5S

THE SECRET TO

JAPANESE SUCCESS

 WHAT PROBLEMS DO U COMMONLY

ENCOUNTER AT YOUR WORKPLACE

HIGH ABSENTEEISM
HIGH TURNOVER
DEMOTIVATED EMPLOYEES
DISORDERED/ CLUTTERED

ENVIRONMENT
MISTAKES/ERRORS

 THE SOLUTION TO ALL THESE

PROBLEMS IS

5S

5S
HOUSEKEEPING TECHNIQUE
PRODUCTIVITY AND SAFETY
ENHANCEMENT TECHNIQUE

IDEA BEHIND 5S
IN ORDER TO ACHIEVE HIGH

LEVELS OF QUALITY, SAFETY,AND

PRODUCTIVITY, WORKERS MUST
HAVE A CONDUCIVE WORKING
ENVIRONMENT

WHAT IS 5S?
5S is a basic, fundamental, systematic

approach for productivity, quality and

safety improvement in all types of
business.
A 5S (Five S) program is usually a part of,
and the key component of establishing a
Visual Workplace and are both a part of
Kaizen - a system of continual improvement which is a component of lean manufacturing.

Visual Workplace
The lean manufacturing system is often

represented as a house.
It refers to a workplace that uses a system
of visual cues and visual communication
tools that impart information visually at the
time and place it is needed.
Involves using proper labeling and signage.

THE 5S PRINCIPLES
SEIRI Sort out
SEITON Systemize
SEISO 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

DISCOVERY OF 5S
Equipments were so clean and well

maintained that any problem such

as a loose bolt or leaking oil could
be easily seen
This passion of cleanliness and
orderliness became a hallmark of
Japanese organizations

ADVANTAGES OF 5S
If tools and materials are conveniently

located in uncluttered work areas

Operators spend less time looking for

items
This leads to higher workstation
efficiency, a fundamental goal in mass
production

ADVANTAGES OF 5S
A clean and tidy workplace leads

to greater well being and increased

motivation
Company image improves

ADVANTAGES OF 5S
Health and Safety is ensured
Machine maintenance
Quality
Productivity
Lean Manufacturing

ADVANTAGES OF 5S
RESULTS IN A PLACE EASIER TO

MANAGE
SMOOTH WORKING
NO
OBSTRUCTION
NO DEVIATION, NO PROBLEMS

B/C EVERYONE KNOWS WHERE THE

THINGS ARE SUPPOSED TO BE

ADVANTAGES OF 5S
TIME SAVING
QUICK RETRIEVAL
ACCIDENTS & MISTAKES

MINIMIZED
INCREASES SPACE
CREATES WORKPLACE
OWNERSHIP

ADVANTAGES OF 5S
FOUNDATION OF ALL QC TOOLS

CONTINUOUS QUALITY

IMPROVEMENT
LEAN MANUFACTURING
KINDERGARTEN OF QUALITY
TOOLS & TECHNIQUES

ADVANTAGES OF 5S
VISUAL MANAGEMENT SYSTEM

VISUAL CONTROL TO SEE THE

ABNORMALITIES
SIMPLE SIGNALS THAT PROVIDE AN
UNDERSTANDING OF THE
CONDITION( NORMAL/ ABNORMAL)
A LOOK AT THE PROCESS REVEALS ITS
DIRECTION (RIGHT/WRONG)

Its the elimination of waste Everywhere

while adding customer value

Its a mindset & commitment to

achieve a totally waste-free
operation thats focused on your
customers success achieved
by simplifying and continuously
improving all processes

From the operations perspective

Lean production cuts costs &
inventories rapidly to free cash, which
is critical
It also supports growth by improving
productivity & quality, reducing lead times,
and freeing huge amounts of resources.

From the operations perspective

For example, lean production frees
office and plant space and
increases capacity so companies can
1. Add product lines
2. In-source component production
3. Increase output of existing products

without acquiring new facilities.

KINDERGARTEN OF ALL THE QC

TOOLS
5S IS THE STARTING POINT OF

ALL THE QC TOOLS

COULD BE SAID AS THE PRE-

REQUISITE OF ALL QC TOOLS

METHODOLOGY
OF 5S

1. SORT (SEIRI)
5S Sorting itself involves five steps:
Cleaning
Classifying
Ownership
Red Tagging
Recycling / Reassignment

5S Sorting - Cleaning
The purpose of "sorting" is to identify

unnecessary items and eliminate them

from the workplace. To do this first
requires cleaning up the workplace so you
can see what you have. Clean up
accumulations of dirt, debris, oil, grease,
broken tools, excess materials, and scrap.
As you do this you'll also be involved with
the second step of 5S sorting.

