1.

T5S Activity (Overview)

Basically refers to overall 5S activities in a field. This activity is to improve

and maintain not only the existing 5S activity but also 3R and visual control
parts.
This activity shall satisfy the followings in comfortable circumstances:

① To create an exciting company atmosphere,

② To make a business easy based upon above conditions, and
③ To increase productivity and quality.

Also,
The most important points are improvement and maintenance which not
returned to the original condition.
2. 5S (Object of Activity)

Office Division
Conference table,passage,conference
Office room,scrubbing things,Window,wall,ceiling,
lighting, dressing room,toilet,welding room

Office machine, desk, drawer, chair, telephone,

Office Supplies cabinet, clock, blackboard, waste basket

Material Document
File,drawings,regulation,standard,
various standards, various forms
Environment/
Product Quality Field Division
Work table,passage,desk,cabinet,
Field lighting,Window,entrance,wall,pillar,
scrubbing things,dressing room,toilet
Equipment Conveyor,machinery,mold,equipment,
Jig and Fixture jig and fixture,tool box,truck,forklift

Material Parts, Material,part,product,document,drawings,

Document work standard,file

Etiquette, Bow,costume,designation marking,

Observance of telephone response,vending machine
use,Document preparation,
Regulation, Rule factory guide for visitor
Work
Observance of Safety rule,putting on safety device,work
Safety & Work Standard,work instruction observance,
Standards smoking place observance
Method of Work
Attending and leaving the office,
Punctuality conference time,break time,
time of opening and closing of office
2. 5S (Activity Order)

Classification of necessary and

unnecessary materials

Removal of unnecessary material

Seiri
Exclusion of surplus holding
material

Designation of depot for

nonconforming product

Arrangement of processing tools

(Mold included)

Arrangement of cutting tool

5S Clean
Arrangement of measuring
Object Seiton instrument and measuring jig
Maintenance Shitsuke Settlement
Improvement
Scope
Arrangement of work in-process

Arrangement of raw material

and part

Arrangement of lubricant

Cleaning

Seisoh Isolation of dust cause

Cleaning and Inspection of

equipment
2. 5S (Requirements for Success of Activity

Total Participation
Seek control, leadership of
supervisor and total participation
bottom-up for importance of 5S.
Shitsuke
Seek settlement of 5S by making a
point of observing the regulated
Autonomous Performance things.
Attempt the complete performance
for planned things by means
of role play clarification and
formalization. Responsibility
Seek an increase of workshop
control level by acting with overall
responsibility.
Creativity
Create the creativity of workshop
such as QC, IE, VE, etc. based on
5S.
2. 5S (Role (Manager / Supervisor)

Take the initiative and set an example for others.

Behavior If others failed to observe the rule, take corrective action to have them
observe it for them on the spot. - It is important to make them observe
Instructions the rule on the spot even though the subsequent work stops.

Expose problems by going around every corner of a work field everyday.

Determination for 5S propelling

Establishment of 5S propelling plan

Obtainment and determination of time of 5S activity

Obtainment and determination of space required to a minimum

for 5S propelling
Key Roles
Preparation of overall rules and check list related to 5S

Preparation and determination of classification standards for acceptable

product, not-required product, unacceptable product by going around

Carrying out 5S related training and guidance to worker

Coordination of department concerned(Role Play)

2. 5S Role (Worker)

Be sure to observe the regulated rule.

Behavior Understand, in connection with waste of production,

why do that should be observed.
Instructions
If required, immediately report to a superior official to take
suitable actions.

Carrying out of 5S activity in a district(facility) assigned

Recommendation of practical problems improvement

Field improvement for 5S can not be achieved so easily.

Important thing is a top’s strong will of “must do it” and certain

practice ability in a field of “let’s do it in advance”.
Key Roles
For this, a company must propel it in a body.

Thus, improvement(team) activity is required.

