Introduction to 5S – Super Organiser
The 5 steps of 5S – Super Organiser are as explained below:
This process identifies the items that are required to perform work in the work areas. Clear (sort out) all other items from the work area. It has following benefits:
- Efficient use of work space
- Improved safety
- Improved productivity
- Improved utilization of materials, supplies, and resource
- More visible work flow
- Improved employee satisfaction
- Improved quality
Set In Order:
Aplace for everything & every person at its place. This supports in ease for retrieval. It has following benefits:
- Elimination of 7 wastes and ease effort needed to search for or retrieve tools and supplies.
- Easy identification of any missing tools
- Improved safety through an organized workplace
- Increased productivity
Proactive/preventive housekeeping to keep work areas, work surfaces, and equipment clean and free from dirt, debris, oil, etc. Benefits:
- Cleaner and more satisfying place to work
- Improved Quality standards
- Maintenance issues exposed faster (planned downtime vs. unplanned downtime)
- Improved safety (fewer accidents)
- Improved work culture
Do things in a consistent and standard way. Formulate standardize procedures for activities, instruction, schedules, checklist for helping keep the workplace clean and organized. Standardize work area layouts and storage techniques wherever possible. Visual Management implementation for ease of maintaining standardisation.
Integrate 5S principles into the organization’s objectives in order to sustain new standards and continually improve the workplace.
Audits-Pillar of any system
Audits are the Action Undertaken for Deviation Identification To Sustain
Audits are very important part of any PDCA cycle. To proceed further, lets explain PDCA cycle.
Plan, Do, Check, Act:- These are very important step of any type activity/project to be successful. Project may be related to engineering, management, social etc.
Rightly said, “To cut a tree, 80% of time should be used for sharpening the axe & remaining 20% to hit at the trunk.” Indeed, Planning plays very important part for any activity.
Implementing as per planning is equally important. Once, the system is in place, Check as per desired specification is important to find the gaps. Corrective action should be taken for filling the gaps.
Audits are an important tools for “check” step of the PDCA cycle. There are different types of audits. Few of them are as given below:
Routine Checks: These are the audits taken at scheduled intervals for monitoring the performance of an established systems. These can be internal & external.
Internal audits are for monitoring own performance with established rules & procedures.
External audits are to map our performance with national & international standards.
Pre startup checks: These type of audits are taken up before commissioning of any project to find out gaps that may result in loss after start up of the equipment/machine etc.
The Audits can also be categorized as :
First party: These are done by internal resources. These may be done by same department or by cross functional teams. Person from shop floor, middle management, upper management, leadership level can be engaged depending on importance & criticality of system.
Second Party: The team can be formed from different location of same company. This brings learning of different sites together.
Third Party: Consultants can be hired to get best knowledge available in market.
Audits helps in finding fault at right time & acting immediately, so that further consequences can be avoided.