5S has played a great role in shaping corporate image, reducing costs, delivering on time, ensuring safe production, highly standardizing, creating a relaxed workplace, and improving on site. It is the success of rapidly improving the quality of Japanese products and marketing them around the world.
Extension of 5S According to the needs of further development of enterprises, some enterprises have increased safety on the basis of 5S, forming "6S"; Savings enterprises increase their savings again, forming "7s"; Other enterprises joined habituation (しゅぅかんか, Latin for Shiukanka), service and persistence (しつこく, Latin for shitukoku), and formed. Some enterprises even carry out "12S", but all the changes are due to "5S". For example, in sorting, it is required to eliminate useless things or articles, which can involve saving and safety in a certain sense. Specifically, such as useless garbage lying in a safe passage, this is the content that safety should pay attention to.
5S activity 1, target 1. Job changes, looking for tools, looking for things immediately, looking for time is zero.
Introduction to 5S activities [1]
2. Clean the site, zero-defect products.
3. Strive to reduce costs and reduce consumption and waste to zero.
4. Work smoothly, complete the task in time, and the delay is zero.
5. No leakage, no harm, safety, neatness and zero accidents.
6. Unite and be friendly, think of others everywhere, actively do your job, and have zero bad behavior.
Two. Principle 1. The principle of self-management
A good working environment cannot be created only by adding equipment, nor can others be expected to create it. We should fully rely on the on-site personnel, who should create a neat, clean, convenient and safe working environment for themselves, so that they can transform their subjective world while transforming the objective world, create a sense of beauty, and cultivate the atmosphere and habits of obeying rules and disciplines and strict requirements required by modern mass production. Because it is the result of self-creation, it is easy to maintain and persist.
2. The principle of economical factory.
Carrying out "5S" activities will clean up a lot of useless things from the production site, some of which are just useless at the site, but can be used in other places; Although some of them are wastes, they should be used in the spirit of turning waste into treasure. If it needs to be scrapped, it should be used by all means, and its "residual value" should be treated according to the scrapping procedure. Never treat them "happily" for a while and throw them away like garbage. The "black sheep" style of extravagance and waste, regardless of enterprise property, should be stopped in time, criticized and educated, and appropriate punishment should be given if the circumstances are serious.
3. The principle of perseverance
The "5S" activity is relatively easy to carry out, and it can be vigorous and achieve obvious results in a short time, but it is not easy to persist, persevere and constantly optimize. Many enterprises are too tight, loose, collapsed and repeated. Therefore, it is very important to carry out "5S" activities. Enterprises should stick to this activity, first of all, put the "5S" activity into the post responsibility system, so that each department and personnel have clear post responsibilities and work standards; Secondly, strictly and conscientiously do a good job in inspection, appraisal and assessment, and link the assessment results with the economic interests of various departments and personnel; Third, stick to PDCA cycle and constantly improve the "5S" level on site, that is, constantly find and solve problems through inspection. Therefore, after the inspection and evaluation, we must also put forward improvement measures and plans for the existing problems, so that the "5S" activities can be carried out continuously.
Third, the role of 1 Improve corporate image
2. Improve production efficiency and work efficiency.
3. Improve the inventory turnover rate
4. Reduce failures and ensure quality
5. Strengthen safety and reduce potential safety hazards.
6. Develop the habit of saving and reduce the production cost.
7. Shorten the operation cycle and ensure delivery.
8. Improve enterprise spirit and form a good corporate culture.
4. Method 1. Fixed-point photography: The so-called fixed-point photography is a method of continuously taking pictures of the same place and facing the same direction. The purpose is to take pictures of unreasonable phenomena at the scene, including operations, equipment, processes and working methods, so as to improve continuity.
2. Red slip operation: The use of red slips allows employees to know at a glance where the factory's shortcomings are and how to sort them out, while the objects of red slips, including inventory, machinery, equipment and space, allow supervisors at all levels to see at a glance which ones are necessary and which ones are redundant.
3. Kanban management: Let people at the work site know where there are things and how many. At the same time, the content and process of overall management, as well as the ordering and delivery schedule and work schedule can be made into kanban, so that workers can easily understand and carry out necessary operations.
4. Color management method: Color management is to simplify complex management problems into different colors and distinguish different degrees by using workers' ability to distinguish colors and unique associations, and present the essence and improvement of problems in an intuitive and visual way, so that everyone has the same understanding and understanding of the problems.
