6S Concept

6S CONCEPT

   

     1 . What 's 6S

     What we call " 6S " is derived from the company's 5S and visual control method popularized by Hiroyuki Hirano (1990 ) - Japanese managers are rooted in the works of two American pioneers who meticulously learned that Frederick W. Taylor ' s ( 1911) and Henry Ford ( 1922 ) . 6S is a method of structuring and maintenance intensive work areas originating from Japan that is used by management in an effort to maintain order , efficiency , and discipline at the work site at the same time improve overall company performance .

     6s is a culture about how people treat their workplace properly and maintain order and keep the workplace neat , clean and orderly so that the work can be created easily . Basically the same with the 5S, 6S but there are additional 1S said the " safety " , with the goal of working efficiency , work productivity , quality of work , safety , increasing capital and labor discipline , and work comfort . So overall , 6S is :

      Sort ( seiri )

      Set in Order ( seiton )

      Shine ( Seiso )

      Standardize ( Seiketsu )

      Sustain ( Shitsuke )

      Safety

    

   6S can increase work productivity with the work ethic rooted in the formation to create a comfortable and safe work environment that has the feeling that would encourage workers to carry out environmental improvement works and train them to reduce waste , unplanned downtime and in-process inventory .

     Once implemented in an integrated manner , 6S will increase employee morale , create positive impressions of the customers and improve the efficiency of the company . Not only workers who are comfortable with the work environment , the effects of which continue to make sustained improvement will encourage waste reduction , better quality and shorter lead times . All of this will make the company become more profitable and competitive in the world market .

      2 . The purpose of 6S

      1 . Zero Breakdown , means better maintenance :

      a. Scrap , dust , furious - furious and pieces - pieces on the floor and on the engine is reduced

     b. By cleaning the machine carefully and regularly , the condition of the machine is known at all times ;

      c. Inspection and maintenance of each day to avoid engine damage becomes severe in the future .

      2 . Zero Defect , which means better quality :

      a. If everything is in place , you avoid taking the wrong item ; 

      b . Clean workplace morale would give to anyone ;

      c . Gauges and indicators work well then the quality will be good .

      3 . Zero Waste , which means reduced costs and increased efficiency :

      a. Inventory and work in process becomes less

      b. The rooms were used for items that are not required to be reduced

      c. The movements are not necessary as avoiding and seeking to diminish

    d. Reduce movement - a movement that is not required such as production , lifting  , putting , counting and moving .

      4 . Zero Set Up Time , which means no time is wasted :

      a. Because everything laid out regularly , the time wasted searching for tools to be suppressed

      b. Clean workplace can improve the efficiency and easier for people to find out how the operation , although trainees can easily operate it .

      5 . Zero Late Delivery , meaning it can meet customer demand on time :

      a. Since no production damaged the subscription request can be fulfilled on time 

      b. Good working environment plant production speed, nothing is wasted and efficiency is increased

      6 . Zero Injury , which means better safety :

      a. The equipment is clean and shiny easily observe the damage and hazards ;

      b. If you know where the equipment is stored , you can retrieve it if needed sooner

      c. If you put something then you can safely avoid the equipment to fall upon you 

     d. If there is a fire ( fire ) and an earthquake or other natural disaster, you know where the location of emergency exits and fire extinguishers ( mitigation )

      7. Zero Customer Claim , means that customers put a high level of confidence :

      a. Clean factory does not produce goods damaged

      b . Clean factory can produce goods that ensure user safety .

      8 . Zero Deficit , meaning your company forward added :

      a. If 6S has been executed well , definitely a place to be comfortable and interesting work , no 

     waste , no accidents , no engine damage and no defective product , you can meet the desires and expectations of customers as well as investors , Return on Investment ( ROI ) you also will be increased after the implementation of 6S .

      3 . Techniques 6S

      1. SEIRI means SHORT or SORTING

    Objective : CHOOSING or summarize GOODS . This is done considering the working space is limited and should be streamlined .

