What is 5S management?
The Significance of "5S" Activities
The "5S" activity originated in Japan and was widely implemented in Japanese enterprises, which was equivalent to the civilized production activities carried out by enterprises in China. The object of "5S" activity is the "environment" of the site. Considering the overall situation of the production site environment, practical plans and measures are formulated to realize standardized management. The core and essence of "5S" activity is self-cultivation. Without the corresponding improvement of employees' self-cultivation, it is difficult to carry out and adhere to the "5S" activities.
Content of "5S" activity
(a) finishing
The first step to improve the production site is to separate the needed people, things and things from the unwanted people, things and things, and then deal with the unwanted people, things and things. Its main point is to classify all kinds of articles actually placed and stagnant at the production site, and distinguish between those needed and those not needed at the site; Secondly, we must resolutely clean up unnecessary items on the site, such as used materials, redundant semi-finished products, chips, leftovers, garbage, waste products, redundant tools, scrapped equipment, workers' personal daily necessities, etc. The focus of this work is to resolutely clean up unnecessary things at the scene. The front and rear of each station or equipment in the workshop, the left and right of the passage, the up and down of the workshop, the inside and outside of the toolbox and the dead corner of the workshop should be thoroughly searched and cleaned to make the best use of everything. Resolutely doing this step is the beginning of establishing a good style of work. Some Japanese companies put forward the slogan: efficiency and safety begin with the end!
The purpose of dressing is: ① to improve and increase the working area; (2) There is no sundries on the site, the streets are unobstructed, and the work efficiency is improved; (3) reduce collision opportunities, ensure safety and improve quality; (4) Put an end to management mistakes such as mixed loading and mixed loading; ⑤ It is beneficial to reduce inventory and save money; ⑥ Change working style and improve working mood.
(2) rectification
Quantify and locate the people, things and things needed. After the completion of the previous step, scientifically and reasonably arrange and place the items that need to be left at the production site, obtain the required items as quickly as possible, and complete the operation under the most effective rules and regulations and the simplest process.
The main points of remediation activities are as follows: ① Articles should be placed in fixed places and areas, so as to be easy to find and prevent mistakes caused by mixing; (2) Articles should be placed in a scientific and reasonable place. For example, according to the frequency of use of items, things that are often used should be placed nearby (such as the work area), and things that are occasionally used or not commonly used should be placed far away (such as concentrated in a certain place in the workshop); (3) Visualize the placement of articles, so that the quantitatively loaded articles can be seen and counted, and the areas where different articles are placed are distinguished by different colors and marks.
Reasonable placement of articles in the production site is conducive to improving work efficiency and product quality and ensuring production safety. This work has developed into a special field management method-fixed location management (its content will be further introduced in the third section).
(3) Cleaning
Clean the workplace, repair the equipment immediately if it is abnormal, and make it return to normal. Dust, oil, iron filings, garbage, etc. Will be produced in the production process of the production site, thus making the site dirty. Dirty scene will reduce the accuracy of equipment, cause frequent failures, affect product quality, and prevent safety accidents; Dirty scenes will affect people's working mood and make people unwilling to stay for a long time. Therefore, it is necessary to remove those dirt through cleaning activities and create a bright and comfortable working environment.
The main points of cleaning activities are: (1) clean your own belongings, such as equipment and tools, without relying on others and adding special cleaning agents; (2) Equipment cleaning, focusing on equipment maintenance. Cleaning equipment should be combined with point inspection of equipment, that is, point inspection and repair; Cleaning equipment should be lubricated at the same time, and cleaning is also maintenance; ③ Cleaning is also for improvement. When cleaning the ground, flying debris and oil-water leakage are found. It is necessary to find out the reasons and take measures to improve them.
(4) cleanliness
After sorting, rectifying and cleaning, it should be carefully maintained to keep the site in perfect and best condition. Cleaning is the persistence and deepening of the first three activities, thus eliminating the root causes of safety accidents. Create a good working environment and let employees work happily.
The main points of cleaning activities are as follows: (1) The workshop environment should not only be neat, but also clean and hygienic, so as to ensure the health of workers and improve their labor enthusiasm; (2) Not only articles should be clean, but also workers themselves should be clean, such as clean work clothes, neat instruments, timely haircut, shaving, manicure, bathing, etc. (3) Workers should not only be physically clean, but also be mentally "clean", be polite and respect others; (4) Protect the environment from pollution, further eliminate turbid air, dust, noise and pollution sources, and eliminate occupational diseases.
(5) Literacy
Literacy is to strive to improve the self-cultivation of personnel and develop the habit and style of strictly observing rules and regulations, which is the core of "5S" activities. Without the improvement of personnel quality, all activities can not be carried out smoothly and can not be adhered to. Therefore, to grasp the "5S" activities, we should always focus on improving people's quality.
Principles of developing "5S" activities
(A) 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 running a factory with diligence and thrift
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.
The essence of carrying out 5S
5S field management method originated in Japan, and 5S is five Japanese words, namely, SEIRI, SEITON, SEISO, SEIKETSU and SHITSUKE, also known as "five-routine method" or "five-routine method".
The origin of 5S
Evolution of 5S
5S originated in Japan and refers to the effective management of production factors such as personnel, machines, materials and methods at the production site. This is a unique management method of Japanese enterprises.
1955, the slogan of Japanese 5S is "Safety begins with sorting and ends with sorting". At that time, only the first two s were implemented, and its purpose was only to ensure the workspace and safety. Later, due to the need of production and quality control, 3S, namely cleaning, cleaning and cultivation, was gradually put forward, which further expanded the application space and scope. By 1986, the works of 5S in Japan were gradually published, which had an impact on the whole field management mode and set off a 5S craze.
