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5-S: WORK PLACE MANAGEMENT

• 5-S is a methodology for organizing, cleaning,

developing, and sustaining a productive work
environment.
• The 5-S Philosophy focuses on effective work
place organization and standardized work
procedures. 5-S simplifies the work environment,
reduces waste and non-value activity while
improving quality efficiency and safety.
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 What are 5S’s

• Seiri – Organising / Sorting

• Seiton - Systematic arrangement
• Seiso - Cleaning / Inspection
• Seiketsu - Standardization
• Shitsuke - Self Discipline

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SEIRI
SEIRI == Sorting
Sorting
Meaning
Meaning Distinguish
Distinguishbetween
betweennecessary
necessaryand
andunnecessary
unnecessary
items
itemsand
andeliminate
eliminatethe
theunnecessary
unnecessaryitems
items

Activity Establish a criteria for eliminating unwanted items

Eliminate unwanted items either by disposing
them or by relocating them.

Success Area saved or percentage of space available

Indicator
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Seiri
Seiri == Sorting
Sorting What is unnecessary

1. Item is not needed

2. Item is needed however quantity in stock is more

than what is needed for consumption in near
future

3. Contingency Parts

Critically decide the quantity of contingency

parts to be retained and criteria for such parts
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 Organization

Frequency of use Storage Method

*Things you have not used Throw them out

LOW in the past one year Store at distance OR
*Things you have used once Keep in store
in the last 6-12 months
*Things you have used only Store it in central place
AVERAGE once in the last 2-6 months in your zone
*Things used more than once Store it in central place
a month in your zone
*Things used once a week Store near the workplace
HIGH
*Things used daily or hourly Store near the workplace

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Seiri
Seiri == Sorting
Sorting Identifying unnecessary

1. Parts & Raw material

Things fallen back behind the machine or rolled under it

Broken items inside the machine
Things under the racks/ platform
Stock of rejected items
Items accumulated over period for rework
Material awaiting disposal decision
Material brought for some trial, still lying even after trial
Small quantity of material no longer in use

Contd..
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Seiri
Seiri == Sorting
Sorting Identifying unnecessary

2. Tools, Toolings, Measuring devices

• Old jigs, tools not in use are lying
• Modified tools, tooling for trial, are lying after trial
• Worn out items like bushes, liners, toggles etc. lying
• Broken tools, bits, etc. may be lying
• Measuring equipment not required for the operation

3. Contingency Parts
• Many times storage place for contingency parts
become
a last refuge for broken parts, surplus items and things
nobody is likely to use Contd..
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Seiri
Seiri == Sorting
Sorting Identifying unnecessary

4. Shelves and Lockers

• Shelves and lockers tends to collect things that nobody
ever uses , like surplus, broken items etc.
5. Passages and Corners
• Dust, material not required seem to gather in corner
6. Besides Pillars and under the stairs
• These places tends to collect junk, spittoon etc.
7. Walls and Bulletin Boards
• Old out dated notices which have lost their relevance
• Posters or bulletins on wall
• Dust, remains of torn notices, cell tape pieces
Contd..
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Seiri
Seiri == Sorting
Sorting Identifying unnecessary

8.Floor, Pits, Partitions

• Defective parts
• Protection caps, covers
• Packing material
• Hardware items , small items
• Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
• Many unwanted, outdated, temporary files pile up

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Seiri
Seiri == Sorting
Sorting Improvement methods

1. Flow Process Chart (Procedural Analysis)

Drawing a process flow chart for the system
eg. How to make and use category wise grouping

2. Operational Analysis
Preparing the sequence of operations for system
eg. How to perform Seiri (sorting)

3. Check List
A check sheet is used to decide what sort of main system
and sub system are necessary.
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Seiri
Seiri == Sorting
Sorting Dealing with papers

How to reduce papers on

your table ?
1. Make a single pile of papers
2. Go through them and sort in
following categories
a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information

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SEITION
SEITION == Systematic
Systematic
Arrangement
Arrangement
Meaning
Meaning -- To
Todetermine
determinetype
typeof
ofstorage
storageand
andlayout
layoutthat
that
will
willensure
ensureeasy
easyaccessibility
accessibilityfor
foreveryone
everyone. .
Place
Placefor
foreverything,
everything,Everything
Everythingin inplace.
place.
Activity - Functional storage
- Creating place for everything and putting
everything in its place

Success - Time saved in searching

Indicator - Time saved in material handling

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Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

How to achieve Systematic Arrangement ?

