Introduction to 5S -The Super Organiser

5S Structure

 

Introduction to 5S – Super Organiser

The 5 steps of 5S – Super Organiser are as explained below:

Sort:

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

Shine:

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

Standardize:

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.

Sustain:

Integrate 5S principles into the organization’s objectives in order to sustain new standards and continually improve the workplace.

Workshop on 5S

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Fault Tree Analysis (FTA)

FTA is fault tree analysis, used for identifying causes required for a particular fault/event to take place.

This technique uses basic symbols of electronic & logic field. The Fundamental symbol used are AND & OR gate.

Truth table for AND & OR gates:

Input Output
A B AND OR
0 0 0 0
0 1 0 1
1 0 0 1
1 1 1 1

Symbols of AND & OR gates:

and or gates

The failure mode being studied is called head event.

The basic concept of this technique is to put all effecting events in a logical form.  Take a case of motor stoppage. The motor can be stopped due to following reasons:

  1. Power loss
  2. Overload
  3. Coil Damage
  4. Process interlock operated

Further power loss can occur if the incomer power supply fails & the emergency generator also fails at the same time. Over load can occur due to chocking in pipe line, or, the isolation valve is closed. Coil can damage due to over current or moisture ingress. Process interlock can be operated due to instrument malfunction or real high vibration.

The Logic tree can be built as follows:FTA

All the identified events can be given probability of failure depending upon MTBF calculated from past events. In case both events are required for resultant event to occur ie. AND gate, the probabilities are multiplied. In case, any one input can have the resultant impact ie. OR gate probabilities are added.

The FTA Analysis is done for finding out all probable faults possible. This enables us to attack on right cause for identify & eliminating the fault.

check some of these interesting posts of time management and of super organiser as well.
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