Ⓒ Tetrahedron Manufacturing Services Pvt Ltd, 2021

Tetrahedron Manufacturing Services Pvt Ltd

End-To-End Solutions for Manufacturing Industry

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Ⓒ Tetrahedron Manufacturing Services Pvt Ltd, 2023

WorkPlace Management (5S)

(25/01/2023)

Private & Privileged © Tetrahedron (2020)

Training Attendance Form Link

https://bit.ly/Safecon-Attendance

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Agenda

• Ice Breaking Game

1. The Circular Wheel.
2. The Machine Gun vs. Sword.
• What is Waste?
1. 8 Lean Wastes
• Introduction to 5S
1. What is 5S?
2. Origin of 5S.
3. Steps of 5S.
• Implementation of 5S
1. Roadmap to 5S Implementation.
2. Guidelines for 5S Preparation.
• 5S: Step-by-Step Implementation
1. 1S - Sort.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Ice Breaking Game

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1

The Circular Wheel

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
The Circular Wheel

Are You Too Busy To Innovate?

No Thanks.
We’re Too Busy.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
2

The Machine Gun vs. Sword

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
The Machine Gun vs. Sword

“I don’t have time to see any crazy salesman;

I have a battle to fight.”
Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
What is Waste?

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What is Waste?

What is Waste???

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
What is Waste?

What is Waste???
Anything that does not directly Add Value to the
Final Product or Contribute to the Products
Transformation.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Value Added vs. Non-Value Added Activities

• Value Added Activities:

– Value Added Activities are those that transform the product from
raw material into finished goods that the customer is willing to pay
for.
• Examples: Mixing, Processing, Shaping, Assembling, etc.

• Non-Value Added Activities:

– Non-Value Added Activities involve work that consumes
resources, but does not add value to the product or service.
• Examples: Transporting Material, Walking, Rework, Repair,
Inspection, etc.
Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Value Added vs. Non-Value Added Activities

Activities that a

Essential
Activities that must be
Minimize/ customer is willing to
performed for legal or Optimize pay for that contributes
regulatory/compliance Redesign to the end product they
reasons.
expect.

Non-Essential

Activities that the

customer would not Eliminate
pay for.

Non-Value Added Activities Value Added Activities

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Definitions

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 Definitions

• Management
– Management is the art of managing resources of the business.

• Manufacturing
– Manufacturing refers to the processing of raw materials into finished goods through the use
of tools, human labor, machinery.

• Process
– A process is a series of actions which are carried out in order to achieve a particular result.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Lean

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 What is Lean?

• Lean is defined as a set of management practices to improve

efficiency by eliminating waste.

• The core principle ofuseful

The ratio of the lean is to reduce and eliminate non-value
work performed by a
adding activities and waste.
machine.

• Lean Manufacturing
– Lean manufacturing is a production process designed to
maximize productivity by minimizing waste.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wastes

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8 Lean Wates

Transportation

Non-Utilized
Inventory
Human Capital

Defects
8 Lean Motion

Wastes

Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Transportation:
Transportation
– Unnecessary movements
Non-Utilized
Talent
Inventory of products & materials.

Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Inventory:
Transportation
– Excess products and
Non-Utilized
Talent
Inventory materials not being
processed.

Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Motion:
Transportation
– Unnecessary movements
Non-Utilized
Talent
Inventory by people (ex. Walking).

Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Waiting:
Transportation
– Wasted time waiting for
Non-Utilized
Talent
Inventory the next step in a
process.

Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Over-Production:
Transportation
– Production that is more
Non-Utilized
Talent
Inventory than needed or before it
is needed.

Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Over-Processing:
Transportation
– More work or higher
Non-Utilized
Talent
Inventory quality than is required by
the customer.

Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Defects:
Transportation
– Efforts caused by rework,
Non-Utilized
Talent
Inventory scrap and incorrect
information.

Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
8 Lean Wates

• Non-Utilized Human
Transportation Capital:
Non-Utilized
Talent
Inventory – Underutilizing people’s
talents, skills &
knowledge.
Defects
8 Lean Motion

Wastes
Over-
Waiting
Processing

Over-
Production

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
3

Introduction to 5S

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
What is 5S?

