Session

Session Rules
Objectives of the session

 Background of 5S
 5S-CANDO-Six Sigma
 5S as part of quality management
 Importance of 5S
 Waste Management
 5S principles
 5S tools
 Garments floor and 5S
 Action Plan

3
Introduction

4
CANDO Attitude

Henry Ford wrote in his book -Today and Tomorrow (1926): “The first job was
to clean up— that is always the first thing to do in order to find out what you
are about…We cannot afford to have dirt around— it is too expensive. …
Everything is painted and kept painted a light color, so the least bit of dirt will
show. We do not paint to cover up dirt— we paint white or light gray in order
that cleanliness may be the order of things and not the exception.”
Six Sigma DMAIC
Ford’s CANDO-Six Sigma DMAIC-
Toyota’s 5S

Ford’s CANDO Six Sigma DMAIC Toyota’s 5S

C – Cleaning Up D – Define Phase S –Sort

A – Arranging M – Measure Phase S – Straighten

N – Neatness A – Analyse Phase S – Sweep

D – Discipline I – Improve Phase S – Standardize

O – Ongoing Improvement C – Control Phase S – Sustain

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What Is Total Quality Management
(TQM)?

 Total quality management (TQM) is the continual

process of detecting and reducing or eliminating
errors in manufacturing, streamlining supply
chain management, improving the customer
experience, and ensuring that employees are up
to speed with training.
 Total quality management aims to hold all parties
involved in the production process accountable
for the overall quality of the final product or
service.
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5S
What is 5S ?

Developed by the Japanese

Housekeeping System
Helps Create a Better Working
Environment and a Consistently
High Quality Process

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5S Principles

SEIRI – Organisation/Sort out

SEITON – Orderliness/Systemize
SEISO – The Cleaning/Shining
SEIKETSU – STANDARDIZE
SHITSUKE - Sustain/Discipline
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12
Importance of 5S

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Aren’t you frustrated in your workplace?

Oh, this position

makes me tired ! I cannot remember
what/how to next…

Where is that
Why I am making
document ?
mistakes again and
I cannot find it !
again

Why we cannot
Oh time is not enough communicate
to complete this work! properly?
Thinking out of the box
Work together and do something with big
positive attitude?
Improve safety
Benefits

18
What is waste?
Types?

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What is Waste (Muda)?
Overproduction
Waiting for materials, machines, or instruction
Transportation or movement
Excessive inventory
Inefficient machine processing and/or operation
Producing defects
Part or line changeover or machine setup
Inadequate housekeeping
Miscommunication or inadequate instruction

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The 7 wastes
Overproduction
Over processing
Inventory

Rework Waiting

Transportation Motion

Mr. Taiichi Ohno, Former President of Toyota Motors

Waste Waste Description
Producing items for which there are no orders for resulting in wasted inventory
1. Overproduction
space, overstaffing and excess transportation time.
2. Waiting (time in Workers wait for the next processing step due to not having tools, lot processing,
hand) equipment downtime, lack of space, bottlenecks, etc…
3. Unnecessary Carrying work in progress long distances, creating inefficient transport, or moving
Transport materials, parts, or finished goods into or out of storage or between processes.

4. Over processing Taking unneeded steps to process the parts. Inefficiently processing due to poor
or incorrect tool and product design, causing unnecessary motion and producing defects.
processing Waste is generated when providing higher-quality products than is necessary.

Inventory Excess raw material, WIP, or finished goods causing longer lead times,
5. Excess obsolescence, damaged goods, transportation and storage costs, and delay. Also,
Inventory extra inventory hides problems such as production imbalances, late deliveries
from suppliers, defects, equipment downtime, and long setup times.
Any wasted motion employees have to perform during the course of their work,
6. Unnecessary
Movement
such as looking for, reaching for, or stacking parts, tools, etc. Also, walking is
waste.
Production of defective parts or correction. Repair or rework, scrap, replacement
7. Defects
production, and inspection mean wasteful handling, time, and effort.
8. Unused
Losing time, ideas, skills, improvements, and learning opportunities by not
employee
creativity engaging or listening to your employees.
Keeping unnecessary and redundant items
generates waste
➢ Workplaces, workshops and factories become even more crowded.
➢ Useful surfaces become unavailable, and cumbersome objects are in the
way.
➢ Shelves and cabinets are used to store redundant or useless items.
➢ It becomes difficult to find items which are really necessary.