5S site management I. Principles: organization, rectification, cleanliness, standardization and self-discipline;
Clean, clean the environment, formulate standards and form a system.
Sort out, distinguish the purpose of the goods, and get rid of unnecessary things.
Rectification, items are placed in different areas, clearly marked, and easy to take.
Clean up, remove dirty garbage and prevent pollution.
Self-cultivation, forming good habits and improving personality cultivation.
Two. Utility 5S The five major utilities of management can be summarized as five S's, namely, Safety, Sales, standardization, customer satisfaction and Saving.
1. Ensure safety.
Enterprises can often avoid fire or slip caused by oil leakage by implementing 5S; Various accidents and failures caused by non-compliance with safety rules; Public hazards caused by dust or oil pollution. Therefore, production safety can be achieved.
2. Expand sales (sales)
5S is a good salesman with a clean and tidy environment, which is safe and comfortable. Enterprises with well-educated staff can often win the trust of customers.
3. Standardization
Through the implementation of 5S, the habit of observing standards is formed in enterprises, so that all activities and operations run according to the requirements of standards, and the results meet the planned arrangements, laying the foundation for providing stable quality.
4. Customer satisfaction (satisfaction)
Impurities such as dust, hair, oil stain and so on often reduce the machining accuracy and even directly affect the product quality. After the implementation of 5S, the cleanliness and cleanliness are guaranteed, and the products are molded, stored and delivered to customers in a healthy environment, with stable quality.
Step 5 save
Through the implementation of 5S, on the one hand, it reduces the auxiliary time of production and improves the work efficiency; On the other hand, it can reduce the failure rate of equipment, improve the use efficiency of equipment, and thus reduce certain production costs, which can be described as "5S is an economizer".
Three. Content Through the implementation of 5S site management, we can standardize the site and existing things, create a clear working environment and cultivate employees' good working habits, with the ultimate goal of improving people's quality:
Get rid of carelessness and get into the habit of being serious about everything (taking every "little thing" seriously at work)
★ Abide by the prescribed habits
★ Consciously maintain a clean and tidy working environment.
★ Polite habits.
1. arrangement
★ Divide everything in the workplace into necessary and unnecessary;
★ Clearly and strictly distinguish between necessary things and unnecessary things;
Unnecessary things should be disposed of as soon as possible.
Purpose:
★ Make room, use space.
★ Prevent misuse and wrong delivery.
★ Create a refreshing workplace
In the production process, there are often some surplus materials, products to be repaired, products to be returned, scrapped products and so on. These not only occupy space but also hinder production, including some unusable fixtures, measuring tools and machinery and equipment. If it is not cleared in time, the site will become messy.
It is a waste to put unnecessary items on the production site;
★ No matter how spacious the workplace is, it will become narrower and narrower.
★ Scaffolding, cabinets, etc. Occupied by sundries, reducing its use value.
★ It increases the difficulty of finding tools, parts and other items, and wastes time.
★ Items are placed in disorder, which increases the difficulty of inventory and leads to inaccurate cost accounting.
Note: To be determined. Unnecessary items should be thrown away directly.
Key points of implementation:
1. Make a comprehensive inspection of your workplace (scope), including the visible and the invisible.
2. Develop criteria for judging whether it is necessary or not.
3. Remove unwanted items from the workplace.
4. Investigate the use frequency of the required items and decide the daily dosage and placement position.
5. Develop waste disposal methods
Check yourself every day.
correct
★ Put the necessary items left at the site after sorting in order.
★ Clear quantity and effective labeling.
Purpose:
★ The workplace is clear at a glance
★ Clean working environment
★ Eliminate the time to find things.
★ Eliminate excessive backlog items.
note:
This is the basis of improving efficiency.
Key points of implementation:
1. The closing work in the previous step should be implemented.
2. Process layout, determine the placement position
3. Specify the placement method and quantity.
4. Line positioning
5. Identification of places and articles
Rectifying "Three Elements": Place, Method and Logo
Placement position
★ In principle, the article position should be set to 100%.
★ The storage of articles should be fixed, constant in volume and quantitative.
★ Only really needed items can be placed near the production line.
Placement method
★ Easy to obtain
★ Within the specified range.
★ Put more effort into the placement method.
Identification method
★ In principle, places and objects are indicated one by one.
★ Representation of existing objects and placement positions
★ Some said that the whole company should be unified.
★ Work harder on the expression method.
