1.T5S Activity (Overview)

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1.T5S Activity (Overview)
Basically refers to overall 5S activities in a
field. This activity is to improve and maintain
not only the existing 5S activity but also 3R and
visual control parts. This activity shall satisfy
the followings in comfortable circumstances
? To create an exciting company atmosphere, ? To
make a business easy based upon above conditions,
and ? To increase productivity and quality.
Also, The most important points are improvement
and maintenance which not returned to the
original condition.
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2. 5S Activity (Concept)
This refers to a basic activity for creating an
exciting and comfortable atmosphere for the
production activity, and means a breathing
movement of a factory as a basic stage for an
improvement, and a movement carried out by 3 I
3 C principle.
? Environmental improvement in factory,
improvement of production and quality 1.
Quality Obtainment 2. Reduction of cost 3.
Improvement of productivity 4. Increase of
Innovation Mind
Shitsuke
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2. 5S Activity (Concept)
One of the most basic tools for living of field
quality innovation
Seiri
To dispose unnecessary things immediately
by classifying necessary and unnecessary things.
Improvement Point
1. Be sure to maintain Seiri and Seiton to
allow everyone to identify easily necessary
things. 2. Propel 5S through participation in of
all Members. 3. 5S is a foundation for
discovering trouble or loss. Be sure to unify
5S with improvement Activity.
Seiton
To show necessary things in designated place
for allowing that to be identified andused
easily by everyone.
Seisoh
To make a work field clear by removing dust,
contamination, foreign materials, etc.
Seiketsu
To maintain and improve 3S activities of Seiri,
Seiton and Seisoh.
Yes! This is the first step for obeying the
basis.
Shitsuke
To make oneself familiar with an attitude to
obey learned matters and designated matters.
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2. 5S (Object of Activity)
Office Division
Office
Conference table,passage,conference
room,scrubbing things,Window,wall,ceiling, lighti
ng, dressing room,toilet,welding room
Office Supplies
Office machine, desk, drawer, chair,
telephone, cabinet, clock, blackboard, waste
basket
Material
Document
File,drawings,regulation,standard, various
standards, various forms
Environment/Product Quality
Field Division
Field
Work table,passage,desk,cabinet, lighting,Window,e
ntrance,wall,pillar, scrubbing things,dressing
room,toilet
Equipment Jig and Fixture
Conveyor,machinery,mold,equipment, jig and
fixture,tool box,truck,forklift
Material Parts, Document
Material,part,product,document,drawings, work
standard,file
Etiquette, Observance of Regulation, Rule
Bow,costume,designation marking, telephone
response,vending machine use,Document
preparation, factory guide for visitor
Work
Observance of Safety Work Standards
Safety rule,putting on safety device,work Standard
,work instruction observance, smoking place
observance
Method of Work
Punctuality
Attending and leaving the office, conference
time,break time, time of opening and closing of
office
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2. 5S (Activity Order)
Classification of necessary and unnecessary
materials
Removal of unnecessary material
Seiri
Exclusion of surplus holding material
Designation of depot for nonconforming product
Arrangement of processing tools (Mold included)
Arrangement of cutting tool
5S Object Scope
Clean Maintenance Improvement
Shitsuke
Settlement
Seiton
Arrangement of measuring instrument and
measuring jig
Arrangement of work in-process
Arrangement of raw material and part
Arrangement of lubricant
Cleaning
Seisoh
Isolation of dust cause
Cleaning and Inspection of equipment
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2. 5S (Requirements for Success of Activity
Total Participation
Seek control, leadership of supervisor and total
participation bottom-up for importance of 5S.
Shitsuke
Seek settlement of 5S by making a point of
observing the regulated things.
Autonomous Performance
Attempt the complete performance for planned
things by means of role play clarification and
formalization.
Responsibility
Seek an increase of workshop control level by
acting with overall responsibility.
Creativity
Create the creativity of workshop such as QC,
IE, VE, etc. based on 5S.