Discovery of problems and improvement review for that

Improvement review and performance

2. 5S (Necessity of 5S and Its Effect)

◈ Necessity of 5S
In general, a factory of higher level has good conditions of arrangement, cleaning and order.
5S is a means to make comfortable factory.
Also this is a technique to isolate sources generating a lot of troubles caused by unnecessary,
non-uniform and unreasonable matters in a factory.

◈ Improvement in Quality
Trouble occurs to accuracy control.

◈ Reduction of Ready Time

30 minutes to find anything are not important for wait time taking several hours of the day, but
3 minutes can be fatal for production of supplied product .

◈ Equipment Protection
It is impossible to take concurrent operating multi processes if a lot of troubles occurs to
equipment.

◈ Minimization of Inventory
Surplus tenement still exists in a place where can not be seen.

◈ Increase of Waste
Various wastes (stock, quality deterioration, efficiency deterioration, cost rising) can not be seen in
a factory where does not carry out 5S activity well.
2. 5S (Necessity of 5S and Its Effect)

◈ Effect of 5S
It takes much time to carry out 5S activity. It is required to take preventive actions
for preventing comparatively relative large waste or loss. Various effects such as
improvement in quality and productivity, removal of waste, stock control, safety
control, etc. can be taken by carrying out 5S activity in cases that it takes much time
to find out product or part caused that 1 minute was saved to arrange the product and
the part, and product gets rusty caused that anti-corrosion process was not be taken,
and so forth. Also, clean and comfortable work circumstances can give effects as
Follows:

① To die down unrest caused by even small defects and minor failures,
② To ensure good feeling, low fatigue and increased efficiency by means of clean
and comfortable workshop where you spend most of the time of the day in,
③ To form high reliability between customers and job seekers, and
④ To assure company development and personnel growth.
2. 5S ( What is our changed figures? )

Seiri Seiton
Development
Classify clearly In Quality
Batch Store the necessary
necessary and things properly to
Production unnecessary things be used and seen easily
and throw away by everyone.
unnecessary
things. Shitsuke

Development Accustom yourself

Reduction
In to observe the specified Of Cost
Operating things at all times.
Rate

Keep 3S activity of Always keep work

Seiri, Seiton and circumstances clean. Delivery
Development Seisoh. Date
In Observance
Safety Seiketsu Seisoh
3. 3R
This refers to a tool to ensure that Right amounts can be stored in Right container in
Right location at all times.
Allocation of • Allocation by classification forms (part, product)
Location • Allocation by using interval (store,depot)
Right
Location • Subsequent process information share
Signboard (Visual Stock Control)
Attachment • Presentation of Classification Move
(First-in First-out)

Size Classification • Iron Basket,Plastic,Adhesive Pallet

by Parts • Large, Medium, Small parts

Right Classification by
• Carrier Box
Container Part Features

Box • Logistics moving amounts

Standardization • Worker Usability

• Box: Indication of quantity by Bundle and bag,

Packaging Form and total quantities of boxes
• Carrier: Indication of piece quantity
Right Classification by • Large Part: Quantity required for 10~30 min.
Amounts Container • Small Part: Quantity required for 2~4 hr.

Determination of • Time required for minimum movement

considered
Max/Min • Quantity allocation by area unit
4. Visual Control

This is to allow trouble to be identified visually by everyone.

Indication of Location and Goods Depot

(Place to go to take goods)

T/Time Indication

Productivity Control Table Per Time

(Status of Production and Input)

Tool for Notice of Standard Work Instruction

Visual (Work Order, Inspection Contents, Standard Quantity
In-Process)
Control

Signboard(Right Position Signboard, Part Table)

Alarm Lamp for Abnormal Conditions

Identification Marking
4. Visual Control

① Are there any tools to identify the troubles as seen by naked eyes
in your field?

② Are those tools structured to be identified easily by everyone(including

personnel who is not concerned in the matter).

③ Can everyone visually identify the production status if approaching to the

production line right now?

