5 s in Manufacturing
The 5S methodology which originated in Japan, is based on the notion that the foundation of a good production system is a clean and safe work environment. The 5S – Seiri, Seiton, Seiso, Seiketsu and Shitsuke are translated ...
5 s in Manufacturing
A work place organization method, developed to, create a comfortable working environment, increase productivity and efficiency and reduce waste. It is typically the first lean method, which also provided foundation on which other lean methods – six sigma, cellular manufacturing, just-in-time production, etc. were introduced.
The 5S methodology which originated in Japan, is based on the notion that the foundation of a good production system is a clean and safe work environment. The 5S – Seiri, Seiton, Seiso, Seiketsu and Shitsuke are translated from Japanese language to the closest English equivalents - Sort, Set in order, Shine, Standardize, and Sustain. Apart from the 5S’s, three other S’s are sometimes included – Safety, Security and Satisfaction.
Organizing the work area, by keeping only the essential tools and materials to perform the required task, so as to increase the product quality and productivity. Sorting also helps reclaim valuable floor space. “Red tagging” is one effective visual method used for sorting (Red-tagged items are those not important to perform the required task).
Systematically arranging necessary objects to eliminate waste in production and clerical activities. Placards to designate proper storage locations, outlining work areas are few of the strategies for effective set in order.
Maintaining clean and well swept work area, which is safer and mess-free. Potential problems caused by any sources of contamination can be easily identified and rectified, by developing standards and norms for cleanliness.
Developing and formulizing standard operating procedures for carrying out tasks and procedures. Orderliness is the core of “standardization”. The most widely used tools to standardize the practices are job cycle charts and visual cues.
It is the one that keeps the first four S’s going and perhaps is the most difficult S to implement. The prerequisites for sustaining the 5S cycle - Imparting the necessary training, encouraging workers to properly maintain and continuously improve operating procedures and the workplace environment.
Toyota was the first company to implement 5S and the main objectives to adopt 5S were to facilitate team work, eliminate wastes that contribute to errors, defects and injuries. The company had implemented 5S by imparting the necessary training to the workforce from the shop floor to the management and rewarded to encourage them, to maintain and continuously improve operating procedures.
5S being one of the important principles of Toyota company, helped it achieve high performance that continues to add value to customers.
Though 5S is a system designed to build a work ethic that is practical, efficient and highly disciplined, it has a few potential short comings like increased use of paints and cleaning supplies, increased waste generation leading to complications in waste handling. However, the advantages of 5S far outweigh the disadvantages.
The article has been contributed by Sujitha Tikka, who is presently a first year PGP student at IIM Raipur. She has worked with Aarvee Associates architects engineers & Consultant Pvt Ltd for 25 months. Her areas of interest include Supply chain management & logistics.She can be reached at pgp12048.sujitha@iimraipur.ac.in.
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3M (1) Amazon (1) Apollo Hospitals (1) Apple (1) bajaj (1) Big Bazaar (1) Blackberry (1) Cisco (1) Dabur (1) Daimler (1) Dell (1) Disney (1) Dominos (1) Flipkart (2) GE (2) Hindustan Unilever Limited (1) Hitachi (1) Honda (1) Hyundai (1) Mahindra and Mahindra (1) Maruti (3) McDonald (1) Mitsubishi (1) Motorola (1) Nissan (1) Pepsi (1) Proctor and Gamble (2) RIM (1) Safexpress (2) Starbucks (1) Suzuki (1) Tata Motors (1) TCS (1) Toyota (3) Walmart (5)
The 5S methodology which originated in Japan, is based on the notion that the foundation of a good production system is a clean and safe work environment. The 5S – Seiri, Seiton, Seiso, Seiketsu and Shitsuke are translated from Japanese language to the closest English equivalents - Sort, Set in order, Shine, Standardize, and Sustain. Apart from the 5S’s, three other S’s are sometimes included – Safety, Security and Satisfaction.
Organizing the work area, by keeping only the essential tools and materials to perform the required task, so as to increase the product quality and productivity. Sorting also helps reclaim valuable floor space. “Red tagging” is one effective visual method used for sorting (Red-tagged items are those not important to perform the required task).
Systematically arranging necessary objects to eliminate waste in production and clerical activities. Placards to designate proper storage locations, outlining work areas are few of the strategies for effective set in order.
Maintaining clean and well swept work area, which is safer and mess-free. Potential problems caused by any sources of contamination can be easily identified and rectified, by developing standards and norms for cleanliness.
Developing and formulizing standard operating procedures for carrying out tasks and procedures. Orderliness is the core of “standardization”. The most widely used tools to standardize the practices are job cycle charts and visual cues.
It is the one that keeps the first four S’s going and perhaps is the most difficult S to implement. The prerequisites for sustaining the 5S cycle - Imparting the necessary training, encouraging workers to properly maintain and continuously improve operating procedures and the workplace environment.
Toyota was the first company to implement 5S and the main objectives to adopt 5S were to facilitate team work, eliminate wastes that contribute to errors, defects and injuries. The company had implemented 5S by imparting the necessary training to the workforce from the shop floor to the management and rewarded to encourage them, to maintain and continuously improve operating procedures.
5S being one of the important principles of Toyota company, helped it achieve high performance that continues to add value to customers.
Though 5S is a system designed to build a work ethic that is practical, efficient and highly disciplined, it has a few potential short comings like increased use of paints and cleaning supplies, increased waste generation leading to complications in waste handling. However, the advantages of 5S far outweigh the disadvantages.
The article has been contributed by Sujitha Tikka, who is presently a first year PGP student at IIM Raipur. She has worked with Aarvee Associates architects engineers & Consultant Pvt Ltd for 25 months. Her areas of interest include Supply chain management & logistics.She can be reached at pgp12048.sujitha@iimraipur.ac.in.
Fast food restaurants are unique operational systems designed to provide customers with efficient and responsive services. Such systems cons...
Pepsi Pennsauken is easing distribution flow by outfitting its sales representatives with handheld computers that instantly send data back...
In 1960, two brothers who were students of the University of Michigan - Thomas S. Monaghan (Thomas) and James S. Monaghan (James) - bought t...
Some think that the retail industry has matured and there are no new opportunities, but Hindustan Unilever Limited (HUL) doesn’t think thi...
Ghari detergent, a product of Rohit Surfactants Private Limited (RSPL) has overtaken all the biggest multinational brands to become the sec...
Manufacturers and retailers have almost always been adversaries for each other, each trying to gain leverage over the other for better profi...
At Mc Donald’s Fast Food Restaurant, strategy of Just in time has been applied and has brought many benefits to the organization and added ...
Anything critical that has to be done must and will be done with enough thought and precaution. But, whatever be the case, one is definit...
3M (1) Amazon (1) Apollo Hospitals (1) Apple (1) bajaj (1) Big Bazaar (1) Blackberry (1) Cisco (1) Dabur (1) Daimler (1) Dell (1) Disney (1) Dominos (1) Flipkart (2) GE (2) Hindustan Unilever Limited (1) Hitachi (1) Honda (1) Hyundai (1) Mahindra and Mahindra (1) Maruti (3) McDonald (1) Mitsubishi (1) Motorola (1) Nissan (1) Pepsi (1) Proctor and Gamble (2) RIM (1) Safexpress (2) Starbucks (1) Suzuki (1) Tata Motors (1) TCS (1) Toyota (3) Walmart (5)
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