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Types of 5s tools
• Red tag
• Alignment
• Labeling, Tapes
• Numbering, Alphabetical cording
• Safety signs
• Zone
• Color cording
• 5S Corner
Red Tag
• Use it when can not decide
an items are “necessary” or
“not necessary”
• Record necessary
information on the Red Tag,
stick or hang it on the item
that cannot make decision.
• If the items is not used for 1
month = Unnecessary item
• If the item is used within 1
month = Necessary item
Alignment
• It is useful to
improve
orderliness and
beautification
when you
organize files,
equipment,
materials and
other items.
Labeling

• Labels are used when

you identify each item
and organize them
properly.
• It is useful especially
for storing files and
items in
cabinets/shelves.
Taping

• Draw a connected diagonal

line on spine of books/files
• The line tells users where to
return and helps to arrange
items in order
Numbering / Alphabetical cording
• Used to organize files and
other items by numbers/
alphabets
• It helps users to find
necessary items or
information quickly and
easily.
• It is very useful for practicing
“Can See - Can Take Out –
Can Return” principle.
Safety signs
• Used to warn visitors and
workers to pay attention on
hazardous items.
• Majority of hazardous items,
which are commonly used
in health facility, has
international/national
standardized safety signs.
• It is recommended to use
common safety signs
Zone

• Zoning is used to identify or recognize proper location/

storage of items.
• It helps people to understand “where it is supposed to be”
Color coding

• Color coding makes

facility users understand
the meaning of
“something” by different
colors.
• It is often used for waste
segregation,
categorization of
areas/zones for particular
items
5S corner
• Use existing notice board or
establish new one
• Can be displayed:
• 5-S posters
• Pictorial progress report
• Implementation progress
chart/table
• M&E information
• Training information
• Production Meeting information
• Mission statement on QI
• Waste bin color coding and type
of waste
• Rules of 5S tools
5S tools utilized by 5S stages
Set in
5S tools Sort Shine Standardize Sustain
order
1 Red tag √
√ √ √
Numbering, Alphabetical
2
cording

3 Labelling, Tapes √ √

4 Safety signs √ √ √

5 Sign board √ √ √

6 Zone √ √

7 Colour coding √ √ √ √

8 5S Corner √ √
The excellent factory

➢ In excellent factory everything is arranged in the best way, everything

is tidy, all work stations are clean

➢ Can any factory achieve excellence without excellence of working

condition?

35
5S – Step 1: SORT

Separate necessary
and unnecessary
items and then
eliminate the
unnecessary ones.

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5S – Step 1: SORT –What to do ???

Separate necessary and unnecessary items, eliminate the unnecessary

ones

➢ Identify all materials which can

be used and should not be
eliminated.
➢ Remove all unidentified
items from area.
➢ Keep only what you need.

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Before

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After

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Tags are a tool to identify and eliminate
problems

Examine items Identify a

in the area problem

Fill in and
apply a tag

Define Solve tag

improvement action

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Deployment : 5S Tags

Colors:

Red Unnecessary items to be scrapped

Yellow Useful material to be located in its right place

Green Material to be repaired (e.g. electrical boxes,

assemblies to be dismantled, …)

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5S – Step 2: SET IN ORDER

Arrange materials
according to well-defined
criteria so as to cut search
time

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5S – Step 2: SET IN ORDER
Why should you look for items?

➢ There are too many

unnecessary items.

➢ There is not the a definite place

for the object.

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List all necessary items in the table

Description of Frequency of Most suitable Store location Note

item use location

Fill 2 these columns

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Workplace Checkpoints

Positions of aisles and storage

places clearly marked?

45
Workplace Checkpoints

Safety equipment easily accessible?

46
Workplace Checkpoints

Floors in good condition?

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5S – Step 3: SHINE

Clean and orderly arrange the

workplace, identify problems

48
Clean and check if the order set in the previous step
is maintained

1. Carry out thorough 2. Check that Step 2 results 3. Take photo to register
cleaning are maintained abnormal

Before

After

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5S – Step 4: STANDARDIZE

Define and write

down new
standards for
cleaning, order and
stock levels

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Why aren’t basic conditions maintained?

