN .......................................................... 16

4. When the activities do not work well ........................................................ 18

AT THE END OF THE TEXT ..............................................................19

Appendix

Situation Analysis Exercise Situation Analysis & Review Sheet (Service)


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INTRODUCTION

You could be knowing about "5S" already? And 5S activities would have been introducedat some dealers.

In this course, you would learn the meaning and activity of 5S. Later, by carrying out 5Sactivities at dealer, you can experience the approach involved, process to be followed andsee the result of your activity.These 5S activities not only have an effect at the work place (work environment, efficiency,

productivity, safety etc.) but also could create a positive influence in your personnel life.

It is pertinent to remember that 5S is not a one time affair, but a continuous and dailyactivity that is fundamental to every improvement activity.

What do you think?

Please write down what you felt?


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What do you think?

What are attributes that you find in photograph 'C & D', when compared to' A & B'

Please write down what you felt?


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5S BENEFITS

Effective implementation of 5S activities could produce the following benefits:

1. Lower operation cost (business running cost)2. Improve safety level of your workshop3. Lower your inventory (slow or dead stock), less waste4. Improve your customer satisfaction rate5. Improve service performance6. Improve teamwork and co-operation

Also lead to

Service Personnel feels

Clean! Easy to perform

Safety!

Comfortable Work effectively

CSimprovement

Reduce waste time

Dealer achieves

Better performance Team-work

Problem solvingmethod

Reduceinventory

ResponsibilityBetter workingcircumstance

Through 5S Activity you can expect

Improve cost


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WHATS 5S?

"5S" represents the '5Priciples', beginning with the letter S

Sort : Organization

Stabilize : Orderliness

Shine : Cleanliness

Standardize : Adherence

Sustain : Self-discipline

1. Sort: Organization

Differentiate the useful from the useless

Distinguish between required and not-required Eliminate all unnecessary items in the dealership

(workshop / warehouse / service receptions / showroom) Take picture before major cleaning is started

W/MUseful

Useless

SORT

Obsolete

Updated


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4. Standardize : Adherence

Establish operational rules Not return to the bad old ways

Visualize the factory (like marking and coloring) Establish internal rules to maintain the good environment

5. Sustain : Self-discipline

Make schemes to let all members follow the rules and continue the activity

Daily 5S create concrete time for 5S activities every day Achieve target by following the given standards Develop new standards Create PRIDE in the work place and maintain good working environment

- 5S award, 5S notice board, group activity

SUSTAIN

5STIME !

Make rules!

5S notice board

! 5S

5S awardDaily 5S

STANDARDIZE

5S


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5S IMPLEMENTATION PROCEDURE

5S by itself is easy to understand and is important in creating a healthy, efficient and safework environment. Also the program could have positive influence on other dealer activities.

But how would you start 5S activity in your dealer?In this chapter, you can learn how to introduce and implement 5S activities effectively in

your dealer.

Continuous and evolving activities

Implementation of Special 4S

Sort Shine

Stabilize Standardize

Implementation of Sustain

Current Situation Analysis

Activities of wholemembers in

dealer

Before

After

After


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1. Current Situation Analysis

When starting 5S activity, you would review current 5S situation in the workshop andclearly identify problem areas.

- Review current situation according to the 5S situation Analysis & Review material.(Refer to appendix)

- Take pictures of poorly kept / maintained/ managed area(s).- Review the result of 5S situation analysis including pictures, and decide the targetarea(s).

- Review the current situation strictly from customer point of view.

Customer pointof view

Take pictures of bad areas

Review current situation


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Sample of 5S Situation Analysis & Review Sheet(In the end of the text, you can find whole review sheet.)

Analysis & Review check-sheet covers all most all of the 'Service facility & activity areas',

including appearance of service staff, HSE etc. (HSE: Health Safety & Environment)

Facility & Service personnelsAppearance


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Following are the features of check-items, listed in the 'Analysis & Review sheet'.On analysis, you can find that all the check-items when implemented well, leads to certain

benefit, as explained in page - 5.

Customer point of view Easy to find?Easy to use?Good / Excellent appearance?Clean?Orderly?Up-dated material?Only necessary things are found?Safe?

Safety Avoid hazard?Not Slippery?Adequate illumination?

Quality Possibility of getting scratch?Use of protectors?

Productivity Easy to work?Easy to retrieve / return?Shortened Time?Easy to find?

Each area is; dedicated / marked / labeled?

Rules Everyone knows?Responsible person available?Frequency?Constancy?Availability of standard and record?

- Situation Analysis

Using Situation Analysis & Review Sheet (See appendix), evaluate your own dealer.


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2. Implementation of Special 4S

Special 4S days: Implement the 4S activities (Sort, Shine, Stabilize, and Standardize) ata time, as a starting event of 5S activities.

Remember the meaning of each "S" and experience the qualitative change realized interms of; cleanliness, orderliness, convenience, safety etc.

Differentiate the useful from the useless

Items left in the dealer are all necessary and inventory is reduced

(1) Differentiate the useful from the useless Identify unnecessary items at each target area by discussion and collective

decision. If therere tools and equipment items which can not be classified immediately,

make a list of questionable objects

Sort

Shine

Stabilize

Standardize

Organization

Cleanliness

Orderliness

Adherence

Sort

Useful Useless Questionable

Useful?