④ Is a system structured so that the contents and corrective actions for

quality defectives can be identified by everyone if the quality defectives
are occurred?

⑤ Can personnel in charge of clean-up be identified if it fails to clean

every corner in a factory?

⑥ Is a monthly improvement plan established and operated, and also is the

progressive status controlled with a method of color marking, etc.?
T5S methods
NO. Items Purposes
1 5S Seiri
:To dispose unnecessary
things immediately by
classifying necessary and
unnecessary things.
Seiton
:To show necessary things in
designated place for allowing
that to be identified and used
easily by everyone.
Seisoh
:To make a work field clear
by removing dust,
contamination, foreign
materials, etc.
Seiketsu
:To maintain and improve
3S activities of Seiri,
Seiton and Seisoh.
Shitsuke
:To make oneself familiar
with an attitude to
obey learned matters and
designated matters.
Contents Remarks
1) Objects :
① JIG and molded mount ②Tool kit,cleaning tool kit
- Red Card
(division, item name,
③ Indoor and floor department, attachment
④ Original/subsidiary materials warehouse reason, attachment date)
⑤ Factory outer ⑥office
2) Progress activities according to a management basis by
section → Division/item name/department/reason should be
specified
1) Organizes needed things - Designates storage place
2) Checks storage place for defective products
3) Determines storage place: using easier method to follow - Performs 3C
4) Marks storage place: position, item name
5) Maintains/checks: marking visibly
(marks in thing itself or classifying using color)
1) Uses a broom(prepare cleaning tools) - 5S MAP
2) Arranges section line: passages, floor lines of correct position - Signboard to divide 5S area
① Passages: straight lines,passing direction marking - Cleaning rules :
② Entrance:dotted lines ③Position lines:place designation Designating a person in
④ Designation of line thickness and color charge of cleaning,
3) Remove and improve the causes of dust or dirt: oil leaks, piping method, tool, location,
leaks, particle blowing period (time)
4) Thorough cleaning: cleaning of oil soaked into floor, painting,
wall, stepped area
1) Periodic check and evaluation of clearing-up, organizing or - 5S evaluation
cleaning status
2) Selects and executes continuously a month key theme ex) floor
cleaning
3) Checks the causes of dilapidation : is it too complicated ?
Is it too distant?
Does not it move back against work action?
4) Filming of the pictures or VTR of dilapidated place.
1) Leader’s leadership
2) Proceeds activity on a principle that total personnel attend
T5S methods

NO Items Purposes Contents Remarks

2 3C Standardization of how 1) Uses signboard so as to be able to know place and amount of

- Signboard
to place things parts correctly
- Standardization of
Where … Correct 2) Regulates amount of stock: marking of load height, amount container
position (max,min) - Connected with material
What … Correct thing 3) Attaches item name and ID card to each part and thing handling improvement
(Correct container) 4) Standardization of used container (size,amount etc) activity
How much … Correct 5) Clears up of JIG tool – Piling table open/drawer-in
volume arrangement
6) Storage place is marked with line, positioned so as to be able
to search easily like supermarket

3 Visual To perceive abnormal 1) Indication light

conditions of working field ①Call indication : Demand of parts - Error Alarm
management quickly, to restore in normal ②Abnormality indication : Indicates situation of assembly - Current state board
conditions and to minimize line, abnormal assembly state etc. - Work guide/new process/
loss ③running indication : Indicates production situation/ sequential inspection card
machine running etc.
④Progress indication : Indicates work progress - OS&D Table,TAG
2) Signboard : Attaches and manages signboard periodically in District division indication
order to be able to know 4M change etc. - Current state board of
3) Defects indication : Attaches/positions markers in a such way Production management
that positive/negative distribution within process is definite - Plant check table (lubrication
record table etc.)
4) Production management : Indicates productive situation of line
①Plan/result management
5) Attaches and manages the signboard about how to work
equipment