Seiri = Sorting

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Quality Improvements
JAPAN
U.S.A
INDIA
1980
1950
1970
1960
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1. 5S Principles

• Elimination of waste
• Every body is involved, Co-operative effort
• Attack root cause
• Human being is not infalliable

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2. Objectives

• Improve housekeeping
• Make every individual responsible for
  housekeeping
• Beautify by simple means
• Productivity improvement by saving time, space
  etc.

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3. 5Ss

• Seiri - Sorting
• Seiton - Systematic arrangement
• Seiso - Cleaning
  Inspection while cleaning
• Seiketsu - Standardization
• Shitsuke - Self Discipline

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5S

• If we do not do 5S, we cant do any
• other work efficiently. They are features which
  are common to all places and are the indicators
  of
• how well an organization is functioning.

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SEIRI Sorting

• Meaning Distinguish between necessary and
  unnecessary items and eliminate the
  unnecessary items

Activity Establish a criteria for eliminating
unwanted items Eliminate unwanted items either
by disposing them or by
relocating them.
Success Area saved or percentage of space
available Indicator
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SEIRI Sorting

• Japanese Meaning The Japanese meaning of
  Seiri is to straighten and contain.
• - Get rid of waste and put it in order according
  to rules
• OTHER JAPANESE MEANINGS -
• farmland cultivation, Make an orderly system and
  straighten

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Seiri Sorting
What is unnecessary
1. Item is not needed 2. Item is needed however
quantity in stock is more than what is needed
for consumption in near future 3.
Contingency Parts Critically decide the
quantity of contingency parts to be retained
and criteria for such parts
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Organization
Frequency of use
Storage Method
Throw them out
Things you have not used in the past one year
LOW
Things you have used once in the last 6-12
months
Store at distance OR Keep in store
Things you have used only once in the last 2-6
months
Store it in central place in your zone
AVERAGE
Things used more than once a month
Store it in central place in your zone
Things used once a week
Store near the workplace
HIGH
Things used daily or hourly
Store near the workplace
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Seiri Sorting
Identifying unnecessary

• 1. Parts Work in Process (WIP)
• Things fallen back behind the machine or rolled
  under it
• Broken items inside the machine
• Things under the racks/ platform
• Extra WIP
• Stock of rejected items
• Items accumulated over period for rework
• Material awaiting disposal decision
• Material brought for some trial, still lying
  even after trial
• Small qty of material no longer in use

Contd..
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Seiri Sorting
Identifying unnecessary

• 2. Tools, Toolings, Measuring devices
• Old jigs, tools not in use are lying
• Modified tools, tooling for trial, are lying
  after trial
• Worn out items like bushes, liners, toggles etc.
  lying
• Broken tools, bits, etc. may be lying
• Measuring equipment not required for the
  operation
• being performed , is lying
• 3. Contingency Parts
• Many times storage place for contingency parts
  become
• a last refuge for broken parts, surplus items
  and things
• nobody is likely to use

Contd..
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Seiri Sorting
Identifying unnecessary

• 4. Shelves and Lockers
• Shelves and lockers tends to collect things that
  nobody
• ever uses , like surplus, broken items etc.
• 5. Passages and Corners
• Dust, material not required seem to gather in
  corner
• 6. Besides Pillars and under the stairs
• These places tends to collect junk, spittoon
  etc.
• 7. Walls and Bulletin Boards
• Old out dated notices which have lost their
  relevance
• Posters or bulletins on wall
• Dust, remains of torn notices, cell tape pieces

Contd..
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Seiri Sorting
Identifying unnecessary

• 8.Floor, Pits, Partitions
• Defective parts
• Protection caps, covers
• Packing material
• Hardware items , small items
• Even tools, tooling
• Items dropped on the floor are never picked
• 9.Computer Hard Disk
• Many unwanted, outdated, temporary files pile up

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Seiri Sorting
Improvement methods
1. Flow Process Chart (Procedural Analysis)
Drawing a process flow chart for the system eg.
How to make and use category wise grouping 2.
Operational Analysis Preparing the sequence of
operations for system eg. How to perform Seiri
(sorting) 3. Check List A check sheet is used
to decide what sort of main system and sub system
are necessary.
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Seiri Sorting
Dealing with papers
How to reduce papers on your table ?
1. Make a single pile of papers 2. Go through
them and sort in following categories
a) Immediate action b) Low priority c)
Pending d) Reading material e) For information
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Seiri Sorting
Dealing with papers
How to reduce papers on your table ?
4 D Principle DO DELEGATE DELAY DUMP
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SEITION Systematic Arrangement

• Meaning To determine type of storage and
  layout that will ensure easy accessibility
  for everyone .