5S Sorting - Classifying
As you are cleaning up you'll find tools,

equipment, materials and supplies. As

each item is found, classify it as to the
type of object. Scrap metal might go
directly to a recycling bin. An item
classified as tool might go to a
collection area for further identification.

5S Sorting - Ownership
Once ownership is determined the

owner can decide what to do with the

item - store it, pass it on to another work
area or department, or dispose of the
item.
Determining ownership may require
asking some questions or doing a little
research.

5S Sorting - Red Tagging

Red tagging involves marking items

with a red tag so that each item can be

evaluated and dealt with appropriately.
Red tagged items are collected in an
area that allows potential owners to
examine them and determine what
should be done with the items for which
they are responsible.

5S Sorting - Recycling /
Reassignment
Red tagged items that are not claimed after
a reasonable amount of time, such as 30
days, may be recycled, disposed of, or if
they are still useful they can be reassigned.
A simple approach for reassigning items is
to, at the end of the 30 day red tag period,
provide a seven day period in which any
supervisor may take any red tagged item
with an expired read tag.

SORT-OUT
PRIORITY FREQUENCY OF USE

HOW TO USE

Low

Less than once per Throw away

year
Store away
Once per year
from the
workplace

Avg.

Once per month

Once per week

Store together
but offline

High

Once Per Day

Locate at the
workplace

2. SET IN ORDER (SEITON)

This is the second step in a 5S

program: organize, arrange, and

identify everything in a work area, as
well as throughout the facility, so that
items can be efficiently and effectively
retrieved and returned to their proper
storage location.

The Basics of 5S Set In

Order

The basic focus of this part of 5S is to

create efficient and effective storage
systems such that anyone can find the
tools, materials, and supplies they
need, and anyone can return those
tools, materials, and supplies to their
proper storage locations.

Labeling - 5S Set In
Order
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

3. SEISO (CLEAN/SHINE)
Once you have everything, from each

individual work area up to your entire

facility, sorted (clutter and debris cleaned
up), and organized, you need to keep it
that way. . It involves regular, usually
daily, cleaning.
While cleaning it's easy to also inspect
the machines, tools, equipment and
supplies you work with.

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 (STANDARDIZE)
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

5S Standardize
Checklists

5S checklists are commonly used as an

auditing tool to ensure the standards
are being followed. A 5S checklist
involves more than verifying that work
areas are clean. For example, checklist
items should include ensuring operating
and maintenance practices that support
5S goals are being followed.

5S Standardize Job
Cycle
Charts
A job cycle chart lists each 5S task that is
to be done in a work area, and gives the
schedule (frequency cycle) for performing
each task. Each task is either assigned to
a particular worker, or to a job duty. An
example of a job duty would be operating a
machine. Whoever operates the machine
that day, has the 5S task of cleaning that
machine at the end of the shift.

5S Standardize Five
Minute
5S
A "Five Minute 5S Period" can be an
Periods
intense, quick clean up (shine) of a
work area, or it can look for
abnormalities in all of the five steps of
5S. The goal is for 5S abnormalities to
be spotted and immediate 5S action
(sort, set in order, or shine) to be taken
to correct the abnormality.

5. SHITSUKE (SUSTAIN / DISCIPLINE)

Means inoculate courtesy & good habits
Driving force behind all 5S
Demings 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

5. SHITSUKE (SUSTAIN / DISCIPLINE)

It is on on-going commitment to the standards

created in the 4th S.

In the sustain step of 5S you'll need to train

people to clean, organize and inspect their

work areas every day, and not let clutter
accumulate in any location. The overall goal of
5S Sustain is to ensure the 5S standards that
resulted from the first four steps of 5S continue
to be followed.

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

1.
2.
3.
4.
5.

Followings can be harnessed form the

5S
NEAT & CLEAN WORKPLACE
SMOOTH WORKING
NO OBSTRUCTION
SAFETY INCREASES
PRODUCTIVITY IMPROVES

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