• Decide where things belong

• Decide how things should be put away

• Obey the Put away rules

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 Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

w to achieve Systematic Arrangement ?

cide where things belong
tandardize Nomenclature
Determine an analytical method of storage

cide how things should be put away

Name & locations to everything. Label both ite
and location
Store material functionally
Prevent mistakes with coding by shapes & col

contd.. 15
 Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

to achieve Systematic Arrangement ?

cide how things should be put away
ollow first in first out rule
If two identical items are to be located, then s
them separately, colour code them.

ey the rules
ut the things back to their location after
their use

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Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

USE :

1) Signboards

2) Colour codes

3) Outline markings

4) Labels

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Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Store frequently used

Usage material
Frequenc near the workplace and
y less
frequently
Weight •&Heavy materialatshould
some be stored
Shape of atdistance
lower levels/layers
Place directly on the material
the
handling device for ease of
Material handling

Functional Storage
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Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Same category of
Category
material may be
stored in one location.
Eg. Allen Screws, Oil
Operation Seals
• All items required for an
Wise operation may be stored in one
location.
Eg. Allen key, spanner etc hand
tools required for setting m

Functional Storage
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 Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

tlining and Placement Marks

Mark boundaries of dept., aisles, Machines
Follow straight line, right angle rule
Nothing shall be kept outside the boundaries

nds and shelves

eep only required number of stands and shelv
Standardize height, size
Provide casters where necessary so that it can
moved

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 Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

res and Ducts

olour code
When there are multiple connections - bundle
wires, label them and make sure that they are
straight line /right angle and firmly anchored
achine-tools & Tools
ut the tools in the order you need them
Location of the tool should be such that it can
put away with one hand
Try to eliminate some hand tools by permanen
attaching it to the bolt head
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 Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

des, Dies, Other important consumables

tore them in the protected place
Maintain these things regularly by applying ru
preventive, oiling etc.
P- Work In Process
esignate a place for each component/part
Decide on how much quantity to be stored
Ensure that there is no damage to good part
during transit, they do not get rusty and they
not mislabeled

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Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Oils
- Reduce number of oils used
(Standardize)
- Colour code for oils
- Safety aspects - fire prevention,
pollution, leak,
spillage
• Instrumentation & Measuring Devices
- Label them, show direction of flow
etc

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SEISO
SEISO == Cleaning
Cleaning
Meaning
Meaning Cleaning
Cleaningtrash,
trash,filth,
filth,dust
dustand
andother
otherforeign
foreign
matter.
matter.Cleaning
Cleaningas asaaform
formofofInspection
Inspection

Activity - Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning inspection

Success - Reduction in machine down time

Indicator - Reduction in no. of accidents

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Seiso
Seiso == Cleaning
Cleaning

• Here cleaning means more than just keeping

things clean. Cleaning should be viewed as a
form of Visual Inspection

• Preventive measures should be taken to tackle

problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated.

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Seiso
Seiso == Cleaning
Cleaning

Various Minor Defects

= Trash = Dirt =Knocking
= Loose parts = Leaks =Scattering
=Skips =Curvature =Abrasion
=Rust =Scratches
=Eccentricity
=Lurching =Heat =Vibration
=Abnormal =Abnormal =Abnormal
Sounds Movements smells
=Faded colour =Hisses
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Seiso
Seiso == Cleaning
Cleaning

5 Minutes Every day for

cleaning
• Devote 5 minutes everyday for cleaning your
work area

• Participation of everyone is required

• Attack hard to clean places regularly

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Seiso
Seiso == Cleaning
Cleaning

Cleaning - Inspection points for most

equipment

Grime, clogging, dust balls, rust,

Cleaning leakage etc.

No oil, Low oil, leakage, filter clogging,

Oils dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
etc.