Rectify the "three principles": fixed point, quantitative and quantitative.
★ Fixed point: Where is it suitable?
★ Constant volume: What container and color are used?
★ Quantization: Specify an appropriate quantity.
clear
★ Clean the workplace.
★ Keep the workplace clean and bright.
Purpose:
★ Eliminate sundries and keep the workplace clean and bright.
★ Stable quality
★ Reduce work-related injuries
note:
Responsibility and institutionalization.
Key points of implementation:
1. Establish clean responsibility area (indoor and outdoor)
2. Perform routine cleaning and remove dirt.
3. Investigate pollution sources and eliminate or isolate them.
4. Clean benchmark, as a specification
clean
Institutionalize and standardize the above 3S implementation practices, and implement and maintain the results.
Purpose:
Maintain the results of the above 3S.
note:
Institutionalization and regular inspection.
Key points of implementation:
1. The previous 3S works
2. Evaluation method
3. Reward and punishment system, strengthen implementation.
4. The supervisor often takes the lead in inspection to show his attention.
5. Literacy
Improve the civilized and polite level of all employees through morning meetings. Cultivate each member to form good habits and abide by the rules. It is easy to cultivate 5S, but long-term maintenance must rely on the improvement of literacy.
Purpose:
★ Cultivate employees who have good habits and abide by the rules.
★ Improve the civilized and polite level of employees.
★ Create team spirit
note:
Long-term persistence can form good habits.
Key points of implementation:
1. Standards for clothing, appearance and identification
2.* * * There are relevant rules and regulations.
3. Etiquette norms
4. Training (new employees strengthen 5S education and practice)
5. Various spiritual improvement activities (morning meetings, etiquette sports, etc.). )
4. misunderstanding 1. Our company has done 5S.
Our company is so small that it is useless to engage in 5S.
3.5S is to clean up the scene.
4.5S is just a matter at the factory site.
5.5S activities can't see economic benefits.
6. I am too busy to do 5S.
7. We are engaged in technology, and doing 5S is a waste of time.
8. It is impossible for our industry to do 5S well.
Five, finishing the implementation points: correct value consciousness-"use value", not "original purchase value"
Rectification: the correct method-"three elements, three decisions"+rectification technology
Cleaning: responsibilities-define the 5S responsibilities of the post.
Cleanliness: institutionalization and evaluation-5s; Inspection, competition, reward and punishment
Cultural literacy: long-term morning meetings and etiquette rules
6. Checkpoint 1. Is there any purpose unknown?
2. Is there anything unclear?
3. Are there any idle containers and cartons?
4. Is there anything you don't want?
5. Are there any articles placed under the conveyor belt and material rack?
6. Did you leave your personal belongings lying around?
7. Did you put anything in the aisle?
8. Is the article parallel or at right angles to the article?
9. Have you modified packaging materials such as boxes?
10. Is the packing box damaged (damaged container)?
1 1. is a fixture, measuring instrument, etc. Put it in the specified location?
12. Is it easy to move?
13. Is there anything behind or on the shelf?
14. Are the items in the shelves and safe deposit boxes placed according to the marked items?
15. Are dangerous goods clearly marked and are fire extinguishers regularly inspected?
16. Are there any messy parts at the operator's feet?
17. Are the same parts scattered in different places?
18. Is there anything necessary (tools, parts, etc.)? ) around the operator?
19. Are there parts everywhere in the workshop?
Seven. Implementation Step 1: Establish implementation organization.
In order to effectively promote 5S activities, it is necessary to establish a promotion organization that meets the conditions of enterprises-5S implementation committee. The persons in charge of the implementation committee include the 5S committee, the Promotion Bureau, the heads of various departments, and the 5S representatives of various departments. Different persons in charge bear different responsibilities, as shown in Table 2- 1. Among them, the general manager of the enterprise is generally the chairman of the 5S Committee, which promotes the implementation of 5S from a global perspective.
Step 2: Formulate implementation policies and objectives.
Policy making: When implementing 5S management, making policies as the guiding principle should be combined with the specific situation of the enterprise and have appeal. Once a policy is formulated, it should be widely publicized.
Goal setting: Goal setting should be combined with the specific situation of the enterprise as the direction of activity efforts, and it is convenient to check the results during the activity.
Step 3: Work out the work plan and implementation method.