      1 . Goods are required to work

      2 . Goods are not required to work

      3 . Items that are not needed at all

      4 . Items that do not fit their placement

      If SEIRI not met, then :

•     Atmosphere and work activities disrupted

•     Difficult to improve productivity , efficiency , and effectiveness of

      Meanwhile, if SEIRI met, then :

•     No waste of space

•     Non- utilized efficiently

•     Work Environment K3 and increased

•     Productivity increased job

•     There was no accumulation of goods 

  

      Application of the method Seiri:

      A. Criteria for goods are set aside

•     Waste or scrap

•     Required elsewhere

•     Not required

•     Prepare labels

      B. Criteria for machinery / equipment / materials

•     When is the item used / certainty of time

•     The use is not excluded

•     Prepare labels

      C. Criteria for work in process ( half finished )

•     Set the certainty of the goods will be used ( time )

•     Determine the required amount within the time limit

•     When there is excess should be set aside

•     Prepare labels

      Installation Label

1    . Specifies the sort order of activities

2    . Observing the items to be sorted

a    . Small items together in one box size

b    . Items that are not needed are installed LABEL

c    . Set shelters were not used goods

d    . If there are items missing , repeat the previous steps

e    . Create photo documentation before and after SEIRI

      Preclude the existence of Goods Required in Phase SEIRI

•   Step seiri or concise tend to precautions that all materials and goods to be used or to avoid the existence of goods which are not necessary .

•    Prevention is more effective when all personnel have realized the importance of phase concise , it would be better if the work culture has become . To measure the implementation stage of this compact as work culture , it requires attention , awareness and concern for all employees on unnecessary items .

•    If still found items and materials that are not necessary mean SHORT awareness and concern has not become culture .

      2 . Seiton or NEAT or ORGANIZATION. 

      Objective : spruce or arranging things NECESSARY .

•     Goods must be done neatly in place

•     Items that do not / have not done should be kept away from work , but still in the working area

•     Waste or Scrap disposed in the space provided for the bin

•     Items needed elsewhere have actually been in a designated place  

      Method of application Seiton

      1 . Prepare labels Seiton

      2 . Create guidelines for the preparation of

      3 . Identify all items

      4 . Goods are not in place label attached Seiton   

      5 . Do it gradually

      6 . Once the label is composed to facilitate the search

      Avoid untidiness in stages Seiton

      If the stage has been run cleanly , but still there is untidiness , there will arise the question why ?Besides, it is also the extent to which staff awareness of the importance of neatness working environment , gradually smoothing the workplace and work environment should be a " Culture of Work" for each employee and exemplary leadership or management team , work culture to work neatly should continuously be imparted to all employees gradual and continuous agenda .

     3 . SEISO means RESIK or CLEANING

     Objective : workplace and work equipment or clean rehearsal .

     Three rounds of SEISO

      1. Operating properties hygiene

       • Discover the cause defilement

       • Perform the cleaning

      2. Object cleanup

       • The workplace

       • Tools work

      3. Prevent damage

•    Find the cause of damage to equipment

•    Use equipment appropriately according to its function

   The role of employees is an indicator of the success of the work culture in the stage RESIK Familiarize work to be part of the work culture is not necessarily easy , because there are elements change a person's behavior , but it can be pursued gradually , through :

•   Commitment coupled with exemplary leadership

•   Campaign RESIK program

     •The system is able to be done by employees

•    Facilities and infrastructure sufficient

     Clean the dirty areas is important , but more importantly how to avoid the reappearance excrement happens .

     Method of application SEISO

        1. Before and after cleaning

        a. collecting the data

        b. Analyzing the data

        2. Prepare Tape Red , Yellow and Lak / Tipp Ex

        a. Red duct tape , paste section of damaged equipment ( can not be fixed that day )

        b. Yellow duct tape , paste section of damaged equipment ( soon to be fixed )

        c. Tipp Ex , for the bolt / nut loose ( after dpt marked Tipp Ex tensioned to easily rectified )

        d. Make a list of equipment to be used

        3. Prepare Form Forms 1,2 and 3

        a. Shape 1 : for recording equipment damaged and can not be repaired

        b. Shape 2 : for recording equipment damaged but can be repaired

     c. Shape 3 : inspect all parts of machinery / equipment carefully , especially the part that is sensitive .

