Awareness on housekeeping and safety measures in work place

AWARENESS PROGRAM
ON
5 - S,
House Keeping,
and
Safety Measures
in Work Place
By: K.C.SAHU, Manager-Maintenance

THE SECRET TO
JAPANESE
SUCCESS
“5 S”

5S
HOUSEKEEPING TECHNIQUE
PRODUCTIVITY AND SAFETY
ENHANCEMENT TECHNIQUE

Housekeeping
does not mean
only cleanliness,
it means much
more than the
only cleanliness

It means cleanliness, tidiness
and much more……

Good housekeeping means
cleanliness, tidiness and…
Place for every thing
&
Every thing in it’s place

Why good housekeeping?
Good housekeeping
promotes
Quality
Safety
Productivity
Clean
Environment

How does good housekeeping help?
Place for
every thing
Inventory of
every item
Get rid of
unwanted
material
Why do
we
need?
Low inventory
means less
cost

How does good housekeeping help?
Every thing in
it’s place
Identific
ation
system
in the
dept.
Searc
hing
time
is
elimin
ated
Discip
line in
the
dept.
Improve
d
product
ivity &

Therefore, the first step towards
good housekeeping will be to
identify if there is a place for
every thing in the department,
and if every thing is in it’s
place.
Are you ready for this exercise?

Workplace Safety
Awareness training

How can we
achieve this in
our
workplace?
Providing and maintaining
safe machines and systems

How can we
achieve this in
our
workplace?
Organising the safe use of
dangerous goods and
hazardous chemicals

Controlling hazards such
as dust, noise and fumes
How can we
achieve this in
our
workplace?

How can we
achieve this in
our workplace?
Providing hygiene facilities
such as toilets and change rooms

How can we
achieve this in
our workplace?
Providing information on
hazards to ensure all
supported employees have
a clear understanding

How can we
achieve this in
our workplace?
Providing instruction,
training
and supervision to
supported employees

How can we
achieve this in
our workplace?
Monitoring your work area
and
employee health

How can we
achieve this in
our workplace?
Maintaining information
and records on health
and safety

Supporting an injured
supported employee’s
return to work
How can we
achieve this in
our workplace?

Demonstrating
safe work
practices

Like all employees, supported
employees must use safe work
practices and methods.
As support staff, your role is to
assist supported employees to use
safe work practices and methods.
How do you achieve this?
Safe work practices and
methods

Case study
Rona enjoys working on the
assembly line. However, she
seems to repeatedly forget the
instructions you have given her
about safe lifting practices.
What are some techniques
you would use to help Rona
work more safely?

employees must use safety clothing
and equipment (PPE).
assist supported employees to use
safety clothing and PPE.
How can you do this?
Safety clothing and
equipment

Case study
Daniel is required to wear ear-plugs when he
works near loud machinery. He is very good at
inserting the ear-plugs correctly, but you have
noticed that he sometimes arrives at work
wearing his ear-plugs. You suspect he is not
removing them when he finishes work.
How would you address this issue?

employees must not interfere with
or misuse equipment.
assist supported employees not to
interfere with or misuse equipment.
How can you do this?
Misusing equipment

Case study
Nicola frequently leaves her gloves on the
conveyor belt. This causes problems on the
assembly line when they become caught.
What would you do to help
solve this problem?

employees must not do anything
that may be dangerous to others.
assist supported employees not to
do anything that may be dangerous
to others.
How can you achieve this?
Endangering others

Case study
Milan can’t reach to put the rolls of paper
towel away on the top shelf. Instead of
getting the safety step, he sometimes
throws the rolls up onto the shelf. Yesterday
one rolled off and hit Jane who was walking
past carrying a tray of glasses.
How would you address this
issue?

Risk management
What are the challenges for you
when identifying OH&S risks for
supported employees in your
organisation?

Handling dangerous goods
What are the issues
you need to address
when training
supported employees
to handle dangerous
goods?

Manual handling
What are some
effective methods
for demonstrating
to supported
employees how
to lift correctly?

Movement
What are the rules
for our workplace?
Are there particular
issues with assisting
supported
employees to follow
them?

Soft tissue and overuse injuries
due to repetitive work
How is the risk of these type of
injuries identified in our
organisation?
Are there particular issues we should
consider for supported employees?

Illegal drugs and alcohol
Are drugs and alcohol an issue
when working with supported
employees?

Medication
What are the issues around
medication management for
supported employees in our
workplace?

