5S Role in Achieving Quality

5S
A STRATEGY FOR
PERFORMANCE
EXCELLENCE

5S

What is 5S ?

An essential step required for Waste

Elimination
Systematic
Organization

Orderliness

Cleanliness

Seiri

Seiton

Seiso

Standardization/Perseverance

Cleanup
Seiketsu

Cleanup
Seiketsu

Shitsuke

An integral step in Kaizen

A required element to achieve Lean-site
Manufacturing.

The Five Elements of 5S

Self-Discipline/ControlEnsuring that Systematic
Organization, Visual
Placement & Cleanliness
are maintained.

Standardizing ControlMaintain and continually

improve the previous
improvements.

Systematic Systematic
Organization- Identifying what
items are required and which
are not.

5S

Scrubbing Clean-Keep the area free from debris,

dirt, oil, items not needed.

Improvement in Performance

Sorting Visual PlacementItems should be easily

retrievable, easy to get, and
visual-easy to see.

Why 5S

To eliminate the wastes that result from

uncontrolled processes.
To gain control on equipment, material &
inventory placement and position.
Apply Control Techniques to Eliminate
Erosion of Improvements.
Standardize Improvements for
Maintenance of Critical Process
Parameters.

The Nine types of wastes.

Overproduction
Delays (waiting time)
Transportation
Process
Inventories
Motions
Defective products
Untapped Resources
Mis-used Resources

Elimination of Waste
5 S Element

Waste/ Improvement Item

Deliverable

Systematic
Organization

Elimination of finding.
Reduction of part selection errors.

Reduced Costs
Improved Quality
Increased Product Options

Sorting-Visual
Placement

Elimination of finding.
Elimination of nonconformances.
Elimination of motion.
Reduction of part selection errors.

Reduced Costs
Increased Safety
Improved Quality
Increased Product Options.

Scrubbing Clean

Increased safety.
Preventive maintenance.
Increased equipment knowledge.

Increased Safety
Improved Quality

Standardization
Control

Increased equipment life.

Higher morale.
Clean environment.
Increased visibility of nonconformances.

Improved Quality
Consistent Delivery
Improved Safety

5S Implementation Plan
Step 1

Step 2

Step 3

Establish 5 S

Develop Specific

Develop Communication

Implementation Team

Implementation Plan

Plan

Step 4

Step 5

Develop 5 S Training Plan

Implement 5 S

Systematic
Organization

Progressive

Standardization

Enhancements

Cleanliness

Visual Placement

Step 6
Verification of Effectiveness

Key to successful Implementation of 5S

Some evidence of standardized work areas

Clear, shiny aisle ways
Color coded areas
Slogans, banners

No work-in-process ( WIP )
One-Piece Flow
Standardized Work Sheets

Visual Color System Implementation

Develop a map identifying the access ways(aisles, entrances, walkways etc.)
and the action areas.
Perform any necessary realignment of walkways, isles, entrances.
Assign an address to each of the major action areas.
Mark off the Walkways, Aisles & entrances from the action areas.
Apply flow-direction arrows to aisles & walkways
Perform any necessary realignment of action areas.
Mark-off the inventory locations
Mark-off equipment/machine locations
Mark-off storage locations( Cabinets,shelves,tables)
Color-code the floors and respective action areas

Cleanliness involves cleaning every aspect of

the Organization and the removal of dirt,
dust,oil, scraps on the floor, & garbage.
Key Deliverables

Increased
Safety

Increased
Efficiency

5S Action Items

5S Action Items
Table of Contents
Section 1

Section 2

Development of 5S To Do Plan: Establishment of the 5S team focused on

the development, training, and implementation of the companys 5S program.
Deliverable includes action plan and associated tasks with the 5S
implementation.
Waste Identification Map: Identification of the 9 wastes associated with
production of products and services. A detailed map of each major work area is
developed describing the major types of wastes in each area. These wastes are
the improvement opportunities that exist prior to
5S...

The overall wastes is calculated for all the work areas and identified on the 9
Waste Radar Chart

Section 3

5S Action sheet: Establishing baseline key performance metrics in terms of

key deliverables, photographs, and current conditions of the before 5S
implementation phase. Deliverable includes the 5S action
sheet.
Red Tag Strategy: The utilization of Red Tags to visually identify items which
are not needed or used infrequently..

Section 5

Visual Color Sheets: Utilization of colors to identify specific work actions,

inventory locations, access areas within the work environment. Initialization
begins with development of Visual Color
Sheets.

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Section 6

Visual Sign Sheets: Utilization of signs to identify machine, equipment, tooling,

inventory, safety, hazard and work center locations. Sample Sign
Sheets.

Section 7

Standard Cleaning Work Sheet: A cleaning matrix identifying the work area
responsibilities, supplies, and schedules for cleaning. ..

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Section 8

Cleaning To Do List: A action list identifying specific cleaning tasks for each
work area identified on the Standard Cleaning Work Sheet..

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5S Status Report: A report identifying implementation effectiveness of each 5S

steps applied. A variable metric ranging from 0-5 is established for each step
implemented..

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Section 9

Section 10

Waste Identification Map: Identification of the 9 wastes associated with

production of products and services. A detailed map of each major work area is
developed describing the major types of wastes in each area. These wastes are
the improvement opportunities that exist prior to 5S
9 Wastes Radar Chart: After the completion of 5S, the results of the waste reduction
is recorded, charted and compared to the initial 9 Waste Radar Chart.

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THANK
YOU