Reasons Actions

❑ Operators ignore basic conditions. ❑ Training:

❑ They do not know how to those who do not know should be
maintain basic conditions. informed as to how, when and why
❑ They know what to do, but they do maintaining basic conditions is
not have the experience required to important to define standards.
adopt countermeasures. ❑ Write and use check list.

❑ Operator knows but does not want ❑ Encouragement: Comment and

to follow Reward

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Basic conditions

✓ The first three steps helped us achieve the best

conditions for the area.

✓ In the future we must ensure to maintain these ideal

basic conditions through the formalization of the
standards.

52
Visual control

Visual Control is a management technique which emphasizes simple visual

aids developed specifically to improve communication between managers
and operators.
Visibility strongly simplifies management activities.

Visual Tools - used by operators, teams, experts, managers and

consultants - help everybody keep the process under control and optimize
organization time.

53
Examples of visual control

Deviations from standards must

be easy to identify by everyone,
so as to promptly intervene by
means of corrective measures

everything is easy to find and to see!

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Standardize

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5S – Step 5 : SUSTAIN
Support continuous improvement

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Continuous analysis

Periodical report meetings

It is advisable to hold meetings on the
shop floor and not in the meeting rooms
Use board
Try to expose ideas so that they can be
adopted by all teams

Department-to-department inspection
It can be an effective way to exchange ideas
5s Basic requirements of
garment enterprise
General requirements for safety and
hygiene
Safety Requirements
1. Aisle width should be sufficient people and equipment to move, and
must be defined clearly by marking. Do not leave any objects on the
aisle
2. Fire protection equipment must be in defined, easily accessed,
checked and maintained periodically.
3. Dangerous areas should have warning and measures for to
prevention of unauthorized persons.
4. The emergency circuit breaker can be easily accessed.
Hygiene requirement
- Infrastructure must be maintained in good condition. The road
markings must be clear and not be scratched;
- Walls, railings are neatly clean.
- Everywhere is clean: especially in the corners, shelves, window
Material and trim warehouse

Requirement 1: SORT
-All obsolete goods (of delivered styles) should be in isolated area and
periodically reviewed and moved out.
Requirement 2: SET IN ORDER
-Should have split areas: Waiting for QC, Checked and Accepted;
Checked and Unaccepted.
- All materials and trims must have labels and the list should be
regularly updated.
- Areas should be clearly indicated (for customers, for type of
materials….)
- Have guidelines (racks, lines...) to reduce search time.
Material and trim warehouse

Requirement 3: SHINE
-All materials should be kept in good condition and clean
- Anywhere in the warehouse must be clean. Cleaning should be
carried out regularly.
- All personal items should be kept out of warehouse
Information display
Information display
Information display
Make a list at the front of shelves to
reduce searching
Information display
Materials are kept in tidy condition
Materials are kept in tidy condition
Materials are kept in tidy condition
Materials are kept in tidy condition
Materials are kept in tidy condition
Materials are kept in tidy condition
Cutting department

Requirement 1: SORT
- Do not take more fabric to the cutting room than needed;
- All of the fabrics, remains of delivered orders (not necessary) should be
removed from workshop and kept in separate place.
-All cut pieces, samples, technical documents of delivered orders should
be removed from the workshop.
-Don’t cut more than needed (to minimize WIP)
-Use as small as possible bundles.
- Don’t store redundant or damaged equipments, devices... in the
workshop.
Cutting department

Requirement 2: SET IN ORDER

-Fabrics waiting for cutting should be placed in most convenient area.
-Remain form fabrics rolls should be kept in defined place with labels (not
under cutting tables)
-Cut pieces should be kept in defined place and in good condition.
-Documents, drawing, patterns, instructions .. should be in defined place
with guide and easy to be accessed.
-All equipments after use should be clean and placed in defined place.
Cutting department

Requirement 3: SHINE
- Workshop must be clean.
- Should have bins or containers for rags. Consider measures to
eliminate source of dirt.
- Fabrics and cut pieces should be clean.
-Machines, equipments should be in good condition, clean and ready
to use.
-Patterns, sample, technical documents are in good conditions and
clean.
Cutting department