The 5S System is a Lean Manufacturing Tool

that Improves Workplace Efficiency and
Eliminates Waste.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Purpose of 5S

This occurs by making

The purpose of 5S is to When used correctly, 5S
tools and materials are
make a workplace ultimately makes
placed in logical locations,
function better by making processes safer and more
Spaces are cleaned
it an easier place to work. efficient.
regularly.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
4

Origin of 5S

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Origin of 5S

The 5S methodology
traces its lineage to post- The 5S methodology
war Japan, where the originated in Japan and
leaders of Toyota was first implemented
Industries were seeking by the Toyota Motor
to reduce manufacturing Corporation.
waste and inefficiencies.

This type of
manufacturing intends The methodology was
to produce only the developed as a way to
amount of a product make just in time (JIT)
that is needed, when it is manufacturing possible.
needed.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
5

Steps of 5S

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

5.
1.
Sustain
Sort (Seiri)
(Shitsuke)

4. 2.
Standardize Set In Order
(Seiketsu) (Seiton)

3.
Shine (Seiso)

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Remove unnecessary items

from each area.
5. 1.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Remove unnecessary items

from each area.
5. 1.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Remove unnecessary items

from each area.
5. 1.
Sustain Sort • Unnecessary Items:
1. Not Needed at all.
4. 2.
2. Needed but not now.
Standardize Set In Order

3. Needed but not here.

3.
Shine
4. Needed but not so much
quantity.
Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Why do 1S?
– Frees up space.
5. 1.
Sustain Sort – Removes clutter/obstacles.

4. 2. – Stops people adding to it.

Standardize Set In Order

– Improves safety.
3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Organize and identify

storage for efficient use.
5. 1.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• “A place for everything and

everything in it’s place”.
5. 1.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Clean and inspect each

area regularly.
5. 1.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Incorporate 5S into standard

operating procedures.
5. 1.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

5. 1.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Steps of 5S

• Assign responsibility, track

progress, and continue the
5. 1. cycle.
Sustain Sort

4. 2.
Standardize Set In Order

3.
Shine

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Guidelines for 5S Implementation

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1

Roadmap to 5S Implementation

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Roadmap to 5S Implementation

PLAN DO CHECK ACT

PHASE 1 PHASE 2 PHASE 3 PHASE 4

Sort

Set In Order
Self-Assessment Continual
PREPARATION
Shine & Improvement
5S Certification
Standardize

Sustain
Feedback

ENABLERS RESULTS
Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
2

Guidelines for 5S Implementation

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Preparation

Provide Training
and Education
for Everyone.

Plan 5S Action
Form 5S
Plan and 5S
Committee.
Launch.

Determine 5S
Objectives,
Goals and Set-up 5S Zones.
Implementation
Phases.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
5S Committee

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Role and Responsibilities

5S Facilitators: 5S Leaders: Employee’s

• Support 5S • Participate in work Responsibilities:
implementation. group implementation • Participate in group
process. activities with full
• Communicate with commitment.
everyone involved. • Communicate with
everyone involved.
• Motivate work groups.
• Monitor progress of
• Ensure employee group activities.
implementation plan.

• Monitor measurement
systems.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Set-Up 5S Zones

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Set-Up 5S Zones

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 FPP - Fixed Point Photography

• FPP or Fixed point Photograph

Before implementing
1S, it is necessary to
take a few photos of
the place from a FPP is giving a visual
For each FPP, the
fixed place with fixed description of the
date and time of the
height, fixed angle, improvement in the
photo is very
and fixed Zoom and area from time to
important.
it is taken every time time.
we make any
improvement of the
place.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 WPP - Worst Point Photography

• WPP or Worst Point Photographs

We select a worst
area in terms of 5S
and convert it into a
best place in that This gives a There should be no.
area by doing motivation for others of WPP with before
multiple to implement 5S. and after photos.
improvement
implementing 1S, 2S
and 3S.

Both FPP and WPP are displayed in the section or the Zone with before and after photograph.
One of the main effort is to prevent reoccurrence and taking action on the source.
Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Scoring System
5S Checklist – Workplace Evaluation

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Target & Goal Setting

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Implementation of 5S system

Before Implementing 5S After Implementing 5S

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
5S: Step-by-Step Implementation

Private & Privileged © Tetrahedron (2020)

1

1S - Sort

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 1S - Sort

• Seiri - Sort (Clearing)

– Clearly separating necessary from unnecessary, and remove unnecessary.