1. Schedule is the basis of implementation and control.
2. Information and references from other factories
3.5S activity implementation measures
4. Identify methods from unwanted items
5.5S activity evaluation method
6.5S activity reward and punishment measures
7. Relevant regulations (5S time, etc. )
8. Work must be planned, so that everyone can have an overall understanding of the whole process. The project leader knows what the work of himself and other leaders is, when it will be completed, and cooperates with each other to create team morale.
Step 4: Education
Education is very important. Let employees know that 5S activities can bring benefits to their work and themselves, so that they can take the initiative to do it, which is completely different from being forced to do it by others. The forms of education should be diversified, such as lectures, videos, observing cases or model areas of other factories and learning implementation manuals. Educational content can include
1. All departments should educate all employees.
2.5S The content and purpose of site management methods
Implementation method of 3.5S site management method
4.5S Evaluation Method of Field Management Law
5. 5S on-site management training for new employees
Step 5: Publicity before the event.
5S activities need the attention and participation of all employees to achieve good results. 5S activities can be publicized in the following ways:
1. Statement issued by the top supervisor (morning meeting, internal newspaper, etc. )
2. Posters, internal newspaper publicity
3. Publicity column
Step 6: Implement
1. Job preparation
2. "Bathing" campaign (national cleaning)
3. Ground marking and project identification standards
4. Development of "Three Definitions" and "Three Elements"
5. photography
6. "5s daily confirmation form" and its implementation
fight
Step 7: Determine the activity assessment method.
1. coefficient: difficulty coefficient, quantity coefficient, area coefficient, education coefficient.
2. Scoring method
Step 8: Check
1. check
2. Ask and answer.
3. Various activities and competitions (such as essay writing activities). )
Step 9: Evaluate, Reward and Punish
Conduct assessment according to the 5S activity competition method, announce the results, and implement rewards and punishments.
Step 10: Check and correct
All responsible departments make improvements according to the deficiencies and make continuous improvements.
Step 1 1: Incorporate routine management activities.
1. Perfection of standardization and institutionalization
2. Implement various 5S site management methods and strengthen monthly activities.
It should be emphasized that enterprises may encounter various problems due to their different backgrounds, structures, corporate cultures and personnel qualities. The executive office should take practical countermeasures according to the specific problems encountered in the implementation process in order to achieve satisfactory results.
8. Implementation method of 1. Seiri's orderly governance. The focus of the work is to sort out what is necessary and what is not. The core purpose of sorting is to improve the degree of discrimination. Common sorting methods are:
1. 1 drawer method: treat all resources as useless and choose useful ones.
1.2 cherry method: pick out the parts that affect the overall performance from the finishing.
1.3 Four Appropriate Methods: Timely, Moderate, Suitable Quality and Suitable Place.
1.4 Question method: Do you need this resource? Do you need to be here? Does the site need such a large quantity?
2.Seion modifies, adjusts, arranges, corrects and handles. And systematically integrating classified resources. The purpose of rectification: to minimize unnecessary working hours, operation, search, defective products, unsafe environment and important waste. Rectification and upgrading are integration. Commonly used tools and methods are:
2. 1 IE method: according to the principle of operation economy, the frequently used resources will be effectively managed.
2.2 Decoration method: Through systematic planning, the effective resources are used in the most valuable places.
2.3 Three principles: easy to obtain, easy to publish and easy to manage.
2.4 Three principles: positioning, quantification and standardization.
2.5 process method: for the layout, standardize the system according to the idea of a process to make it orderly.
2.6 Marking method: Mark all resources and establish effective resource information.
3.Seiso cleaning, clarification, removal and closing. Exclude resources that should not appear in the area of responsibility. The purpose of cleaning up is to reject all unfavorable factors before the incident, severely crack down on and clean up the existing unreasonable existence, and create a good working atmosphere and environment. Clean promotion action. Common cleaning methods are:
3. 1 three-sweep method: sweep black, leak and blame.
3.2 OEC method: the sky has passed, the sky has cleared, and the sky is high.
4. Clear, clear, simple, clean and tidy. Continue to do a good job of sorting out, rectifying and cleaning up, that is, form a culture and habit. Reduce defects and flaws. The purpose of cleaning: beautify the environment, atmosphere, resources and output, so that oneself, customers, investors and society can benefit from it. Cleanliness enhances aesthetic power. Commonly used methods are:
4. 1 radar method: scan all loopholes and heresies within the scope of authority.