Development of 5S
Japanese enterprises regard 5S movement as the basis of management and implement various quality management methods. After World War II, the quality of products improved rapidly, and the status of an economic power was established. Under the advocacy of Toyota, 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 the site, and has gradually been recognized by management circles in various countries. With the development of world economy, 5S has become a new trend of factory management.
According to the needs of further development of enterprises, some enterprises have increased safety on the basis of the original 5S, that is, formed "6S"; Some enterprises add Save to the table "7s", some enterprises add up Shiukanka, Service and Shikoku to form "10S", and some enterprises even advertise "12S", but all of them are derived from "5S", such as removing useless things or articles in sorting, which is in a sense.
Perform the duties of 5S.
1, enhance corporate image
2. Improve production 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. Enhance enterprise spirit and form a good corporate culture.
Objectives of 5S activities
(1) When you change jobs, you will find tools and articles immediately, and the search time is 0.
(2) Clean production limit, and the defective product is 0.
(3) Strive to reduce costs, reduce consumption, and waste is zero.
(4) The work is smooth, the task is completed in time, and the delay is 0.
(5) No leakage, no harm, safety and cleanliness, and the accident is 0.
(6) unite and be friendly, think of others everywhere, actively do their job, and the bad behavior is 0.
Effectiveness of 5S management
The five main effects of 5S management can be summarized as follows:
5 s, namely: sales, economy, safety, standardization and satisfaction.
1, 5S management is the best salesman (sales)-the clean and tidy factory praised by customers makes customers confident and willing to place orders; Many people will come to the factory to visit and study; Will make people want to work in such a factory.
2.5S management means saving)-reducing unnecessary waste of materials and tools; Reduce the time to find tools, materials, etc. Improve work efficiency.
3, 5S management safety (SAFE)-wide and bright workplace, broad vision, compliance with accumulation restrictions, the danger is clear at a glance; Clear walkways will not cause confusion and affect the smooth progress of the work.
4.5S management is the promoter of standardization-\ "three definitions \" and \ "three elements \" to standardize the work site. Everyone carries out the task according to the regulations, with stable procedures and stable quality.
5, 5S management to form a satisfactory workplace (satisfication)-to create a bright, clean workplace, so that employees have a sense of accomplishment, can create an atmosphere for all employees to improve.
The content of 5S field management law
By standardizing the scene and existing things, creating a clear working environment and cultivating employees' good working habits is a unique management method of enterprises, and its ultimate goal is to improve people's quality:
Get rid of carelessness and get into the habit of taking everything seriously.
Take every "little thing" in your work seriously.
★ Abide by the prescribed habits
★ Consciously maintain a clean and tidy working environment.
★ Polite habits.
5S site management method: 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:
Be firm, and unnecessary items should be flattened.
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.
5S site management method: rectification
★ 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.
5S site management method: cleaning
★ 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
5S site management method: cleaning
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.
5S site management method: 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.). )
Implementation steps of 5S field management method
I have mastered the basic knowledge of 5S field management methods, but I don't have the ability to carry out 5S activities. Due to improper implementation steps and methods, it is not uncommon to get twice the result with half the effort or even give up halfway. Therefore, it is very important to master the correct steps and methods.
Step 1: Establish the implementation organization.
1. Establish a committee and an executive office.
2. Determine the location of the organization
3. Main work of members
4. Grouping and division of responsibility areas
It is suggested that the main leaders of the enterprise serve as the director of the implementation Committee of 5S activities as the support of this activity. Specific arrangements can be made by the deputy director in charge of overall implementation activities.
Step 2: Formulate implementation policies and objectives.
Policy formulation:
When carrying out 5S management, we should formulate policies as the guiding principle.
Example 1: Carry out 5S management and build the first-class image of CIMC.
Example 2: Say goodbye to yesterday, challenge yourself and create a new image of Hongjie.
Example 3: Create a new company image from details.
Example 4: Standardize the scene and existing things to improve people's quality.
The formulation of policies should be combined with the specific situation of enterprises and attractive. Once a policy is formulated, it should be widely publicized.
Goal setting:
First, set the desired goal as the direction of the activity, which is convenient for checking the results during the activity.
Example 1: In the fourth month, all departments scored above 90.
Ex. 2: Guests don't need to make temporary preparations in advance to visit the factory.
The formulation of goals should also be combined with the specific situation of enterprises.
Step 3: Work out the work plan and implementation method.
1. Schedule is the basis of implementation and control.
2. Information and references of 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
★ All departments should educate all employees.
★ The content and purpose of 5S site management method
★ Implementation method of 5S field management method
★ Evaluation method of 5S field management method
★ 5S on-site management training for new employees
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.
Step 5: Publicity before the event.
5S activities need the attention and participation of all employees to achieve good results.
★ Statements issued by the top executives (morning meetings, internal newspapers, etc.). )
★ Posters and internal newspaper publicity
★ 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.
1. Quality control technology
skill
In 5S activities, proper introduction of QC technology and IE technology can make 5S activities more smooth and effective.
Step 1 1: Incorporate routine management activities.
★ Perfection of standardization and institutionalization
★ Carry out 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.
Key points of implementation of 5S field management law
Finishing: 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
The Relationship between 5S Site Management Law and Other Management Activities
5S is the foundation of site management, the premise of safety 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.
5S management checkpoint
1, is there any unknown purpose?
2. Is there anything unknown?
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 passage?
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 (container damaged)
Yes 1 1, fixtures, measuring instruments, 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 under the operator's feet?
17. Are the same parts scattered in several different places?
18. Is there anything necessary (tools, parts, etc.)? ) around the operator?
19. Are there parts everywhere in the workshop?