Useful!! Useless! Questionable!


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(2) Eliminate all unnecessary items in the dealership(Workshop / warehouse / service receptions / showroom)

Clean all areas Make no compromise

- Clean and comfortable environment for both dealer personnel and customers- Improved safety level- Easy to discover trouble or damage on any items and helps in maintenance.- Avoid things getting dirty, so that frequent cleaning-up is not required.

(1) Clear the target areas of all the items that could be moved out.

(2) Cleanse the facility, lifts, tools etc. completely using appropriate cleaner & tools.

(3) Discover the source of dirt and get rid of it.(4) If necessary, paint the walls, floors, lift etc.

Discover the trouble or damage of the items during cleaning.

Shine


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Create a place for everything and put everything in its place

- Items are stored in good order- The efficiency in the dealer is improved (easy to take out, easy to put back)- Safety level is improved

(1) Decide on layout of zones in the warehouse / workshop

(2) Identify places for tools & equipment by white plastic tape tentatively and post label.(3) Find suitable storage and create functional storage system. (Easy to identify andretrieve)

Stabilize

Identified by whiteplastic tape

Name & labels

Functional Storage


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Establish operational rules Not return to the bad old ways

- Everyone can understand the rules and 5S activities are continued

(1) Establish visual operational rules. (Everyone can understand the rule; location of

rooms, tools & equipment.)

(2) Make 5S operation rule and decide staff / team in charge of each area formaintenance and review.

Appropriate '5S administration' should to be established to ensure that thestandards are sustained and objectives' of continuous improvement is realized.

Ex.- Establish Operation rule Decide cleaning and reviewing responsible and its cycle Make cleaning and reviewing result sheet for each area Maintenance check sheet for tools and equipment

- Set 5S day Polish up day Disposal day

Standardize


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Before and Improved after special 4S.


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3. Implementation of Sustain

Through Special 4S activity, you and dealer staff could realize good work environment,well defined rules have been made, more suggestions' regarding improvements are being

received and could build excellent team spirit.

Final Step: "Sustain", Implement a comprehensive 5S administration to ensure that theprogram and activity is continued in a well defined manner, in order to sustain standardand realize continuous improvement.

To implement 4S (Sort, Shine, Stabilize and Standardize) firmly and to practice it on adaily basis, eventually to realize that as a work-culture at the dealer.

- Continuous improvements of dealer facilities- Improved morale- Improved internal communication in the dealer- Motivated dealer- Strengthen the team spirit

There are various activities relevant to the stage "Sustain". So you may choose the most

appropriate ones, pertain to your respective situation and progress made.

- To maintain the activity

Set standardsStandards such as : Avoid making dirt in order not to have to clean up When you made something dirt, clean it immediately Put tool back at its place, after you use it. When you produced trash, put it into garbage can immediately etc.

5S is ourwork-culture!


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Set daily 5S timeTo implement the daily 5S, it is important to set daily 5S time (for example, set5S time at 9:00 to 9:15 in the morning). This means following two things. Dealer Management emphasizing their due commitment towards 5S

activities. Make the dealer personnel recognize and implement 5S activity as

personnels duty

Group ActivitiesAs it may be the first time for personnel to do daily 5S activity, they may confuseas what to do to improve working environment. So it is effective to organizegroups and implement daily 5S activity. Group activities also improveinter-personnel communication and strengthen the team spirit.

Assign a zone / responsible area

Assign a zone / responsible area to each group. This will generate the dutyconsciousness among personnel.

Group meeting It is practical to hold a group meeting at daily 5S time. Review the activities and discuss how to progress the activities, how to

solve problems, schedule, share of work with all group members. It isimportant that decision made during these meetings should be collective.

Dealer Management participation is recommended in these meetings, asthat will reflect their interest in the 5S program and could motivate all staff.

Layout of workshop

Reception andshowroom

Group responsible

Chart of 5S area

Tools &Equipment


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4. When the activities do not work well

Messiness could be found everywhere From where should we start?

After the 4S activities, our dealer was back to bad old days.

No time and space for 5S activities in dealer


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AT THE END OF THIS TEXT

Remember 5S benefits again.

1. Lower operation cost (business running cost)2. Improve safety level of your workshop3. Lower your inventory (slow or dead stock), less waste4. Improve your customer satisfaction rate5. Improve service performance6. Improve teamwork and co-operation

When you have finished this course, you would have gained better understanding of thesebenefits than you would have known at the beginning.

Also you would know the inherent meaning that 5S represents.

Sort : Organization

Stabilize : Orderliness

Shine : Cleanliness

Standardize : Adherence

Sustain : Self-discipline

Imagine what you could do, after you have returned to your work place?Probably it is obvious you know that already!

If your dealer is already in to 5S activities, your focus could be on accelerating the programor making a qualitative difference by own activity as the situation warrants.

5 S


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5S Appendix: [Situation Analysis Exercise]AA555-18-05H

Service Reception & Counter

Entrance of service reception

Business hour8:00 17:00


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5S Appendix: [Situation Analysis Exercise]AA555-18-05H

Customer Parking


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5S Appendix: [Situation Analysis & Review Sheet]AA555-18-05H


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5s Student Guide