4.2 Matrix shift method: advance from point to surface one by one.
4.3 Law of Honor: Combine reputation with reputation, and decide the prestige and income of the executing agency or individual by reputation.
5. Quality, education. Work focus: establish good values and ethics. Literacy is the core competitiveness. Through ordinary details optimization and continuous teaching and training, we can establish a good working and living atmosphere and optimize personal quality and education. Commonly used methods are:
5. 1 process reengineering: the lack of execution is not a human problem, but a process problem, and process reengineering is to solve this problem.
5.2 Pattern diagram: Establish a complete pattern diagram to support the effective implementation of process reengineering.
5.3 Coaching Method: Through the camera-style supervision mode and the same training as the coach, all embarrassing requirements are turned into real habits.
5.4 dredge method: dredge the factors that seriously affect literacy, just like the Yellow River.
Nine. Implementation difficulties 1. Employees are unwilling to cooperate, do not follow the regulations or do not follow the standards, and have poor understanding of concepts.
2. Insufficient planning in advance, poor placement and many unreasonable places.
3. The company is developing too fast, the factory space is insufficient, and there is nowhere to pile up materials.
4. The implementation is not thorough enough, the continuity is not good, and the mentality of coping is held.
5. The evaluation system is not good, which leads to unfairness and everyone is at a loss.
6. All judges will be rewarded for fear of hurting their feelings, thus losing the meaning of the competition.
X. Significance of implementing 5S 5S is the basis of on-site management, the premise of safe production for all employees, the first step of total quality management and the guarantee of effective implementation of ISO9000.
5S field management method can create a good atmosphere of "everyone actively participates and everything is done according to standards". With this atmosphere, the implementation of ISO, TQM and TPM is easier to get the support and cooperation of employees, which is conducive to mobilizing the enthusiasm of employees and forming a strong driving force.
The effect of implementing ISO, TQM, TPM and other activities is hidden and long-term, and it is difficult to see significant effects for a while. The effect of 5S activities is immediate. If 5S is introduced in the process of implementing ISO, TQM, TPM and other activities, it can achieve remarkable results in a short time and enhance the confidence of employees.
5S is the foundation of site management. The level of 5S represents the level of managers' understanding of site management, which in turn determines the level of site management and restricts the smooth and effective implementation of ISO, TPM and TQM activities. Through 5S activities, it can get twice the result with half the effort to improve the "physique" of enterprises from on-site management.
XI。 Suggestions for improvement 1. Make appropriate positioning according to the actual situation.
On the other hand, look back at the management models of other excellent enterprises at home and abroad, and then make appropriate positioning according to the reality. Through learning, managers and employees realize that "5S" is the cornerstone of on-site management. If "5S" can't be done well, enterprises can't become excellent enterprises, and adhering to "5S" management is an important business principle. The "5S" executive office plays an important role in the implementation process and should be held by middle and senior leaders with certain prestige and strong coordination ability. In addition, if you ask a consultant to guide the implementation, you should pay attention to avoiding the peak season of production and the period of large personnel changes.
2. Establish a scientific management concept
Managers must learn and deepen their understanding of the ultimate goal of "5S" management mode. The top management of the top leadership company must establish the concept that "5S" management is the foundation of on-site management, and talk about it once a year and once a month, and gradually deepen on-site management activities in a planned and step-by-step manner to improve on-site management level. "Attack is the best defense", and so is management. We must always introduce new and higher-level ideas, systems and methods to maintain the vitality of enterprises. After all, "5S" is only the basic project of site management. According to the production site management level of Liugang, it is suggested that after the introduction of "5S", total production management, total cost management, lean production, target management, enterprise resource planning and cost planning of each workshop should be introduced. However, before many on-site management foundations have been established and cadres' scientific management consciousness has not been established, blindly spending money to introduce these will definitely get twice the result with half the effort and even fail, because these are not only a management tool, but also a management concept and a management culture.
3. Take a variety of management forms according to actual positions.
Determine the positioning of "5S", and then adopt various management forms according to the actual post and formulate various corresponding feasible methods. Seeking truth from facts, perseverance, all-round implementation and planned process control are very important. The company can advocate the model first, guide the cadres and workers to actively accept the "5S" through the change of the model area, and introduce red card combat, visual management, daily confirmation system, "5S" evaluation system and "5S" competition. In a planned way, at an appropriate time, in the process of normalization and habituation, all employees will gradually establish a good work style and scientific management consciousness.