Hazard
identification
and emergencies

What is a hazard in our
workplace?

Emergencies
In the case of an accident or
emergency, it is important to know
where the emergency equipment is
and what to do.

Reporting accidents and
Emergencies
Are you aware of the workplace
emergency and accident
procedures?
What are your responsibilities?

 Chemical protective rain suits
 Slip resistant shoes
 Safety glasses
 Face shield
 Gloves
 Hearing protection and respirators (when
appropriate)
 Proper hygiene practices

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• Lifting and Carrying:-
– injury to finger
– Injury to neck,
– Injury to back, arms and legs.
– Sprains, and
– Fractures
• Falling from Height:-
– Slipping, Tripping, Falling
• Burns:-
– Contact with hot parts of machine,
– electric burn
– electric shock
• Repetitive Strain Injury
• Chemical
Injury at their workplace:

 Lifting and Carrying:-
 injury to your neck,
 back, arms and legs.
 Sprains, whiplash and
 Fractures
 Falling from Height:-
 Slipping, Tripping, Falling
 Burns:-
 electric
 shock
 electric shock
 Electrocution
 Repetitive Strain Injury
 Post Traumatic Stress
 Chemical
Injury at their workplace:

The main sources of ignition involved in almost all
industries are:
 smoking
 heat of cutting
 spontaneous oxidation from grinding
 welding
 cutting
 hot surfaces such as furnaces etc.
 electrical sparking
 arching
 impact ignition, etc…
Source of Ignition:

Objectives
 Purpose of personal protective
equipment (PPE)
 PPE requirements
 Basics of selecting PPE

IDEA BEHIND 5S
 IN ORDER TO ACHIEVE HIGH
LEVELS OF QUALITY, SAFETY,AND
PRODUCTIVITY, WORKERS MUST
HAVE A CONDUCIVE WORKING
ENVIRONMENT

WHAT IS 5S?
 Developed by the Japanese
 Housekeeping System
 Helps Create a Better Working
Environment and a Consistently
High Quality Process

THE 5S PRINCIPLES
 SEIRI – Organisation/Sort out
 SEITON – Orderliness/Systemize
 SEISO – The Cleaning/Shining
 SEIKETSU – STANDARDIZE
 SHITSUKE - Sustain/Discipline

DISCOVERY OF 5S
 Thirty years ago researchers started
studying the secret of success of
Japanese manufacturing companies
 5S turned out to be the most
impressive "secret"
 The factories were so well organized
that abnormal situations were readily
apparent

METHODOLOGY
OF 5S

1. ORGANISATION(SEIRI)
 Decide what you need
 Remove unnecessary clutter
 All tools, gauges, 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
RED
TAG

For wavering items
 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
RED
TAG

2. ORDERLINESS(SEITON)
 ONCE YOU HAVE ELIMINATED ALL
THE UNNEEDED ITEMS
 NOW TURN TO THE LEFT OVER
ITEMS

ORDERLINESS(SEITON)
Organise 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”

ORDERLINESS(SEITON)
Workplace Checkpoints:-
 Positions of aisles and storage places
clearly marked?
 Tools classified and stored by frequency
of use?
 Pallets stacked correctly?
 Safety equipment easily accessible?
 Floors 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

SEISO (CLEAN/SHINE)
 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

5. SHITSUKE (SUSTAIN / DISCIPLINE)
 Means inoculate courtesy & good habits
 Driving force behind all 5S
 Deming’s point number 1: Constancy of
purpose
 Make it a way of life
 Part of health and safety
 Involve the whole workforce*
 Develop and keep good habits

LITMUS TEST FOR 5S
 30 SECOND RULE
 ONE MUST LOCATE THE ITEM WITH
IN 30 SECOND IF 5S IS PROPERLY
IMPLEMENTED
 ALSO APPLIES TO THE ELECTRONIC
RECORDS RETRIEVAL

WHAT U HAVE COME ACROSS
AT THE END OF DAY
Followings can be harnessed form the
5S
1. NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES

Cont.
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME
SPACIOUS

1910.132 General Requirements
 (a)Protective equipment,
including personal
protective equipment for:
– Eyes,
– Face,
– Head, and extremities,
– Protective clothing,
– Respiratory devices, and
– Protective shields and
barriers,
 Shall be provided,
used, and
maintained in a
sanitary and reliable
condition wherever
it is necessary by
reason of hazards
of processes or
environment

1910.132(f) Training
 (3) When the employer has reason to believe
that any affected employee who has already
been trained does not have the understanding
and skill required by paragraph (f)(2) of this
section, the employer shall retrain each such
employee. PPE
Refresher

Routes of Exposure
Inhalation Absorption Ingestion
What is the 4th route of exposure??