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2. 5S (Role (Manager / Supervisor)
Take the initiative and set an example for others.
Behavior Instructions
If others failed to observe the rule, take
corrective action to have them observe it for
them on the spot. - It is important to make them
observe the rule on the spot even though the
subsequent work stops.
Expose problems by going around every corner of a
work field everyday.
Determination for 5S propelling
Establishment of 5S propelling plan
Obtainment and determination of time of 5S
activity
Key Roles
Obtainment and determination of space required to
a minimum for 5S propelling
Preparation of overall rules and check list
related to 5S
Preparation and determination of classification
standards for acceptable product, not-required
product, unacceptable product by going around
Carrying out 5S related training and guidance to
worker
Coordination of department concerned(Role Play)
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2. 5S Role (Worker)
Be sure to observe the regulated rule.
Behavior Instructions
Understand, in connection with waste of
production, why do that should be observed.
If required, immediately report to a superior
official to take suitable actions.
Carrying out of 5S activity in a
district(facility) assigned
Recommendation of practical problems improvement
Field improvement for 5S can not be achieved so
easily.
Key Roles
Important thing is a tops strong will of must
do it and certain practice ability in a field
of lets do it in advance.
For this, a company must propel it in a body.
Thus, improvement(team) activity is required.
Discovery of problems and improvement review for
that
Improvement review and performance
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2. 5S (Necessity of 5S and Its Effect)
? Necessity of 5S
In general, a factory of higher level has good
conditions of arrangement, cleaning and order. 5S
is a means to make comfortable factory. Also this
is a technique to isolate sources generating a
lot of troubles caused by unnecessary, non-uniform
and unreasonable matters in a factory.
? Improvement in Quality
Trouble occurs to accuracy control.
? Reduction of Ready Time
30 minutes to find anything are not important for
wait time taking several hours of the day, but 3
minutes can be fatal for production of supplied
product .
? Equipment Protection
It is impossible to take concurrent operating
multi processes if a lot of troubles occurs
to equipment.
? Minimization of Inventory
Surplus tenement still exists in a place where
can not be seen.
? Increase of Waste
Various wastes (stock, quality deterioration,
efficiency deterioration, cost rising) can not be
seen in a factory where does not carry out 5S
activity well.
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2. 5S (Necessity of 5S and Its Effect)
? Effect of 5S It takes much time to carry out 5S
activity. It is required to take preventive
actions for preventing comparatively relative
large waste or loss. Various effects such
as improvement in quality and productivity,
removal of waste, stock control, safety control,
etc. can be taken by carrying out 5S activity in
cases that it takes much time to find out product
or part caused that 1 minute was saved to arrange
the product and the part, and product gets rusty
caused that anti-corrosion process was not be
taken, and so forth. Also, clean and comfortable
work circumstances can give effects as Follows
? To die down unrest caused by even small defects
and minor failures, ? To ensure good feeling,
low fatigue and increased efficiency by means of
clean and comfortable workshop where you spend
most of the time of the day in, ? To form high
reliability between customers and job seekers,
and ? To assure company development and
personnel growth.
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2. 5S ( What is our changed figures? )
Development In Quality
Batch Production
Seiri
Seiton
Classify clearly necessary and unnecessary
things and throw away unnecessary things.
Store the necessary things properly to be used
and seen easily by everyone.
Shitsuke
Development In Operating Rate
Reduction Of Cost
Accustom yourself to observe the specified things
at all times.
Development In Safety
Keep 3S activity of Seiri, Seiton and Seisoh.
Always keep work circumstances clean.
Delivery Date Observance
Seiketsu
Seisoh
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3. 3R
This refers to a tool to ensure that Right
amounts can be stored in Right container in
Right location at all times.

