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THROUGH
5S PHILOSOPHY
DR. I. P. S. AHUJA
PROFESSOR (Mechanical Engineering)
The 5S Philosophy
5S is an acronym for five Japanese words
SEIRI, SEITON, SEISO, SEIKETSU & SHITSUKE.
5S Philosophy
What is 5S?
Orderliness
Cleanliness
Seiri
Seiton
Seiso
Cleanup
Standardization
Seiketsu
Seiketsu
Perseverance
Shitsuke
The 5S Philosophy
The 5S Philosophy
Japanese
Nomenclature
English 5 S
English 5 C
SEIRI
SORT
SEITON
SEISO
SHINE
SEIKETSU
STANDARDISE CONFORMITY
SHITSUKE
SUSTAIN
CLEAR
CUSTOM &
PRACTICE
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5S
Review
1.
Sort
Objective:
Clutter reduction by clearly distinguishing
between what is needed and to be kept and
what is unneeded and to be discarded.
2.
Set in Order
Objective:
To ensure everything has a place, and there is a
place for everything needed.
3.
Shine
Objective:
4.
5.
Standardize
Objective: Make sure that there is a standardized method to do
the first 3 pillars.
Sustain
Objective: Make a commitment to the 5S process for now and
the future.
To enhance safety
WHERE 5S
At
all
work
Machine centres
centres,
At offices, administrative
sections
Whole organization
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BY WHOM 5S
Workmen to be committed to
create a loveliest work place,
worthy and proud to own and
work.
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5S Aims to Promote
Organisation
Cleanliness
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5S Aims to Promote
Visual Controls
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5S Objectives
Eliminate waste
Quality improvement
Improve safety
Reduce inventory
Identify deterioration
Improvement of efficiency
Waste of Overproduction
Waste of Waiting
Waste of Transport
Waste of Inventory
Waste of Movement
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Sort (Seiri)
The first S focuses on eliminating unnecessary
items from the workplace.
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Sort (Seiri)
The Sort process also helps prevent the hoarder job mentality
(I might need it).
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Sort (Seiri)
This
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Sort (Seiri)
A red tag is placed on all items not required to complete the job.
These items are then moved to a central holding area. This process is for
evaluation of the red tag items.
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2.
3.
4.
5.
6.
Sort (Seiri)
Red
Red Tagging
Tagging Criteria
Criteria and
and
Action
Action on
on Red
Red--Tagged
Tagged Items
Items
Frequency
Frequency of
of Use
Use
Action
Action
Obsolete
Obsolete (unneeded)
(unneeded)
Sell,
Sell, throw,
throw, or
or give
give away
away
Seldom
Seldom used
used (once/year)
(once/year)
Store
Store in
in distant
distant place
place
Less
Less than
than once
once a
a month
month
Store
Store in
in factory/office
factory/office
Once
Once a
a week
week
Store
Store in
in area
area
Once
Once a
a day
day or
or more
more
Carry
Carry or
or keep
keep at
at workplace
workplace
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VISIBLE 5S
VISIBLE PROPER ARRANGEMENT & ORDERLINESS
NO
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1.
2.
3.
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Orderliness Targets
Efficiency
Efficiency
Safety
Safety
Frequency of use
Frequency of use
Quantity / Quality
Quantity / Quality
Availability/
Availability/
Proximity
Proximity
Visibility
Visibility
Space/Height
Space/Height
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Painting floors
Outlining work areas and locations
Shadow boards
Modular shelving and cabinets
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SEITON ACTIVITIES
A Place for Every thing and Every thing in its place.
1.
2.
3.
All items like cutting tools, gauges, files are kept in orderly manner
and ready for use
4.
Separate location assigned for essential items like tools,die sets and
measuring instruments
5.
6.
Locate notice boards where they are accessible and easy to read
7.
8.
9.
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SCRAP
Return to
Supplier
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Shine (Seiso)
Having eliminated the clutter and junk that has been clogging the
work areas and identified, located necessary items, next step is to
thoroughly clean the work area.
Workers take pride in a clean and clutter-free work area and the
Shine step will help create ownership in the equipment and facility.
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Shine (Seiso)
SEISO ACTIVITIES
Floor should be clean from oil, water, scrap, chips, raw material & waste
Water, air & oil lines checked for leakage, blockage and clean up
Empty out scrap and thrash cranes at the end of the shift
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Standardize (Seiketsu)
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Standardize (Seiketsu)
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Standardize (Seiketsu)
Standardize means establishing Best Manufacturing Practices,
including:
SEIKETSU ACTIVITIES
Keep things standardized and maintain good environment
Make it a habit to be personally clean and keep the work place clean
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Standardize
Adherence can be charted - or simply take pictures of
actual vs. expectation
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Standardize
As with any standards, there need
We need to ensure people have the
means to maintain conditions
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Standardize
Create
Use
Once
Fix
Continue
Achieve
Sustain (SHITSUKE
)
(
This is by far the most difficult S to implement and achieve.
Human nature is to resist change and more than a few
organizations have found themselves with a dirty cluttered
shop a few months following their attempt to implement 5S.
The tendency is to return to the status quo and the comfort
zone of the old way of doing things.
Sustain focuses on defining a new status quo and standard of
work place organization.
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Achieving Sustain?
Practice,
Practice, practice,
practice,
practice
practice
Training
Training
Continuous
Continuous
Improvement
Improvement
Inspection
Inspection
Feedback
Feedback
Total
Total Employee
Employee
Involvement
Involvement
Coaching
Coaching
Facilitation
Facilitation
Education
Education
Discipline
Discipline
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Sustain (SHITSUKE)
5S Examples
Before 5S
After 5S - Cleaned,
organized and drawers
labeled (less time and
frustration hunting)
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5S Examples
Before 5S
After 5S
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5S Examples
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IMPLEMENTING 5S
THE
PROGRAMME
REQUIRES
TOP
MANAGEMENTS
COMMITMENT
Increase
140 %
Quality
Reduction
Improvement
90%
in
Defects
1% -0.1 %
Reduction in maintenance
cost
15%
No of accident free days in
a year 365
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Zero
Zero waste
waste
Zero
Zero injuries
injuries
Zero
Zero downtime
downtime
losses
losses
Zero
Zero defects
defects
Zero
Zero waste
waste in
in
changeovers
changeovers
Zero delays
Zero delays
Zero customer
Zero customer
dissatisfaction
dissatisfaction
Zero red ink
Zero red ink
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5S PHILOSOPHY
Once fully implemented, the 5S process can increase moral,
create positive impressions on customers, and increase
efficiency of the organization.
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19
16
12
14
5
Total
100
WE SHOULD BE 100%
DISCIPLINED IN LIFE
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