      4 . SEIKETSU means treating or maintaining a work environment that is already good.

      Goal and objectives include:

•     Maintaining a work environment that is already well

•     There should be a uniform standard , the labeling instructions at all operating conditions

•     Check the state of the dean workplace equipment used

•     Available trash

      In this stage of care is more difficult than maintaining the reach , because maintaining consistency requires continuous work . Maintaining workplace conditions have been good this required the participation of all employees to participate. All employees should have the same determination to defend it is by three principles:

•     No unnecessary items

•     Do not scattered

•     Not Dirty

     Rule Free SEIKETSU:

•    All employees involved and responsible for the implementation of the 5 - S

•    Sense of charge must be cultivated

•    Clean it expensive, but much more expensive dirty

•    Officer in charge of the area is in charge of hygiene, cleaning service but as a supporter of hygiene

     Method of application SEIKETSU

     1 . In the individual the burden of care , both at work and equipment .

    2 . Garbage / dirt dumped in the space provided , because not only cleaning service who should be responsible .

     3 . Cultivated .

   CARE is a continuation of Phase RESIK stage therefore monitoring and evaluation activities necessary RESIK stage :

      1 . Are there any items that are not needed are still being around you ?

      2 . Do not use equipment that can be taken ?

      3 . Do RESIK do every morning ?

      4 . Do RESIK done every day after work ? 

      5 . The extent to which the role of the employee to work neatly ?

   

      5 . Shitsuke means diligently or habituation

      Objective : Accustomed to foster self-discipline . This means that :

•   Employees must be willing , able and daring to change the behavior of a controlled direction  Changes in attitude must be in accordance with the cultural values

•     Strive continuously to improve achievements

      Do what you must do and do not do what should not be done

•  Willing to remind and be reminded each other everything should be done consistently and continuously

      Benefits Shitsuke

      1 . There is no wastage

      2 . Work environment and K3 supported

      3 . Maintenance of the machine can be done better  

      4 . Possible defects inevitable product

      5 . Timely service

      6 . There is no grievance / complaint from customers

      7 . Welfare of employees increased

      Visual control in the workplace as part of the stage or diligent Shitsuke

•     The first step in controlling the phase that is visually diligent at work .

•     Is the 5 - s program has been implemented and has been the work culture at the same time?

    Anyone can judge objectively without being influenced by anyone. In order to control the visual workplace matters that need to be considered are as follows:

      1. Always open to give feedback or criticism of workplace conditions

      2. Accept criticism or input will basically strengthen the implementation of 5S

      3. If there is a problem please make particular remedial action by personnel associated parts

    

      6. Safety

      Objective: Minimize the occurrence of accidents, injuries or other incidents. Thus, each person should have a role and responsibility in terms of safety as well as understand how to prevent accidents. Everyone who has a role and responsibility in terms of both safety manager, asst managers, engineers, supervisors, foreman, and operators must observe and correct the behavior if there are colleagues who ignore safety.

      The first thing to do is hazard recognition which includes an analysis of the presence of hazardous situations caused by workers , equipment , materials , methods of work , to the environment in a work area . If the hazard is found, then make use of certain tools that can be used to improve safety. Measurable parameters of safety success is seen from the Key Performance Indicator (KPI), namely;

     

     1 . Total Recordable Frequency Rate (TRFR)

   

      TRFR = ( ( LTA + RWC + MTC ) x 1,000,000 ) / hours worked 

   

      LTA = Loss Time Accident

      RWC = Restricted Work Case

      MTC = Medical Treatment Case

     

      2 . Safety Behaviour Observation (SBO)

   This observation was made ​​by Manager 1x/week, 2x/week Asst Manager, Engineer and Supervisor3x/week , 1x/day Foreman , Operator 1x/day . 5S itself is in line with ergonomics and can be considered as part of the ergonomics. Meanwhile, the latest S (safety) were added to the 5S or 6S. 5S thus becomes + 1 is one of the main parts in ergonomics. This causes 6S become an issue very closely with the ergonomics.