In this session, I would like to talk about organization(sorting & arranging), and some essential safety rules
Accident prevention is closely related to organization and tidying as we may say safety begins and ends with those two
Generally, when we talk about organization(sorting&arranging), we simply think it as tidying up scattered items and cleaning them in one place, however, from a safety perspective, it holds a deeper meaning
Shall we explore the methods of organization and essential safety rules that should be known before starting work?
So, what is "organization"?
Sorting refers to the act of distinguishing necessary and unnecessary items, and only keeping the right ones
Arranging means setting items in a way that makes them easy find and use by marking their proper location and quantity
To understand the concept of organization, it is necessary to first understand 3R5S
3R5S was developed as one of the methods when building the JIT production system by the Deputy Manager of Toyota Motor in the 1970s
JIT, or Just In Time production, is a concept that eliminates waste in daily life and manufacturing plants
by managing inventory at "0" to minimize unnecessary costs
The term 5S refers to the 5 Japanese words that start with S and was derived from the mindset of reconsidering the basics
The purpose of 3R5S is to distinguish between normal and abnormal conditions in both the on-site and management, making it easy to identify problems and take corrective actions
Firstly, 3R refers to visual management, making it easy for anyone to see how, how much, and where items are located by managing items
in terms of Right Product, Right Quantity and Right Location
Right Product is determining which products should be stored and its storage methods, then labeling those names
Right Quantity means understanding the usage status of stored items to indicate appropriate storage quantities
and Right Location means determining storage locations to enable visual management
and involved in organization such as first in first outs
Next, we will have a look at the 5S
First is Seiri(Sorting)
Sorting means distinguishing between necessary and unnecessary items, keeping the necessary ones, and discarding the unnecessary ones
It involves establishing principles for distinguishing between usable, unusable, and surplus items, identifying and categorizing between unusable and surplus items, registering their status, and disposing of them
Surplus items are those that can be reused but have a low frequency of use or should not be in the current storage location
while unusable items are those that are useless and should be disposed of, sold, or returned to the supplier
Second is Seiton(setting in order), which means marking proper locations and quantities to facilitate easy access to necessary items
Arranging items neatly in rows is called "arrangement," not "setting in order"
Designating storage areas and quantities, determining storage methods, and attaching inventory boards are part of setting in order
Third is Seisoh(cleanling), which involves removing dust and foreign matter from areas or items after sorting, arranging, and 3Rs
Designating cleaning areas and inspection facilities, standardizing cleaning methods, creating cleaning method and equipment inspection guidelines, and conducting small group activities based on 5S themes are part of cleaning
Fourth is Seiketsu(hygeine)
which involves maintaining a clean environment without dust or dirt, keeping an area clean means maintaining organization and cleanliness
If these are not maintained, it's easy to determine whether a condition is normal or abnormal
Lastly, fifth is Shitsuke(habituation), which means establishing habits to correctly execute designated tasks
Conducting 5S-related education through consciousness-raising and guidance checks, establishing and operating guidance check teams, and holding regular check meetings are essential for habituation
Among the 5S we've discussed, sorting, setting in order, cleaning, and hygiene are the means, while the end(purpose) is Shitsuke(habituation)
5S activities without habituation result in the continuous generation of unnecessary items, failure to maintain organization, and only showing effectiveness during activities
not contributing to productivity improvement, and resulting a passive consiousness
Therefore, these activities should be aimed to be done habituated
When implementing 3R5S, it's crucial to follow the sequence of sorting, setting in order, cleaning, hygiene, and habituation
The effect of organization improves efficiency by reducing waste and cutting costs
Long-term waste of inventory and wasted storage space are eliminated
Moreover, unnecessary actions such as excess transportation equipment and unnecessary actions such as searching or dodging items are removed
and other worthless actions wasting time and effort are eliminated
Secondly, it enhances safety, leading to accident prevention
Effective cleaning helps identify hazardous areas easily, and proper material arrangement allows for space allocation for rest and clearance of passages
By securing only the minimum amount of materials for stacking, risks of collapse, protrusion, and handling large quantities can be minimized
Also, in case of unforeseen accidents such as fires, well-organized fire extinguishing system allows
for swift action and easy evacuation, consequently minimizing damage
Thirdly, machine and equipment maintenance becomes easier
Cleaning removes factors such as dust and sand that cause defects in machinery and equipment, extending their lifespan and maintaining performance
Good cleaning facilitates essential managements and makes it easier to identify abnormalities
Fourth effect is on the improvement on product quality
By maintaining equipment and machinery, defective products are not produced, preventing deformation due to temperature differences during waiting between processes
and ensuring the use of unspoiled materials enhances the quality
Fifth effect is on minimizing losses during product changes
Well-organized tools reduce search losses, enabling rapid adjustment to changed production plans within a short period