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Seiso
Seiso == Cleaning
Cleaning

Cleaning-Inspection points for most

equipment

Loose bolts, welding detachment,

Tightening loose parts, vibration or bumping
noise, friction

Heat Oil tanks, motors, heater, axles, control

panels, washing/ cleaning water,
bearing, wiring etc.

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Seiso
Seiso == Cleaning
Cleaning

Cleaning-Inspection points for most

equipment

Breakage, cracks, dent on sliding

Breakage,
parts, handle has come off, broken
Cracks switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.

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Seiso
Seiso == Cleaning
Cleaning

Function wise Cleaning check list of

equipment

Compressed Air lines, air valves,

Pneumatics connections, meters, filters,
reservoirs etc.

Hydraulic oil tank, oil valves,

Hydraulics filters, pumps, hoses, gauges,
cylinders etc.

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Seiso
Seiso == Cleaning
Cleaning

Function wise Cleaning check list of

equipment

Mech. Eqpt. Motor fan, fan belt, couplings,

Joints, pulleys, chains, pump
bearings etc.

Control panel, lamps, light, switch,

Electrical sensors, wiring, ducts, fuses etc.

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Seiso
Seiso == Cleaning
Cleaning

Function wise Cleaning check list of

equipment

Tools, fixtures, gauges, dies,

Toolings measuring instruments, etc.

Equipment Furnaces, rollers, chutes,

Specific CNC machines, etc.

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SEIKETSU
SEIKETSU == Standardization
Standardization
Meaning
Meaning Setting
Settingup
upstandards
standards//Norms
Normsfor
foraaneat,
neat,clean,
clean,
workplace
workplaceand
anddetails
detailsof
ofhow
howto
tomaintain
maintainthethe
norm
norm(Procedure)
(Procedure)
Activity - Innovative visual management
- Colour coding
- Early detection of problem and early action

Success Indicator - Increase in 5S indicator

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Seiketsu
Seiketsu == Standardization
Standardization

• Regularizing 5S activities so that

abnormalities are revealed
• Make it easy for everyone to identify
the state of normal or abnormal
condition

• For maintaining previous 3S, deploy

visual management

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Seiketsu
Seiketsu == Standardization
Standardization

• It has been estimated by scientific

study that 60% of all human activities
starts with sight

• 5S is easy to do once.It’s consistency

is difficult. That is why Visual
Management is so important, so that
everybody will know that there is
some problem. Visual Management
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Seiketsu
Seiketsu == Standardization
Standardization

What visual control communicates ?

It grabs one or more of our senses in

order to

• Alert us to an abnormality
• Help us recover quickly
• Promote adherence and prevention
• Enable successful self management
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Seiketsu
Seiketsu == Standardization
Standardization

Some methods for visual communication

Colour coding
 Use of Labels
 Danger alerts
 Indication where things should be
put
 Directional arrows / marks
 Transparent covers
 Performance indicators
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Seiketsu
Seiketsu == Standardization
Standardization

Points to remember in making visual

management tools
Make them easy to see from distance
1.Put the display on the things
2.Everyone can tell what is right and
what is wrong
3.Anybody can follow them and make
necessary corrections easily
4.Work place should look brighter &
orderly
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Seiketsu
Seiketsu == Standardization
Standardization

Some everyday visual management

examples
 Traffic signal
 Zebra crossing
 In car - Petrol indicator
- Speed indicator
 Direction arrows
 Electric danger sign etc.

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Seiketsu
Seiketsu == Standardization
Standardization

Some visual communication signs

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SHITSUKE
SHITSUKE == Self
Self Discipline
Discipline
Meaning
Meaning Every
Everyone
onesticks
sticksto
tothe
therule
ruleand
andmakes
makesititaahabit
habit

Activity- Participation of everyone in developing good

habits
- Regular audits and aiming for higher level

Success - High employee morale

Indicator - Involvement of all people

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Shitsuke
Shitsuke == Self
Self Discipline
Discipline

We need everyone to maintain 5S

guidelines.

To maintain DISCIPLINE, we need

to practice and repeat until it
becomes a way of life.

Discipline is the Core of 5-S

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Shitsuke
Shitsuke == Self
Self Discipline
Discipline

Discipline means making a steady

habit of properly maintaining
correct procedure.
procedure

Time and effort involved in

establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.
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THANK YOU!

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