• Allocation by classification forms (part,
  product)
• Allocation by using interval (store,depot)

Allocation of Location
Right Location

• Subsequent process information share
• (Visual Stock Control)
• Presentation of Classification Move
• (First-in First-out)

Signboard Attachment

• Iron Basket,Plastic,Adhesive Pallet
• Large, Medium, Small parts

Size Classification by Parts
Right Container
Classification by Part Features

• Carrier Box

• Logistics moving amounts
• Worker Usability

Box Standardization

• Box Indication of quantity by Bundle and bag,
• and total quantities of boxes
• Carrier Indication of piece quantity

Packaging Form
Right Amounts

• Large Part Quantity required for 1030 min.
• Small Part Quantity required for 24 hr.

Classification by Container

• Time required for minimum movement
• considered
• Quantity allocation by area unit

Determination of Max/Min
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4. Visual Control
This is to allow trouble to be identified
visually by everyone.
Indication of Location and Goods Depot (Place to
go to take goods)
T/Time Indication
Productivity Control Table Per Time (Status of
Production and Input)
Tool for Visual Control
Notice of Standard Work Instruction (Work Order,
Inspection Contents, Standard Quantity
In-Process)
Signboard(Right Position Signboard, Part Table)
Alarm Lamp for Abnormal Conditions
Identification Marking
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4. Visual Control
? Are there any tools to identify the troubles as
seen by naked eyes in your field? ? Are
those tools structured to be identified easily by
everyone(including personnel who is not
concerned in the matter). ? Can everyone
visually identify the production status if
approaching to the production line right
now? ? Is a system structured so that the
contents and corrective actions for quality
defectives can be identified by everyone if the
quality defectives are occurred? ? Can
personnel in charge of clean-up be identified if
it fails to clean every corner in a
factory? ? Is a monthly improvement plan
established and operated, and also is the
progressive status controlled with a method of
color marking, etc.?
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5S - Image by step
? Step
? Step
? Step
? Step
? Step
- Workplace Image is smart, continuous
environmental improvement activities Are performed
Person in charge of cleaning is designated and
individual autonomy management is performed
The entire of factory is maintained cleanly by
habituation of all employees
Periodical management is performed, even though
hidden place
Organizing of needed items is performed
Image
- Cleaning tools are provided - Cleaning is
performed with cleaning cycle and object not
clear - Jig Fixture kit is open and arranged
in place easier to use - Needed items and
unneeded items divided and the latter is removed

• Cover is transparent enough to see the inside,
  and cleaned
• - The results of actions, associated with
  improvement activities are appeared gradually
• - Events are held regularly to promote attitude
  of activities

• - The whole employees are satisfied with work
  environment, and have self-confidence
• There is long term environment plan, and it is
  carried out as scheduled

- Cleaning rules (objection to be cleaned, a
person in charge, time, cycle, check points) are
regulated, and autonomous check and evaluation
are performed - Public facilities (toilet,
lounge, dressing room) are kept in clean state -
Floor and outer of factory are kept/ managed in
clean state
- Ceiling or steam pipe of wall face is preserved
in clean state - Even hidden places are being
cleaned
conditions
Sequence
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3C Image by step
? Step
? Step
? Step
? Step
? Step
Organized so that Workers can handle easily
Operated according to 3C operation basis -
continuous version up is performed
Organized to be able to see what is in where
Passage/Depot are divided
Organized to allow first-in first-out
Image
- 3C has habituated and maintained - Continuous
improvement Activities, connected with material
handling Improvement proceeded, and effect of
improvement realized

• Be organized to be able to use parts in the order
  of their warehousing
• L/No is specified and organized to be able to
  handle easily
• Correct part/ defective part/ remains are
  classified and controlled
• - Organized to be able to store Jig/tools as open
  type

- There is operation basis so that 3 C can be
obeyed - There are Correct position markings of
workbench or parts mounts by line process -
Being marked in order to be able to things
(parts) that is under the control within district

• Basis of division per district is set up
• - Places for lay parts(things) on are set and
  divided
• - Basis that controls the height of storage
  presents

- Standardization/ using in common of container
are proceeded - Be managed to be able to see the
change of inventory - Container becomes
Standardization/ common in use and is made of
usable structure
Conditions
Order
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Visual management - Image by step
?step
?step
?step
?step
?step
Attachments such as Current state board is
replaced and controlled regularly
Organized to be able to see the
abnormal conditions
Organized to be able to share production/ quality
situation
R/time of information on abnormal conditions is
shared and processed quickly
Visual marking is made to parts/equipment/
districts
Image
- Current state board is controlled regularly -
Attachments are replaced regularly, and shared by
employees - Able to see work guide, sequential
inspection, and production plan by time zone to
actual result loss

• There is marker that allows visual management
• - Nameplate recorded/controlled regularly. Power
  Distribution panel, S/W/ equipment name CTQ
  process, Time Check

