5S Implementation : Creating Disciplined People and Bright Factory Through 5S
here are five factors attributing company’s success, namely man, money, machine, material and method. But, the Japanese has added one more factor, namely workplace environtment is defined as how a workplace is managed and how the employees maintain their wokplace. This reflects employees’ attitude towards their work.
5S stands for the following Japanese words : Seiri, Seiton, Seiso, Seiketsu and Shitsuke, which respectively means : Sort Out, Set In Order, Shine, Standardize, sustain. Basically 5S is focused on workplace organizing activities. 5S is considered as the fundamentals of quality and productivity improvement programs.
5S is a method to educate employees ‘Work dicipline to create a comfortable, safe, and free of waste workplace. In this way, the factory will function like a “showroom”. In turns this will directly contribute to productivity, quality and safety improvement.
The 5S Program Can Accelerate Time Processing (Process Flow)
Spare Parts Area
- Develop systems and standardization of structuring spare parts (spare parts management) to speed up the search time, reduce loss and damage
- Develop a system of ordering and inventory of spare parts using historical data of customer demand (demand analysis)
Office Area
- Designing process / document work flows, utilizing visual aids and document storage systems can speed up the search time
- Visualizing the progress of work to facilitate control and improve the service level (level of service)
5S Program Can Help Improve Service (Service Level)
Service Part Area
- Standardization process flow receipts, repair (service) and delivery (after repair / service).
- Standardization time interval completion of repair (service), such as: Service Light, Medium and Heavy
- Visualization control person in charge of the work, daily work items and control the status of the job
Home Service Machine Area
- System settings laying machine
- Standard machine status (target workmanship, in the repair / ready)
- The standard of cleanliness machine ready for use
- Quality Check / Inspection (Checklist) and completeness of the machine after service
- Given the limited area, designed to accelerate the turnaround process flow in and out of the machine after service
5S Program Can Help Reduce Potential Damage (Defect) and Error
Warehouse Rental Machine Area
- Standardization of component placement machine (leg machine) potential defect (defect)
- Speeding pickup
- Easy cleaning area
- Inventory control components / parts and easy identification number set visually
Office Service Area
- Standardize the placement of goods ready to be shipped to consumers
- Standardization document placement
- Reduce errors pickup
- Improving the quality of service and speed of service (Service Level)
Background
Have you ever wasted your time searching for a document?Searching for things but fail to find them, and ending up by having to buy them again? Do you feel you lack of space for keeping documents or supplies of materials? Time is merely spent on unnecessary movement? Having no idea who is borrowing a document? Important documents are are mixed with other ones? Is it not clear who is suppossed to be responsible for office cleaningand tidiness?
These problems commonly occur in the office. They reflect the lack of of employees’ care for their own workplace. How much is wasted?
Such wastes will be reveald and solve through the implementation of “5S in the office” program. 5S is the abbreviation of the following five Japanese words : Seiri, Seiton, Seiso, Seiketsu and Shitsuke which respectively means : Sort Out, Set In Order, Shine, Standardize, Sustain. 5S is considered as the fundamentals of quality and productivity improvement programs.
The implementation of 5S in the office emphasize the importance of employees’ care on non-added value as to create a comfortable, safe and efficient workplace. In this way, the office may function like a “showroom”. Ultimately, this will directly contribute to productivity, quality and safety improvement.
About The Program
Program Objectives
- To promote awareness of the importance of workplace/Gemba
- To understand KAIZEN as the basic philosphy of 5S
- To understand the concept and the benefit of 5S
- To understand the implementation steps of 5S in the office
Program Outline
- The importance of workplace/Gemba
- Kaizen (Continuous Improvement) : 5S basic philosophy
- 5S concepts, definition nad benefit
- Implementation steps of 5S in the office:
- Organization of 5S
- 5S step-by-steps
- 5S
- Key success factors of 5S implementation in the office
Background
Stands for the following Japanese Words : Seiri, Seiton, Seiso, Seiketsu and shitsuke which respectively means : Sort Out, Set In Order, Shine, Sandardize, sustain. 5S is a method to improve wokplace and at the end will promote a disciplined working culture.
A good 5S implementation may be reflected through, for example : Easy and quick search for documents, items, tools or materials. As the result, there’s a guaranty of a comfortable, clean & tidy workplace is guaranteed, no unnecessary items are scattered around and disciplined employees in implementing the working standards.
