“5S & 3T” the secret of success of Japanese companies

It’s a mindset & commitment to achieve a totally waste-free operation that is to focus on your customer’s success… achieved by simplifying and continuously improving all processes.

METHODOLOGY OF (5 S)

1.       ORGANISATION (SEIRI)

Decide what you need.

Remove unnecessary clutter.

All tools, materials, classified and then stored.

Remove items which are broken, unusable or only occasionally used.

RED TAG TECHNIQUE

GIVE STAFF RED LABELS

ASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACE.

ASK IF NEEDED & THOSE THAT ARE NEEDED, IN WHAT QUANTITY.

NOT NEEDED - RED TAG IT.

STORE IN THE RED TAG AREA.

PLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEK.

ALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMS.

AT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNED

ORGANISATION

PRIORITY	FREQUENCY OF USE	HOW TO USE
Low	Less than once per year Once per year	Throw away Store away from the workplace
Avg.	Once per month Once per week	Store together but offline
High	Once Per Day	Locate at the workplace

2.       ORDERLINESS (SEITON)

ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS.

NOW TURN TO THE LEFT OVER ITEMS.

Organize layout of tools and equipment.

–        Designated locations.

–        Use tapes and labels.
Ensure everything is available as it is needed and at the “point of use”.

METHODOLOGY OF (3 T)

1.       TIE – (Where to put)

Decide the location where to put something at our workplace.

2.       TIE HIN – (What to put)

Decide what item needs to put.

3.       TIE RIYO – (How much to put)

Decide how many quantities of items we need to put there.

Workplace Checkpoints:-

Positions of aisles and storage places clearly marked?

Tools classified and stored by frequency of use?

Pallets stacked correctly?

Is safety equipment easily accessible?

Is floor in good condition?

3.       SEISO (CLEAN/SHINE)

Create a spotless workplace

Identify and eliminate causes of dirt and grime – remove the need to clean

Sweep, dust, polish and paint.

Divide areas into zones

Define responsibilities for cleaning

Tools and equipment must be owned by an individual

Focus on removing the need to clean

4.       SEIKETSU (STANDARDISE)

Generate a maintenance system for the first three.

Develop procedures, schedules, practices.

Continue to assess the use and disposal of items.

Regularly audit using checklists and measures of housekeeping.

Real challenge is to keep it clean.

Make everyone understood that it is driving force behind all 5S.

Make it a way of life a part of health and safety program.

Involve the whole workforce.

5.       SHITSUKE (SUSTAIN/DISCIPLINE)
Develop and keep good habits.
Make it a way of life.
Involve the whole workforce.

WHAT U HAVE COME ACROSS AT THE END OF DAY

1.  NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME SPACIOUS

“ONE MUST LOCATE THE ITEM WITH IN 30 SECOND IF 5S IS PROPERLY IMPLEMENTED”

Rakesh K. Singh

  Logistics Professional 

Ten Important Questions for a 3PL Company’s Warehouse Manager

1.Question- What is warehouse ?

· Answer- A place where to store the goods.

2.Question- What should be the right approach for a warehouse manager?

·Answer-To take care of his customer like a nurse do for her patient and value the customer inventory like a banker value his customer money.

3.Question- What is necessary for warehousing?

·  Answer- Proper Storage of goods, Correct Inbound and Correct Outbound.

4.Question – What is necessary for warehouse manager?

·Answer- Goods need to be secured in safe conditions; Goods need be counted and well maintained.

5.Question- What is Inventory?

·Answer- The condition in which the customer’s goods are stored in the still quiet condition.

6.Question- What is inventory checking?

· Answer- To prove the customer’s goods quantity is as same as the controlled figure.

7.Question-If Inventory is not accurate, what will be?

· Answer- You cannot ship the goods properly, cannot tell the customer how much he is having, and critical damage of your company brand.

8.Question- How to control inventory?

· Answer-

· Every day checking in perfect quiet circumstances,

· Every day reconciling the discrepancy and making correction if needed,

· Maintain perfect match up of all data verses actual.

9.Question- What is WMS?

·Answer-Warehouse management system is the management of inventory, inbound, outbound.

10.  Question- What is purpose to use WMS?

· Answer-

· WMS need to be updated at the same timing as goods movement.

· WMS calculates inventory by entering inbound & outbound.

·Single entry of inbound and outbound is the key to achieve perfect inventory management.

·  Warehouse manager can check how much inbound and how much outbound has been done at the moment.

·  Warehouse manager could know what happened previously by referring WMS.

Rakesh K. Singh

Logistics Professional