Activity - Functional storage - Creating place
for everything and putting everything in
its place
Success - Time saved in searching Indicator -
Time saved in material handling
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SEITION Systematic Arrangement

• Japanese Meaning
• Dictionary meaning of Seiton is to be correctly
• preparedand to prepare correctly.
• In short these means
• (a) arrange correctly in accordance with the
  correct method of doing activities and
• (b) make thorough preparations so that activities
  can be done even if they occur abruptly

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SEITION Systematic Arrangement

• The main target areas for Seri-Seiton improvement
  are
• Tool-setting and preparation operations, line
  balancing and process planning, parts supply to
  assembly line, peak time problems etc.
• Improvement Methods
• Kit Method / Assembly box method / Outside
  tool setting
• Cassettisation / Parallel operations / Changes
  in assignment method

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Seiton Systematic Arrangement

• How to achieve Systematic Arrangement ?
• Decide where things belong
• Decide how things should be put away
• Obey the Put away rules

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Seiton Systematic Arrangement

• How to achieve Systematic Arrangement ?
• Decide where things belong
• - Standardize Nomenclature
• - Determine an analytical method of storage
• Decide how things should be put away
• - Name locations to everything. Label both
  item
• and location
• - Store material functionally
• - Prevent mistakes with coding by shapes
  colour
• contd..

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Seiton Systematic Arrangement

• How to achieve Systematic Arrangement ?
• Decide how things should be put away
• - Follow first in first out rule
• - If two identical items are to be located,
  then store
• them separately, colour code them.
• Obey the rules
• - Put the things back to their location after
• their use

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Seiton Systematic Arrangement
USE 1 ) Signboards 2) Colour codes 3)
Outline markings 4) Labels
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Seiton Systematic Arrangement
Functional
Storage
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Seiton Systematic Arrangement
Usage Frequency

• Store frequently used material
• near the workplace and less
• frequently at some distance

• Heavy material should be stored
• at lower levels/layers
• Place directly on the material
• handling device for ease of
• handling

Weight Shape of the Material
Functional Storage
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Seiton Systematic Arrangement

• Same category of material may be
• stored in one location.
• Eg. Allen Screws, Oil Seals

Category

• All items required for an
• operation may be stored in one
• location.
• Eg. Allen key, spanner etc hand
• tools required for setting m/c

Operation Wise
Functional Storage
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Seiton Systematic Arrangement

• Outlining and Placement Marks
• - Mark boundaries of dept., aisles, Machines
• - Follow straight line, right angle rule
• - Nothing shall be kept outside the
  boundaries
• Stands and shelves
• - Keep only required number of stands and
  shelves
• - Standardize height, size
• - Provide casters where necessary so that it
  can be
• moved

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Seiton Systematic Arrangement

• Wires and Ducts
• - Colour code
• - When there are multiple connections -
  bundle the
• wires, label them and make sure that they
  are in
• straight line /right angle and firmly
  anchored
• Machine-tools Tools
• - Put the tools in the order you need them
• - Location of the tool should be such that it
  can be
• put away with one hand
• - Try to eliminate some hand tools by
  permanently
• attaching it to the bolt head

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Seiton Systematic Arrangement

• Blades, Dies, Other important consumables
• - Store them in the protected place
• - Maintain these things regularly by applying
  rust
• preventive, oiling etc.
• WIP- Work In Process
• - Designate a place for each component/part
• - Decide on how much quantity to be stored
• - Ensure that there is no damage to good part
  
• during transit, they do not get rusty and
  they are
• not mislabeled

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Seiton Systematic Arrangement

• Oils
• - Reduce number of oils used (Standardize)
• - Colour code for oil
• - Safety aspects - fire prevention,
  pollution, leak,
• spillage
• Instrumentation Measuring Devices
• - Label them, show direction of flow

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SEISO Cleaning

• Meaning Cleaning trash, filth, dust and other
  foreign matter. Cleaning as a form of
  Inspection

Activity - Keep workplace spotlessly clean -
Inspection while cleaning - Finding minor
problems with cleaning inspection
Success - Reduction in machine down
time Indicator - Reduction in no. of accidents
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SEISO Cleaning

• Japanese Meaning
• Dictionary meaning to clean up and
• getting rid of dirt and unclean items
• While cleaning potential defects such as
  abrasion, damage, loose parts, deformities, leaks
  temp., vibration, abnormal sound etc. are
  revealed hence Seiso is Inspection

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Seiso Cleaning

• Here cleaning means more than just keeping
• things clean. Cleaning should be viewed as a
• form of Visual Inspection
• Preventive measures should be taken to tackle
• problems of dust, grim, burrs, leakage etc.
• Root cause of the problem should be identified
• and it should be eliminated

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Seiso Cleaning
Various Minor Defects Trash
Dirt Knocking Loose parts
Leaks Scattering Skips Curvature Abrasion R
ust Scratches Eccentricity Lurching Abnormal
Vibration Movements Abnormal
Heat Abnormal Sounds smells Faded
colour Hisses
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Seiso Cleaning

• 5 Minutes Every day for cleaning
• Devote 5 minutes everyday for cleaning your
• work area
• Participation of everyone is required
• Attack hard to clean places regularly