• Before • After
Pattern keeping
Cut piece keeping
Sewing Department

Requirement 1: SORT
-No cut pieces of delivered orders in the workshop;
- No documents, fabrics, trims, samples, patterns.. of delivered orders in the
workshop
- Do not receive more cut pieces than needed (issue regulations and try to
cut down quantity of cut piece in sewing lines)
- No un-needed personal items in the workshop (issue regulation)
- No un-used equipment in production lines (put in the line only equipment
in use)
- No breakdown, redundant equipment in the workshop.
Sewing Department

Requirement 2: SET IN ORDER

-All cut pieces are in defined place with guide.
- Line arrangement should follow production steps, flow can be easily
recognized.
- Sewn product should be placed in defined place with indication and in
good condition.
- Sample, instruction should be in sight;
- Sewing line should be standardized.
Sewing Department

Requirement 3: SHINE
-Workshop must be kept clean ;
- Should have container for rags and thread. Consider measures to
eliminate source of dirt.
- Cut pieces are clean and in good condition.
- Equipment should be maintained, clean and ready to use.
- Patterns, samples, documents are in good condition, neatly clean.
- Have periodic cleaning regulation.
Before After
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87
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Before After

90
Before After

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Keep the device clean
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Finishing Department

Requirement 1: SORT
-No finished products, materials, technical documentation ... of delivered order
in workshop
- Do not get more sewn product than needed (issue regulation);
- Do not receive more packaging materials than needed (issue regulation)
- No un-needed personal items in workshop (issue regulation)
- No redundant or damaged equipments in workshop;
Requirement 2: SET IN ORDER
-All trims should be in defined place with clear instruction;
- The finished product should be in defined place regulations and in good condition.
- The boxes, cartons with finished goods should be put in defined place with
appropriate height (give instruction)
- The workplace should be standardized.
Finishing Department

Requirement 3: SHINE
-Workshop should be always clean;
- Equipment should be maintained and in good condition, ready to
use;
- Patterns, samples, documents in good condition and clean.
- Have regulation for periodic cleaning. Consider measures to eliminate
source of dirt.
Finishing section

• Before • After
Final Product Warehouse

Requirement 1: SORT
-No finished good of delivered order in warehouse (should be in isolated area)
- No documents of delivered order in warehouse (should be in office)
- No un-needed things in warehouse;
- No redundant or damaged equipments in warehouse.
Requirement 2: Sort

-Finished goods are separated by customer, style with guide boards;

- Cartons should stacked at definite height to avoid fall down(issue instruction)

Final Product Warehouse

Requirement 3: SHINE

-Warehouse should be clean everywhere;

-Should be periodically cleaned.
Not tidy
arrangement
Store
Store
• Before • After
Do not use workshop
as warehouse
Too high =>
inclined
Machine Warehouse

❑ Requirement 1: SORT
- Remove all broken machines, equipments, attachments no longer can be
used;
- Remove all un-needed items.
❑ Requirement 2: SET IN ORDER
- Tools should be arranged in order, easy to see, easy to get and return.
- Split areas for machines ready to use and machines waiting for repair;
- Machines have no use for long time should be isolated and kept in good
condition with list for avoiding potential loss;
- Machines ready to use should be neatly arranged, classified by types
with guide board.
- Machines should be arranged in easy to access way.
Machine Warehouse

Requirement 3: SHINE
- Everywhere should be clean;
- Have periodic cleaning regulation.
- Machines are kept in best condition.
Machine arrangement in warehouse
Machine is kept in good condition
Outside Of Factory

❑ Requirement 1: SORT
- No items outside of defined area.
- No broken equipments, furniture... outside of defined area.
 Requirement 2: SET IN ORDER
- Define area for junks. Check and remove periodically.
- Should have clear line to indicate the roadway
Outside Of Factory

❑ Requirement 3: SHINE
- No water leakage
- No steam leakage
- Road are clean ;
- Have garbage bins in area.
❑ Requirement 4: Safety
- Instruction for danger and isolated areas;
- Abide governmental regulation on safety
Clean and tidy everywhere
Garbage bins
are available in
area
5s-
Housekeeping

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Thank You

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