• Seiton - Set in order (Configure)

– Visually arrange and identify items for ease of use and retrieval.

• Seiso - Shine & Check (Clean & Check)

– Keep the workplace clean (not pretty) to allow problems to be identified.

• Seiketsu - Standardize (Conformity)

– Continually monitor the level of clearing, organizing and cleaning.

• Shitsuke - Sustain
– (Custom & Practice, Consensus) - work towards a shared set of values regarding clearing, organizing and
cleaning.

• Safety
– Improve through better clearing, organizing, cleaning and visual control.
Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Red Tagging

• Red Tagging is a tool to Make 1S more visible.

• Red tagging clearly marks the unneeded items, which we can move over to a
temporary pile of “red tagged” items for subsequent disposal.

Mark Item Type Actions needed to

those red tagged items

Reasons Behind Red

Tagging

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Red Tagging

• This suggests that when an item has been identified by the Work
Group it must than be placed into one of several categories.

• The categories and resultant actions are summarized below:

Category Action
Obsolete Sell, give away or throw away.
Defective Return to supplier or throw away.
Scrap Remove from area.
Trash/garbage Throw away or recycle.
Unneeded in the area Remove from area.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Red Tagging

• Frequency of Use Rule:

Carry with person or keep at place of

Used at least once A day
use.

Used about once per week Store in area.

Used less than once per month Store where accessible.

Store in distant place, sell, give away

Seldom-used
or throw away.

Use unknown Find out use or remove from area.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Overall Procedures for Implementing Red Tagging

Step 1: Separate Step 2: Move Out Step 3: Dispose

Step 4: Intensive
Needed Items From The Unneeded Whatever is Really
Improvement
Unneeded Items Items Not Needed

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Unwanted Items Categories Lists

Excess Raw
Material

Excess In-process
Consumables Stock

Office Idle
Products Equipment

Unneeded
Finished
Tools and
Products
Fixtures

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Examples of SORT in Factory

Unwanted Unwanted Excess Raw Out dated Outdated

Broken
rejected items tables, chairs, Outdated, Material & SOP’s / customer
trolleys,
and materials Fixtures & Obsolete & Finished documents drawings,
Pallets, Bins,
lying in the Measuring Expired items. Goods in the still hanging specifications
Work tables.
work place. instruments. Shop Floor. around. etc.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Examples of SORT in Office

Irrelevant/useless Old diaries/old

Papers, registers, circulars / memos Outdated floppy
note books, files. in notice boards. discs, CD’s etc.

Unused/Broken Broken furniture. Equipment's - not

pens / Board working / Broken
Markers. / outdated ones
etc.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Red Tag Items Status

Red Tag Details

Tag No. Zone Name Item Auditor Status
468 Zone 6 Painting Booth JST Removed
469 Zone 6 Painting Booth JST Removed
466 Zone 4 Packing Hold Baskets JST Removed
477 Zone 6 1st Sample Rake CPM Removed
478 Zone 6 Buffer Tank CPM Pending
490 Zone 8 Suit Case NILESH Removed
491 Zone 8 Plywood NILESH Removed
492 Zone 5 Grinding Machine NILESH Removed
494 zone 13 Mound Cutting Mc AMIT Pending
495 zone 7 Weighing Scale AMIT Removed
601 zone -15 Bata Belt S.K.Sagar Removed
604 zone 8 Computer S.K.Sagar Removed
607 Zone 3 Sample Material Rack GAURAV Removed
609 ZONE2 Cork Material KCP Removed
610 ZONE2 Oven Lying In Back Side KCP Removed

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Red Tag Summary

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Total Area Recovered From Red Tag

Total Area Recovered From Red Tag

250
197
200

150
112
100 71
58
50 30 24 23 22
10 5 5 4 3 2 2 0 0
0

Total Area Recovered-568 Sq. Ft

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Potential Impacts

Necessary items
are identified
Working
and positioned Unwanted items Searching time Space utilization
environment is
in the right are eliminated. is reduced. is maximized.
improved.
workplace and
location.

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
Effect of Sort - Before and After

Management Consulting Training & Skill Development Automated Guided Vehicle & Industry 4.0
 Ⓒ Tetrahedron Manufacturing Services Pvt Ltd, 2023

Thank You!!!

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