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Seiso Cleaning
Cleaning-Inspection points for most equipment
Grime, clogging, dust balls, rust, leakage etc.
Cleaning
No oil, Low oil, leakage, filter clogging, dirty
oil, dirty or bent oil lines, clogged drainage,
oil spillage, worn torn ports etc.
Oils
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Seiso Cleaning
Cleaning-Inspection points for most equipment
Loose bolts, welding detachment, loose parts,
vibration or bumping noise, friction
Tightening
Oil tanks, motors, heater, axles, control panels,
washing/ cleaning water, bearing, wiring etc.
Heat
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Seiso Cleaning
Cleaning-Inspection points for most equipment
Breakage, cracks, dent on sliding parts, handle
has come off, broken switches, wire joints come
off, wires are broken or crack, crack dial
of various pre. gauges, meters etc.
Breakage, Cracks
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Seiso Cleaning
Function wise Cleaning check list of equipment
Compressed Air lines, air valves, connections,
meters, filters, reservoirs etc.
Pneumatics
Hydraulic oil tank, oil valves, filters, pumps,
hoses, gauges, cylinders etc.
Hydraulics
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Seiso Cleaning
Function wise Cleaning check list of equipment
Motor fan, fan belt, couplings, Joints, pulleys,
chains, pump bearings etc.
Mech Power Train
Electrical
Control panel, lamps, light, switch, sensors,
wiring, ducts, fuses etc.
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Seiso Cleaning
Function wise Cleaning check list of equipment
Tools, fixtures, gauges, dies, measuring
instruments, etc.
Toolings
Equipment Specific
Furnaces, rollers, chutes, CNC machines, etc.
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SEIKETSU Standardization

• Meaning Setting up standards / Norms for a neat,
  clean, workplace and details of how to maintain
  the norm (Procedure)

Activity - Innovative visual management -
Colour coding - Early detection of problem and
early action
Success Increase in 5S indicator Indicator
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SEIKETSU Standardization

• Japanese Meaning
• Dictionary meaning
• unsoiled things, purity and cleanliness
• Clean manners ,
• Clean cloths, clean politician
• It is the proof that 3 Ss are being faithfully
• carried out.

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SEIKETSU Standardization

• Tools used for analysis
• MTTR
• MTBF
• OEE

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Seiketsu Standardization

• Regularizing 5S activities so that
• abnormalities are revealed
• Make it easy for everyone to identify
• the state of normal or abnormal
• condition
• For maintaining previous 3S, deploy
• visual management

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Seiketsu Standardization

• It has been estimated by scientific
• study that 60 of all human activities
• starts with sight
• 5S is easy to do once.It is consistency
• that is difficult. That is why Visual
• Management is so important, so that
• everybody will know that there is
• some problem.

Visual Management
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Seiketsu Standardization

• What visual control communicates ?
• It grabs one or more of our senses in
• order to
• Alert us to an abnormality
• Help us recover quickly
• Promote adherence and prevention
• Enable successful self management

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Seiketsu Standardization

• Some methods for visual communication
• Colour coding
• Use of Labels
• Danger alerts
• Indication where things should be put
• Directional arrows/ marks
• Transparent covers
• Performance indicators

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Seiketsu Standardization

• Some methods for visual communication
• Labels
• Precision management labels
• Inspection labels
• Temperature labels
• Responsibility labels

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Seiketsu Standardization
Points to remember in making visual c control
tools 1. Make them easy to see from distance 2.
Put the display on the things 3. Everyone can
tell what is right and what is wrong 4.
Anybody can follow them and make necessary
corrections easily 5. Work place should look
brighter orderly
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Seiketsu Standardization

• Some everyday visual management
• examples
• Traffic signal
• Zebra crossing
• In car - Petrol indicator
• - Speed indicator
• Direction arrows
• Electric danger sign etc.

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Seiketsu Standardization
Some visual communication signs
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SHITSUKE Self Discipline

• Meaning Every one sticks to the rule and makes it
  a habit

Activity - Participation of everyone in
developing good
habits - Regular audits and aiming for higher
level
Success High employee morale Indicator
Involvement of all people
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SHITSUKE Self Discipline

• Japanese Meaning
• Dictionary meaning is
• learning of the manners
• having manners, dressing neatly OR
• training children for good customs

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SHITSUKE Self Discipline

• Activities
• 5S Committee
• 5S Training
• 5S Competition / evaluation
• 5S Month
• Posters , Literature etc.

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Shitsuke Self Discipline
We need everyone to maintain 5S guidelines. To
maintain DISCIPLINE, we need to practice and
repeat until it becomes a way of
life. Discipline is the Core of 5S
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Shitsuke Self Discipline
Discipline means making a steady habit of
properly maintaining correct procedure. Time
and effort involved in establishing proper
arrangement and orderliness will be in vain if
we do not have discipline to maintain it.
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Shitsuke Self Discipline
Pledge

• It shall be my constant effort to
• maintain my workplace in good
• order by
• Assigning a place for everything
• keeping everything in its place
• Sorting out unwanted material
• periodically discarding them
• Keeping my work area neat
• clean everyday

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Organization

• Departments into areas
• Coordinators at department level
• Coordinator at each area level
• Training for all
• Audit each area and make action check list
• Implement actions
• Audit and evaluation on continuous basis

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Implementation Target

• TOTAL FACTORY
• 400 people/month to be trained
• Every 3 month 25 area will be covered