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Why Implement 5S?

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Why Implement 5S?
We can change from this …...
Why Implement 5S?
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The Benefits of 5S Implementation
 A clean and clear environment: eye of the customer
 Easy detection of abnormalities and problems
 Waste elimination
 Safe and effective workstations
 Less time wasted
 Breakdown reduction
 Heightened professionalism of production personnel
 Maintaining and respecting established standards
 Heightened responsibility and initiative
 Implication and pride of workmanship
The 5S Program
1: SORTING (SEIRI) – Separate necessary from
unnecessary & Eliminate everything which is unnecessary

2: ORGANIZATION (SEITON)- A place for everything &


everything in its place

3: CLEANING (SEISO) - Daily cleaning of area & equipment

4: STANDARDIZATION (SEIKETSU)– Create a standard to


maintain the area and standardise best practices defined in
phases 1, 2 and 3

5: DISCIPLINE (SHITSUKE) – Apply the first 4 S’s with


discipline and maintain standards
1: SORTING (SEIRI)

When in doubt clear it out.


: SORTING (SEIRI) «0UÀr¸ÀÄ
SEIRI (CLEARING)
SORING THE LIST OF ITEMS/ DOCUMENTS
AVAILABLE IN YOUR WORK

Clearing
IDENTIFY THE EXCESS ITEMS
the Unwanted
items IDENTIFY ANY RED TAG (GOOD CONDITION
BUT NOT IN CURRENT USE) ITEMS

IDENTIFY ANY DAMAGED ITEMS

IDENTIFY ANY USED CONSUMABLES


SEIRI (CLEARING) PÀæªÀĪÁV
eÉÆÃr¸ÀÄ
EXCESS ITEMS- TO SEPARATE STORAGE AREA
( EARMARK STORAGE AREA)

RED TAG ITEMS – TO RED TAG AREA


DISPOSAL (EARMARK RED TAG AREA)
ACTIONS
DAMAGED ITEMS-TO VALUE YARD (EARLIER
SCRAP YARD)

USED CONSUMABLES- TO DISPOSAL YARD


2: ORGANIZATION (SEITON)

Storage space is easily identified and any


abnormalities are obvious
2: ORGANIZATION (SEITON)
SEITON (ORGANISING THE
REQUIRED ITEMS )
SORTING THE REQUIRED ITEMS IN THE WORK
PLACE BY FUNCTION / SUBJECT.

IDENTIFY PRIMARY ITEM-FREQUENTLY USED


ITEMS
TASKS
IDENTIFY SECONDRY ITEMS-LESS
FREQUENTLY USED ITEMS

IDENTIFY STORAGE ITEM-RARELY USED ITEMS


SEITON (ORGANISING THE
REQUIRED ITEMS )
PRIMARY ITEMS-VERY NEAR TO YOUR HANDS

ALLOCATING SECONDRY ITEMS-LITTLE AWAY FROM YOUR


PLACES SEAT/ WORKING LOCATION (10 TO 15 STEPS)

STORAGE ITEMS-AWAY FROM YOUR WORKING


LOCATION

PRIMARY ITEMS-One inch dia. circular sticker-Yellow


colour
SECONDRY ITEMS-One inch dia. circular sticker-Blue
ENSURING colour
THE ITEMS STORAGE ITEMS-One inch dia. circular sticker-Green
LOCATIONS colour
MARKING LINES FOR STORAGE AREAS

LEBALING/ NUMBERING OF THE ITEMS


LIST OF THE ITEMS AVAILABLE IN THE LOCATIONS- TO BE DISPLAYED
3: CLEANING (SEISO)

A clean workstation is proof of quality, safety and pride of workmanship


3: CLEANING (SEISO)
The Operating Phases of Cleaning
1. Divide the area into zones, designate a zone
manager.
2. Select a cleaning order for the area and the
equipment and note problems or abnormalities.
3. Study cleaning instruments and methods to reach
difficult areas.
4. Establish rules to maintain a clean work area.
4: STANDARDIZATION (SEIKETSU)

There’s no point in cleaning once you’ve avoided the mess


5: DISCIPLINE (SHITSUKE)
 Apply the first 4 S’s with discipline and maintain standards
 New habits and reflexes bring about further improvements
 The commitment of management at all levels is essential
 At the end of each day, the team leader ensures that 5S
methodology is used on the shop floor
 Regular auditing using check-lists ensures that 5S principles
are followed
 Visual displays of the results of each area must be obvious
5S, you can see the difference …..

Before :
Untidily stored tools

After :
Tools stored and sorted in a
cupboard (shadow board)
situated where the tools are
to be used
5S, you can see the difference …..

Before :
Untidily stored tools

After :
Tools stored and sorted in a
cupboard (shadow board)
situated where the tools are
to be used
5S, you can see the difference …..

Before :
Untidily stored documents

After :
Documents stored and
sorted using colour codes
for each speciality

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