Unit of Competence: Apply 5s procedures

Module Title : Applying 5s procedures

Learning outcomes;
Lo1; develop understanding of quality system
Lo2; Sort needed items from unneeded
Lo3; Set workplace in order
Lo4; Shine work area
Lo5; Standardize activities
Lo6; Sustain 5S system
 Lo1; develop understanding of quality system
• Quality assurance (QA) is a process-centered
approach to ensuring that a company or
organization is providing the best possible
products or services.
• It is related to quality control, which focuses on
the end result, such as testing a sample of items
from a batch after production.
• quality assurance focuses on enhancing and
improving the process that is used to create the
end result, rather than focusing on the result itself.
• Good QA requires
good social skills,
communication skills, and
unilateral thinking and
acting on the QA person's part
gathering and implementing semantics from the
customer, not just heartless specifications
Quality Assurance Systems
• Quality assurance is an organized way in which systems and
procedures are tested and maintained for the highest possible
production and efficiency.
Quality Control and Assurance
• This is especially important for service-oriented companies,
because the employees are the product that they provide to
customers.
• Often, quality control is confused with quality assurance.
Though the two are similar, but there are some basic
differences.
• One of the reasons that many people use quality assurance
and quality control interchangeably is that there is often a
great deal of overlap in terms of the personnel that engage in
each phase.
Quality Assurance Jobs
• Training department managers to locate and correct
potential problems before they occur is a huge
aspect of quality assurance, not only from a profit
standpoint, but also from a safety standpoint.
• In some industries, quality assurance directors also
work alongside the staff to create new products or
improve existing ones, meaning that they have to be
extremely organized and very flexible within their
daily operations.
• Quality assurance jobs typically require a strong
knowledge of the business processes of an
organization.
5S system
The heart and soul of visual management is 5S. It is systematic
approach to workplace organization and cleaning that will
transform a disorganized workplace into an efficient running
machine.
 The 5Ss are: listed by English & Japanese language
• Sort (Seiri) – The first step in 5S is to eliminate all the things in
the workspace that are not being used and store them away.
If a tool are material is not used on a daily basis, eliminate it
from the workstation.
• Set in Order(Systematize / Stabilize / Straighten)(Seiton) –
The second step is to arrange the items used on a daily basis
so that they can be easily accessed and quickly stored. Your
goal is to make eliminate any unnecessary movements and
actions by the worker to make his process as efficient as
possible.
• Shine/Sweep/Clean (Seiso) – Next is to get everything
cleaned and functioning properly. The goal is to remove
all the dirt and the grime and to keep it that way on daily
basis. You want to get it clean and keep it clean.
• Standardize/Sanitize (Seiketsu) – The fourth step is to
develop a routine for sorting, setting and shining.
Standardize creates a system of tasks and procedures that
will ensure that the principles of 5S are performed on a
daily basis.
• Sustain/Self-discipline (Shitsuke) – In the last step, you
want to create a culture that will follow the steps on a
daily basis. The chief objective of sustain is to give your
staff the commitment and motivation to follow each step,
day in and day out.
What is 5S?
5S is a systematized approach to:
 organize work areas
 keep rules and standards
 maintain discipline
5S utilizes for:
 workplace organization
 work simplification techniques
5S practice:
 develops positive attitude among workers
cultivates an environment of efficiency,
effectiveness and economy
What can you gain from 5S?
Practicing 5S brings benefit not only to the company’s
business but also to the people who practice it.
• 5S makes your workplace more pleasant
• 5S makes you work more efficiently
• 5S improves your safety
What can a company gain from 5S?
• 5S increases PRODUCTIVITY.
• 5S improves QUALITY.
• 5S reduces COST.
• 5S makes DELIVERY on time.
• 5S improves SAFETY.
• 5S improves MORALE.
Why 5S brings such benefits?
• 5S improves CREATIVITY of people.
• 5S improves COMMUNICATION among
people.
• 5S improves HUMAN RELATIONS among
people.
• 5S improves TEAMWORK among people.
• 5S improves CAMARADERIE among people.
• 5S gives VITALITY to people.
 5S in WORK STATIONS
VISIBLE RESULTS:
• Decrease in the number of accidents and close calls
• Proper storage
• Improved productivity
• Greater people involvement in improvement activities
• Better use of floor space
• Early detection of problems
• High product quality
• Decreases delay
• Low employee turnover
• Low machine breakdown rates
• Detection system
• Zero breakdown
INVISIBLE RESULTS:
• Happier employees with high morale.
• Happier customers.
5S PHILOSOPHY
• Productivity comes from the elimination of
waste
• It is necessary to attack the root cause of a
problem, not just the symptoms
• Participation of everybody is required
LO2; SORTS NEEDED ITEMS FROM UNNEEDED SEIRE (SORT)

