5S 1

5S KAIZEN

Source: Takashi Osada The 5Ss: Five Keys to a Total Quality Environment APO, 1991.

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5S KAIZEN

What is

5S

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5S stands for 5 initials of the following Japanese words:

1. 2. 3. 4. 5. Sei-ri (Organization) Sei-ton (Neatness) Sei-so (Cleaning) Sei-ke-tsu (Standardization) Shi-tsu-ke (Self-discipline)

5S

ONCSS
1

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International 5S
5 Steps for improvement

KAIZEN

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Sei-ri

Seiri

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Seiri = Organization
Dictionary definition:

To put things in order (or organize them) according to a specific rule or principle. Industrial definition:

To distinguish between necessary things and unnecessary things, and getting rid of what you do not need.

5S 7

Why is my desk getting messy?

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Solution

The Japan HR Association

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Red tag movement

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Red tag movement

At the beginning of each month, put a red tag on every item. During the month, remove the red tag when item is used. At the end of the month, decide whether the item with the tag is necessary or not.
2

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Wooden Pallet

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Key Words:

1. Classification management
(Necessary & unnecessary things)

2. Red tag movement For unnecessary things, find their true causes.
1

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Typical Seiri Activities

1. Eliminate defects and breakage 2. Organize the warehouse

Before

After

T. Sugiyama The 5S Approach to Improvement PHP, 1995

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Sei-ton
Seiri Seiton
2

Sei-ri Sei-ton

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Seiton = Neatness
Dictionary definition:

Establishing a neat layout so that you can always get just as much of what you need when you need it. Industrial definition:

It is a way of eliminating search.

1

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Question
When you ask someone to bring a hammer, how long can you wait without getting mad? How long is your patience?
5 minutes? 2 minutes?? or 5 seconds???

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30 Second Rule
Tool Box

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K.P.Shrestha (Nepal)

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30 Second Rule

The Japan HR Association

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Key Words:

1.Design an efficient layout.

(Functional storage)

2.Eliminate search
(Less search)

Everything should have a name.

(A place for everything and everything in its place)

Reserved seats
1

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Typical Seiton Activities

1. Stripes on files 2. First in, first out 3. Easy to read notices

Before

After

T. Sugiyama The 5S Approach to Improvement PHP, 1995

Posters of Seiri

5S 22

Malaysia, AOTS

Oman

Posters of Seiton

5S 23

Malaysia, AOTS

Oman

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Sei-ton
Seiri Seiton Seiso
3

Sei-ri Sei-ton Sei-so

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Seiso = Cleaning
Definition:

Eliminating trash, filth, and foreign matters for a cleaner workplace. Cleaning as a form of inspection.

5S 26

Key Words:

Keep things clean

+ Inspection
(Caring attitude)

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Cleanliness is a big business today.

Sanitation engineers Laundry Dry cleaner Janitor Garbage collector Pollution control operator Clean-room designer One-third (1/3) or one-fourth (1/4) of the total investment amount is used for cleanliness. 1

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Typical Seiso Activities

1. Quick 5S drill 2. Sparkling clean campaign 3. Everybody is a janitor
Broom Dust pan Mop
Marugoto 5S Tenkai Daijiten, Nikkan-kogyo Shinbun, 1992

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Sei-ke-tsu

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Sei-ke-tsu Sei-ton
Seiri Seiton Seiso Seiketsu
4

Sei-ri Sei-ton Sei-so Sei-ke-tsu

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Seiketsu = Standardization
Definition:
SEIRI SEITON

Keeping things organized, neat, and clean, even in personal and environment aspects.
SEISO

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What is Problem ?
Problem is something like ----.

5S 33

Charles H. Kepner Benjamin B. Tregoe

The New Rational Manager Princeton Research Press, Shinkanrisha no Handanryoku (Japanese Edition), 1985

GAP Ideal State

Current State

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Key Words:

1. Define an ideal state 2. Standardize the solution

(5S standardization)

Documentation (ISO 9000)

1

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Kathmandu, NEPAL

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Streets in Kathmandu

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Typical Seiketsu Activities

1. Make quality manual 2. Directional markings 3. Color-coded pipes

Before

After
T. Sugiyama The 5S Approach to Improvement PHP, 1995

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Shi-tsu-ke Sei-ke-tsu Sei-ton

Seiri
5

Sei-ri Sei-ton Sei-so Sei-ke-tsu Shi-tsu-ke Shitsuke Seiton Seiso Seiketsu

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Shitsuke = Self-discipline
Definition:

Doing the right things as a matter of course.

5S 40

ATA Boiler Company

(at a suburb of Rio de Janeiro)

Morning exercise

5S 41

The Japan HR Association

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Key Words:

1. Habit formation
(Make it a habit)

2. Create a disciplined workplace

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Typical Shitsuke Activities

1. Wear your safety shoes 2. Exercise time 3. No smoking at workplace

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5S in Colombo

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Exercise

Establish a clean-up time every day. SEISO Eliminate oil leakage. SEIRI Make a reserved seat for each tool. SEITON Paint yellow lines at workplace. SEIKETSU Wear safety badge this week. SHITSUKE
SEIRI SEITON SEISO SEIKETSU SHITSUKE

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Exercise

Remove expired materials. SEIRI Display names of tools on the shelf. SEITON Force workers to greet each other. SHITSUKE Prepare a manual of the work. SEIKETSU Clean up a hidden place. SEISO
SEIRI SEITON SEISO SEIKETSU SHITSUKE

Posters of 5S

5S 47

Nepal

Thailand

Posters of 5S

5S 48

SEIRI SEITON SHITSUKE

SEISO

SEIKETSU

Nepal

Benefits of 5S

5S 49

National Productivity Board, Singapore

5S 50

Why not start 5S today?

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