The 5S application in companies is often not smooth and even gets stuck. There are many reasons for this, among others : lack of management support, absence of system to monitor its application and so on. Aome companies at first successfully implemented the 5S but gradually the application degraded before it totally “disappeared” from their workplace.
One way to maintain and improve the quality of 5S is to evaluate the level of achievement in the workplace through reguler 5S audits.
About The Program
Program Objectives
- To understand the role and benefit of 5S audit in 5S
- To understand the steps of 5S audit imlementation in companies
- To be able to conduct 5S audit
Program Outline
- 5S Overview
- Audithor : roles and responsibilities 5S audit implementation steps in the company
- 5S audit tools
- Key success of 5S audit in 5S implementation
- 5S audit exercise
- Report & Follow up of 5S audit
Background
A good warehouse is the one which is well organized and enable the users to manage its functions, namely : receiving, allocation, storage, preservation, maintenance and retrieval.
Meeting these requirements needs a disciplined, efficient, productive industrial culture and work system to manage the warehouse. One of the principles of the principles of culture & work pattern building is to manage the workplace properly through the implementation of 5S in the warehouse. The activities to manage the workplace are known as 5S, which stands for the following Japanese words : Seiri, Seiton, Seiso, Seiketsu and shitsuke.
The core application of 5S in the warehouse is on how to organize effectively the warehouse activities, such as receiving, allocating, keeping, protecting, maintaining and taking out. It is expected that 5S implementation will create a safe warehouse and efficient operations for all parties who interact with warehouse.
About The Program
Program Objectives
- To create awareness of the importance of warehouse management
- To understand KAIZEN as the basic philosophy of 5S
- To understand the implementation steps of 5S in the warehouse
Program Outline
- The challenge in warehouse management
- 5S Concept Overview
- 5S role in improving efficiency & effectivity of warehouse management
- Implementation steps of 5S in the warehouse:
1. 5S ste-by-step 2. 5S tool
- + Benefit of 5S Implementation
The 5S Program Can Accelerate Time Processing (Process Flow)
Spare Parts Area
- Develop systems and standardization of structuring spare parts (spare parts management) to speed up the search time, reduce loss and damage
- Develop a system of ordering and inventory of spare parts using historical data of customer demand (demand analysis)
Office Area
- Designing process / document work flows, utilizing visual aids and document storage systems can speed up the search time
- Visualizing the progress of work to facilitate control and improve the service level (level of service)
5S Program Can Help Improve Service (Service Level)
Service Part Area
- Standardization process flow receipts, repair (service) and delivery (after repair / service).
- Standardization time interval completion of repair (service), such as: Service Light, Medium and Heavy
- Visualization control person in charge of the work, daily work items and control the status of the job
Home Service Machine Area
- System settings laying machine
- Standard machine status (target workmanship, in the repair / ready)
- The standard of cleanliness machine ready for use
- Quality Check / Inspection (Checklist) and completeness of the machine after service
- Given the limited area, designed to accelerate the turnaround process flow in and out of the machine after service
5S Program Can Help Reduce Potential Damage (Defect) and Error
Warehouse Rental Machine Area
- Standardization of component placement machine (leg machine) potential defect (defect)
- Speeding pickup
- Easy cleaning area
- Inventory control components / parts and easy identification number set visually
Office Service Area
- Standardize the placement of goods ready to be shipped to consumers
- Standardization document placement
- Reduce errors pickup
- Improving the quality of service and speed of service (Service Level)
- + Promoting Efficiency through 5S In The Office
Background
Have you ever wasted your time searching for a document?Searching for things but fail to find them, and ending up by having to buy them again? Do you feel you lack of space for keeping documents or supplies of materials? Time is merely spent on unnecessary movement? Having no idea who is borrowing a document? Important documents are are mixed with other ones? Is it not clear who is suppossed to be responsible for office cleaningand tidiness?
These problems commonly occur in the office. They reflect the lack of of employees’ care for their own workplace. How much is wasted?
Such wastes will be reveald and solve through the implementation of “5S in the office” program. 5S is the abbreviation of the following five Japanese words : Seiri, Seiton, Seiso, Seiketsu and Shitsuke which respectively means : Sort Out, Set In Order, Shine, Standardize, Sustain. 5S is considered as the fundamentals of quality and productivity improvement programs.
The implementation of 5S in the office emphasize the importance of employees’ care on non-added value as to create a comfortable, safe and efficient workplace. In this way, the office may function like a “showroom”. Ultimately, this will directly contribute to productivity, quality and safety improvement.