Sorting is a step that involves selecting what you

need to complete the job and removing everything
else from your work area.
• Taking out and disposing unnecessary items.
• Sort/classify the items that you “need” from the
items that you “want or not needed”.
• Dispose the items that you do not need and
regroup the items that you need..
• Clearly distinguish needed (frequently used) items
from unneeded items and eliminate the later.
• PROCESS/PROCEDURE:
Step 1: - Look around your workplace with your colleagues.
Decide and identify which items are unnecessary for you.
Dispose of unnecessary items.
Step 2: - If you and your colleagues cannot decide if an item is
unnecessary, place a Disposal
Notice on the item,
indicate the date and set the item aside.
Step 3: - After a certain period, check if the item is still needed or
not.
• If no one needs the item after 3 months, it only means that
the item is no longer needed hence, dispose the item right
away.
NOTE:
• It is recommended that this approach be used
company-wide, involving people from
different departments.
• Never keep anything which is unnecessary to
your work.
• While looking around for unnecessary items in
your workplace, look at every nook and corner
like when you are looking for cockroaches.
 LO3; SET WORKPLACE IN ORDER
SEITON (SYSTEMATIZE / SET IN ORDER /
STRAIGHTEN)
This step customizes your workstation and
surrounding area to meet your work area needs.
Arrange remaining items so they are easy to
select, use, and to return to their proper location.
• Arrangement / organization of necessary items
in good order for use.
• Keep needed items in correct place and
sequence of use to allow easy and quick
retrieval.
PROCESS/PROCEDURE:
Step 1: - Make sure that all unnecessary items are eliminated
from your workplace.
• Decide where you can place necessary items.
• Take into consideration the flow of your work.
• Take into account the movement of carts or even people
passing your desk from this
• point of view to ensure safe and efficient operation.
Step 2: - Place frequently needed items close to the user to
minimize effort and time wastage.
• Things that are not used often could be places slightly
farther away.
• Make a plan on these principles and locate/store things
accordingly.
Placement of Materials/Equipment Based on
Frequency of Use
priority Frequency of Use How to Store
low Less than once a year Throw away
Once a year or so Store in distant place