1910.133 Eye and face protection
 (a)(1)Ensure that each affected employee uses
appropriate eye or face protection when
exposed to eye or face hazards from:
–Flying particles,
–Molten metal,
–Liquid chemicals, acids or caustic liquids,
–Chemical gases or vapors, or potentially

 (a)(2)Ensure that each affected employee uses
eye protection that provides side protection
when there is a hazard from flying objects*
*Detachable side protectors (e.g. clip-on or
slide-on side shields) meeting the pertinent
requirements of this section are acceptable.

 (a)(3)Ensure that each employee who wears
prescription lenses while engaged in operations
that involve eye hazards
–Wears eye protection that incorporates
the prescription in its design, or
–Wears eye protection that can be
worn over the prescription lenses
–Without disturbing the proper position of the
prescription lenses or the protective lenses

Protective eye and face devices purchased after
July 5, 1994 shall comply with ANSI Z87.1-1989
Z 87.1-1989

 Workplace respiratory hazards: dusts, mists,
fogs, fumes, sprays, smokes or vapors
 Primary objective: Prevent atmospheric
contamination
 1st Priority: Engineering controls:
–Enclosure or confinement of the operation,
–General and local ventilation, and
–Substitution of less toxic materials
 Only where engineering controls are not
feasible should respirators be used

 Where respirators are required you need:
–Written program
–Worksite-specific procedures
–Required elements:
 Training
 Fit testing
 Medical evaluations
 Care and maintenance
 Procedures for respirator selection
 Procedures for routine & emergency use

1910.134(c)(2) Where respirator
use is not required:
–(i)If voluntary respirator use is permissible,
provide the respirator users with the
information contained in Appendix D and,
–(ii)Establish and implement those elements of
a written respiratory protection program*
necessary to ensure that any employee using
a respirator voluntarily is medically able to
use that respirator
–(ii)That the respirator is cleaned, stored, and
*Written program not required for voluntary use of dust masks

1910.134(e) Medical evaluations
 Using a respirator may place a physiological
burden on employees that varies with the type
of respirator worn, the job and workplace
conditions in which the respirator is used,
and the medical status of the employee
 The following are minimum requirements for
employee medical evaluations

1910.135(a) General requirements
 (1)Ensure that each
employee wears a protective
helmet when working in areas
where there is a potential for
injury to the head from falling
objects

Classes and types of Hard hats
 Type I hard hats - intended
to reduce the force of
impact resulting from a
blow to the top of the head
 Type II hard hats -
designed to provide
protection against both side
impact (lateral) and blows
to the top of the head
Classes
 G (old A)
 General
 2,200 volts
 E (old B)
 Electrical
 20,000 volts
 C (same)
 Conductive

1910.135(a) General requirements
 (2)The employer shall ensure that a protective
helmet designed to reduce electrical shock
hazard is worn by each such affected employee
when near exposed electrical conductors which
could contact the head

1910.135(b) Criteria for
protective helmets
 (1)Protective
helmets purchased
after July 5, 1994
shall comply with
ANSI Z89.1-1986

–Action Level = 85 dBA
Requires a hearing conservation
program
Annual audiograms
Training
– = 90 dBA
– Hearing protection is required
1910.95 Noise Standard

Earmuffs Earplugs Canal Caps
Types of Hearing Protectors

 Ensure that each affected
employee uses protective
footwear when working
in areas where there is:
–A danger of foot injuries due
to falling or rolling objects, or
–Objects piercing the sole,
and

1910.136(b) Criteria for protective
footwear
 (1)Protective footwear purchased after July 5,
1994 shall comply with ANSI Z41-1991,
"American National Standard for Personal
Protection-Protective Footwear,"

Good Personal Hygiene Practices
For ALL Employees Include
 Good Personal Habits
 Proper Clothing
 Good Health
 Hand Washing
 Handling Products Properly

Keep Yourself Clean
 Bathe or shower
daily
 Keep fingernails
clean and
trimmed at all
times

How to Wash Your Hands
1. Wet hands with warm water;
2. Use ample liquid soap from a dispenser;
3. Lather exposed arms and hands for 20
seconds by vigorously rubbing;
4. Thoroughly rinse hands in warm water;
5. Use foot operated faucets to prevent
re-contamination of hands;
6. Dry hands thoroughly and properly
dispose of paper towels;
7. Dip hands in sanitizing solution; and
8. Do not touch unsanitary objects.