- Alarm lamp is installed and used - Be operated
so that upon changing 4M, anyone can know it
(Process signboard etc.) - Rules about 4M change
are managed, especially changed process is
managed preponderantly
- Production/quality situation shared, and
current Mfg. state board is operated -
Rreconsideration meeting reconsideration meeting
is held regularly, and situation of abnormal
symptoms is shared - RTY system is established,
and data upgraded regularly
- R/time on Error is shared and linked to
Improvement Activities - Be systematized so
that, upon abnormal conditions occurring, anyone
can realize it and it shall be not reoccurred
Conditions
Order
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T5S methods
NO.
Purposes
Remarks
Items
Contents
1) Objects ? JIG and molded mount ?Tool
kit,cleaning tool kit ? Indoor and floor ?
Original/subsidiary materials warehouse ? Factory
outer ?office 2) Progress
activities according to a management basis by
section ? Division/item name/department/reason
should be specified
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5 S
Seiri To dispose unnecessary things immediately
by classifying necessary and unnecessary things.
- Red Card (division, item name, department,
attachment reason, attachment date)
Seiton To show necessary things in designated
place for allowing that to be identified and used
easily by everyone.
1) Organizes needed things 2) Checks storage
place 3) Determines storage place using easier
method to follow 4) Marks storage place
position, item name 5) Maintains/checks marking
visibly (marks in thing itself or classifying
using color)
- Designates storage place for defective
products - Performs 3C
1) Uses a broom(prepare cleaning tools) 2)
Arranges section line passages, floor lines of
correct position ? Passages straight
lines,passing direction marking ?
Entrancedotted lines ?Position linesplace
designation ? Designation of line thickness and
color 3) Remove and improve the causes of dust or
dirt oil leaks, piping leaks, particle
blowing 4) Thorough cleaning cleaning of oil
soaked into floor, painting, wall, stepped area
Seisoh To make a work field clear by removing
dust, contamination, foreign materials, etc.
- 5S MAP - Signboard to divide 5S area -
Cleaning rules Designating a person in charge
of cleaning, method, tool, location, period (time)
SeiketsuTo maintain and improve 3S activities
of Seiri, Seiton and Seisoh.
- 5S evaluation
1) Periodic check and evaluation of clearing-up,
organizing or cleaning status 2) Selects and
executes continuously a month key theme ex) floor
cleaning 3) Checks the causes of dilapidation
is it too complicated ?
Is it too distant? Does
not it move back against work action? 4) Filming
of the pictures or VTR of dilapidated place.
Shitsuke To make oneself familiar with an
attitude to obey learned matters and designated
matters.
1) Leaders leadership 2) Proceeds activity on a
principle that total personnel attend
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T5S methods
Purposes
Remarks
Items
Contents
NO
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3 C
Standardization of how to place things Where
Correct position What Correct
thing (Correct container) How much
Correct volume
1) Uses signboard so as to be able to know place
and amount of parts correctly 2) Regulates amount
of stock marking of load height, amount
(max,min) 3) Attaches item name and ID card to
each part and thing 4) Standardization of used
container (size,amount etc) 5) Clears up of JIG
tool Piling table open/drawer-in arrangement 6)
Storage place is marked with line, positioned so
as to be able to search easily like supermarket
- Signboard - Standardization of container -
Connected with material handling improvement
activity
To perceive abnormal conditions of working field
quickly, to restore in normal conditions and to
minimize loss
1) Indication light ?Call indication Demand
of parts ?Abnormality indication Indicates
situation of assembly line, abnormal assembly
state etc. ?running indication Indicates
production situation/ machine running
?Progress indication Indicates work progress 2)
Signboard Attaches and manages signboard
periodically in order to be able to know 4M
change etc. 3) Defects indication
Attaches/positions markers in a such way that
positive/negative distribution within process is
definite 4) Production management Indicates
productive situation of line ?Plan/result
management 5) Attaches and manages the signboard
about how to work equipment
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Visual management
- Error Alarm - Current state board - Work
guide/new process/ sequential inspection card
etc. - OSD Table,TAGDistrict division
indication - Current state board of Production
management - Plant check table (lubrication
record table etc.)