average Once every 2-6 months Store together some-

Once a month where in the office
Once a week
high Once a day Carry or keep at
Once an hour your workplace
STEP 3: - It is necessary to make sure that
everyone in your workplace knows where things
are
• kept for efficient use.
• Make a list of things with their locations.
• Label each drawer and cabinet to show what
is kept inside.
STEP 4: - Apply the same principles as in Step 3.
• Indicate the places where fire extinguishers
are located as well as passages for carts.
• Place warning signs for safety precautions.
NOTE:
Three Rules for Storage Space
• Get rid of all unnecessary items
• Decide proper storage layout/classification
• Standardize names
Arrange necessary items in good order
• prevent loss and waste of time
• easy to find and pick up necessary items
• ensure first-come-first-served basis
• make production flow smooth and work easy
SEITON PRACTICES
• Don’t place goods in frontage along passages
• Store goods for first-in-first-out retrieval
• Everything must have its location
• Label items and their location systematically,
mark everything Separate special tools from
common ones
• Frequently used items nearer to the user
• Make things visible to reduce searching time,
organize by color
• Keep space for safety equipment and
evacuation passages clear
 LO4; SHINE WORK AREA
SEISO (SHINE / SWEEP)
This step is powerful because its purpose is to
find the reason why things become dirty.
• Emphasis is on the removal of dust, dirt and
grime to reveal the source and eliminate it.
• Cleaning of the workplace, including tools and
equipment
• Clean it so that defects are so easy to spot and
eliminate.
PROCESS/PROCEDURE:
Step 1: - Determine the subject of clean up (what to clean)
• e.g., location (storage, shelves, etc.), equipment, space
(passageway, room, etc.)
Step 2: - Assign persons responsible for cleanup (who,
where).
Step 3: - Determine the method of clean up (how to do it).
• Target the areas for cleaning (storage, equipment and
surroundings)
• Draw up a cleaning responsibility map
• Create a cleaning schedule.
Step 4: - Implement cleaning.
Step 5: - Make a daily 5-minute cleaning habit before going
home (Keep it simple and easy to understand.)
NOTE:
• Do not wait until things get dirty.
• Clean your workplace; machines and equipment,
tools and furniture regularly.
• Put aside 3-minute of seiso per day.
• Be responsible for your own work area.
• Never throw anything and make it your habit.
• Cleaning is also checking.
Clean your workplace completely
keep environmental condition as clean as the
level necessary for the products
prevent deterioration of machinery and
equipment and make checking of
abnormalities easy
Keep workplace safe and work easy
SEISO PRACTICES
• Big Seiso ( Clean-Up Day )

• 3-5 minute cleaning daily

• Assign owner to each machine

• Combine cleaning with inspection

• Make daily maintenance points clear by providing

visible instructions
• Prevent causes of dust and dirt
 LO5; STANDARDIZE ACTIVITIES
SEIKETSU (SANITIZE / STANDARDIZE)
• This step creates a work area free of
checklists; if good standards are put in place it
will be easier to maintain and continue
improving.
• Maintaining the workplace in high standard of
housekeeping and organization.
• Set easy-to-follow standards and develop a
structure to support the three first (S’s) pillars.
PROCESS/PROCEDURE:
Step 1: - Establish standards for maintaining
compliance with 3S.
Remember the 3 “NO” principles:
No unnecessary items
No mess
No dirt
Step 2: - Make a schedule for cleaning your
workplace.
Step 3: - Interdepartmental competition and
cooperation is a very effective means of sustaining
and enhancing people’s interest in 5S
Maintain a high standard of housekeeping and
workplace organization at all times.
• Maintain cleanliness and orderliness
• Prevent miss-operation
• Make it easy to find out abnormality
• Standardize good practices
SEIKETSU PRACTICES
• Visual control signs
• Color coding
• Maintenance labels
• Fixed-point photography
 LO6; SUSTAIN 5S SYSTEM
• SHITSUKE (SUSTAIN/SELF-DISICPLINE)
• Sustaining is the end result of how well we
have performed the previous four S’s.
• In the sustainability stage, think of ways to
eliminate effort in maintaining an area.
• Doing things spontaneously without being
told.
• Educate people so that 5S expands beyond
initial limits and turns into natural standard
behavior.
PROCESS/PROCEDURE:
Step 1: - Create reasonable rules.
• Create reasonable rules of behavior in the workplace.
• Engage everyone concerned in the creation of rules
not just the department heads or supervisors.
• Discuss the rules with everyone concerned. This will
result to a feeling of involvement.
• Show rules and standards clearly and attractively using
illustrations, photographs and color-coding.
Step 2: - Exhibit before and after 5S photos where
everyone will see them.
Step 3: - Recognize good practices and good
performance.
Train people to follow good housekeeping rules autonomously.
• Enhance autonomous management activities
• Maintain the discipline needed to do a good job
• Upgrade productivity and quality consciousness
• Wash hands after going to the toilet
• Wash hands before and after meals
• Eat and smoke at designated places
• Keep workplace always clean and tidy
• Wear clean uniform and shoes
• Follow safety rules
• Put things back in their proper places
• Work according to standards
• Observe proper office decorum
 E ND
TH E