About The Program
Program Objectives
- To promote awareness of the importance of workplace/Gemba
- To understand KAIZEN as the basic philosphy of 5S
- To understand the concept and the benefit of 5S
- To understand the implementation steps of 5S in the office
Program Outline
- The importance of workplace/Gemba
- Kaizen (Continuous Improvement) : 5S basic philosophy
- 5S concepts, definition nad benefit
- Implementation steps of 5S in the office:
- Organization of 5S
- 5S step-by-steps
- 5S
- Key success factors of 5S implementation in the office
- + Auditing 5S Implementation
Background
Stands for the following Japanese Words : Seiri, Seiton, Seiso, Seiketsu and shitsuke which respectively means : Sort Out, Set In Order, Shine, Sandardize, sustain. 5S is a method to improve wokplace and at the end will promote a disciplined working culture.
A good 5S implementation may be reflected through, for example : Easy and quick search for documents, items, tools or materials. As the result, there’s a guaranty of a comfortable, clean & tidy workplace is guaranteed, no unnecessary items are scattered around and disciplined employees in implementing the working standards.
The 5S application in companies is often not smooth and even gets stuck. There are many reasons for this, among others : lack of management support, absence of system to monitor its application and so on. Aome companies at first successfully implemented the 5S but gradually the application degraded before it totally “disappeared” from their workplace.
One way to maintain and improve the quality of 5S is to evaluate the level of achievement in the workplace through reguler 5S audits.
About The Program
Program Objectives
- To understand the role and benefit of 5S audit in 5S
- To understand the steps of 5S audit imlementation in companies
- To be able to conduct 5S audit
Program Outline
- 5S Overview
- Audithor : roles and responsibilities 5S audit implementation steps in the company
- 5S audit tools
- Key success of 5S audit in 5S implementation
- 5S audit exercise
- Report & Follow up of 5S audit
- + 5S In The Warehouse
Background
A good warehouse is the one which is well organized and enable the users to manage its functions, namely : receiving, allocation, storage, preservation, maintenance and retrieval.
Meeting these requirements needs a disciplined, efficient, productive industrial culture and work system to manage the warehouse. One of the principles of the principles of culture & work pattern building is to manage the workplace properly through the implementation of 5S in the warehouse. The activities to manage the workplace are known as 5S, which stands for the following Japanese words : Seiri, Seiton, Seiso, Seiketsu and shitsuke.
The core application of 5S in the warehouse is on how to organize effectively the warehouse activities, such as receiving, allocating, keeping, protecting, maintaining and taking out. It is expected that 5S implementation will create a safe warehouse and efficient operations for all parties who interact with warehouse.
About The Program
Program Objectives
- To create awareness of the importance of warehouse management
- To understand KAIZEN as the basic philosophy of 5S
- To understand the implementation steps of 5S in the warehouse
Program Outline
- The challenge in warehouse management
- 5S Concept Overview
- 5S role in improving efficiency & effectivity of warehouse management
- Implementation steps of 5S in the warehouse:
1. 5S ste-by-step 2. 5S tool
PQM Consultants Case Study for 5S
Client Profile/Description
PT Pacific Brands Indonesia (PT PBI) is a manufacturer of intimate apparel located in Jababeka Industrial Estate, Cikarang. Established in 1998, PT PBI wholly owned subsidiary of Pacific Brands Holdings Pty Ltd, Melbourne – Australia. Its products are Brassiere, ladies clothing, Men’s clothing under brands such as Bonds, Berlei, Holeproof, Jockey, Hestia, Target, etc
Challenge
As with many industries ‘labor intensive’, PT PBI has faced several challenges, such as increasing labor costs (7% (2008), 11% (2009), 8% (2010), 10% (2011), 17% (2012 ), 37% (2013) and 22% (2014) and also increase the cost of raw materials and higher local inflation.
On the other hand customers are demanding shorter and shorter lead time, require more varieties of products with small batch sizes. In addition, their facilities are very limited at this time to accommodate the increased volumes required by customers.
BEFORE
1ST CHANGE
2ND CHANGE
Preparation of Standardized Layout to Reduce The Time Wasted
5S activities in the Finished Goods Warehouse in March 2010 results:
- Increase productivity by 5%
- Creating space in the packing area
Results:
- Max-min stock – reducing the spare parts are not available when needed.
- Preparation faster to QCO
Results:
- Reduce stock consumable tools some 20% by the determination of min and max.
- Every user in the office area has 5S control in the office, and they use it as a trigger for future bookings