5S BASIC TRAINING
What is 5S and why do we want to do it?

What is 5S and why do we want to do it?
5S is short for: Sort, Set in Order, Shine, Standardize
and Sustain
5S represents 5 disciplines for maintaining a visual
workplace (visual controls and information systems).
These are foundational to Kaizen (continuous
improvement) and a manufacturing strategy based "Lean
Manufacturing" (waste removing) concepts.
5S is one of the activities that will help ensure our
company’s survival.

5S
1. Sort - All unneeded tools, parts and supplies are
removed from the area
2. Set in Order - A place for everything and everything is
in its place
3. Shine - The area is cleaned as the work is performed
4. Standardize - Cleaning and identification methods are
consistently applied
5. Sustain - 5S is a habit and is continually improved
Also - Work areas are safe and free of hazardous or
dangerous conditions

Some New Words
Red Tag-Process for tagging, removing and disposing of
items not needed in the work area.
Lean Manufacturing-concepts that seek continuous
improvement by removing waste in processes
Some Japanese words you need to know:
Kaizen-(pronounced “ki zen”) - improvement
Kaizen Event and 5S Event-Planned improvements to a
specific area or process (usually take 3 to 5 days).
5S Events focus on making 5S improvements.
Muda-(pronounced “moo da”) - waste
Gemba-(pronounced “gim ba”) - workplace

New Words - Continued
Kanban-(pronounced “kon bon”) - Pull type inventory
control system. Items are only produced to meet customer
needs. The request to produce more is signaled from an
upstream operation and/or customer orders.
Value Stream Map - A diagram of all processes needed to
make and deliver the product to the customer.
OTHER PROBLEM SOLVING TOOLS
TOC-Short for Theory of Constraints. Problem solving
and constraint management methods. Use the 5 Step form
of TOC to solve problems that you will encounter in your
continuous improvement efforts.

Some 5S Examples
Before 5S
After 5S - Cleaned,
organized and drawers
labeled (less time and
frustration hunting)

5S Examples - Sort, Set in Order
See the difference?
1. Sort - All unneeded tools, parts and supplies are removed
from the area
2. Set in Order - A place for everything and everything is
in its place By: K.C.SAHU, Manager-Maintenance

5S Examples - Shine
3. Shine - The area is cleaned as the work is performed
(best) andor there is a routine to keep the work area
clean. By: K.C.SAHU, Manager-Maintenance

5S Examples - Standardize
4. Standardize - Cleaning and identification methods
are consistently applied
Departments have weekly 5S tours
Every job has duties that use Sort, Set in Order and
Shine
We all have common duties to do our part to keep all
areas of the plant in shape - breakroom, restrooms,
locker area, parking lot, etc

5S Examples - Sustain
5. Sustain - 5S is a habit and is continually improved
5S is a simple concept with powerful results.
You will get additional information on 5S so that you
will be well equipped.
Our experience is that the more we do 5S the better the
work environment becomes: cleaner, safer, more
organized, the work is easier, less confusion and less
stress.
Use the 5S (workhomeplay) - The more you use it the
easier it becomes and life just gets better and better.

The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S

The Good

What is Waste (Muda)?
Some of the main forms of waste are:
Overproduction
Waiting for materials, machines, or instruction
Transportation or movement
Excessive inventory
Inefficient machine processing and/or operation
Producing defects
Part or line changeover or machine setup
Inadequate housekeeping
Miscommunication or inadequate instruction

Improvement (Kaizen) Principles
Get rid of all old (false) assumptions.
Don't look for excuses, look for ways to make it happen . .
Don't worry about being perfect - even if you only get it
half right “start NOW”!
It does not cost money to do KAIZEN.
If something is wrong “Fix it NOW”.
Good ideas flow when the going gets tough.
Ask "WHY" five times - get to the root cause.
Look for wisdom from Ten people rather than one.
Never stop doing KAIZEN.

Summary
5-S is for you.
Clean-up and organize your work area every day so that
each new day is easier and safer than the day before
Share your input with your leaders so that the tools you
need will be available to you, increasing your efficiency.
Volunteer to help with the 5S tours and 5S events.
Take a good look around...Imagine zero waste/zero
confusion!

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Awareness on housekeeping and safety measures in work place

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