1. By Abhineet Aggarwal

2. What is 5 S ?
5S is the name of a workplace organization method that uses a list of five Japanese
words:
1. SEIRI – SORT – SEGREGATION
2. SEITON – SET IN ORDER – ARRANGEMENT
3. SEISO – SHINE – HOUSEKEEPING
4. SEIKETSU – STANDARDIZE – MAINTAINANCE OF STANDARDS
5. SHITSUKE – SUSTAIN – DISCIPLINE
Transliterated or translated into English, they all start with the letter "S". The list
describes how to organize a work space for efficiency and effectiveness by
identifying and storing the items used, maintaining the area and items, and
sustaining the new order. The decision-making process usually comes from a
dialogue about standardization, which builds understanding among employees of
how they should do the work.

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What is 5S??
5S Original Japanese Meaning in English
1S SEIRI Sort out unnecessary items in the workplace
and discard them
2S SEITON Arrange necessary items in good order so that
they can be easily picked for use
A place for everything
Everything in its place
3S SEISO Clean your workplace thoroughly so that there
is no dust on floors,machines and equipments
4S SEIKETSU Maintain high standards of workplace at all
times
5S SHITSUKE Train people to follow good housekeeping
discipline automatically

5. 1ST S – SEIRE (Sorting)
Separating the useful from the useless: ELIMINATION
Sorting out and keeping only what is necessary for the environment through:
1. The elimination of the useless items
2. The selection of the items required for efficiency in the workplace
Objective: the implementation of useful tools for creating an effective work
environment without bothersome and useless influences
INDICATOR OF SUCCESS :
1. Decrease in unnecessary items and reserve stock
2.Percentage of area / space saved

6. 2nd S – SEITON (Set in order)
Organizing items based on their use: Organization
Putting things in their proper place by:
1. Selecting the best place for each object
2. Selecting a method for the organization and identification of each object
Objective: Eliminating the need to look for objects
INDICATOR OF SUCCESS :
1. Time saved in searching
2. Time saved in handling material

7. Putting in order
Things needed Things not needed
Things used
Constantly
Things used
occasionally
Seldom used
But still needed
Place as close
as possible
Place a little
further
Enclose in a sepearate
Designated
Place
Potentially
usefull
No potential
use
Consider where
usefull and move
to designated place
Disposal after
careful analysis

8. 3rd S – SEISO (Housekeeping)
Eliminating the sources of dirt and smudges: CLEANING
Efficient elimination of dirt by:
1. Identifying the sources of dirt and smudges at the time of each cleaning
procedure
2. Implementing measures to eliminate the sources of dirt and smudges and ensure
cleanliness with minimal effort
Objective: To keep things clean
INDICATOR OF SUCCESS :
1. Reduction in machine downtime
2. Increased life of the machine parts
3. Reduction in number of accidents
4. Reduction in rejection / rework

9. 4th S – SEIKTSU (Standardize)
Visually standardize better practices: STANDARDIZE
This Step is Combination of segregation (seiri), arrangement (seiton) and cleaning
(seiso). As as,an on-going programme to maintain a clean and well – organised
workplace.
To implement effective organization by:
1. Identifying better practices
2. Simple procedures for these practices (visual assistance)
3. Communication and training for use
Objective: To observe proper practices
Indicator of success :
1. Number of areas / covers made transparent
2. Number of new problems exposed and solved

10. 5th S – SHITSUKE (Sustain)
To systematize compliance with better practices: SUSTAIN
Ensuring compliance with established standards by:
1. Acquiring new habits
2. Options for continued self-determination regarding compliance with established
rules
3. Information and processing of noted problems
Objective: To use the best practices and continuously improve them
INDICATORS OF SUCCESS :
1. High employee morale
2. Involvement of people in the movement

11. Benefits of 5 S
• Less Waste (Improved Efficiency)
• Reduced Space Used For Storage
• Improved Maintenance
• Improved Safety
• Better, More Committed Employees
• Improved Quality

12. Less Waste Equals Improved Efficiency
A key principle of 5S is to get rid of items that are not used, and make it more
convenient to find those items that are needed. This gets rid of clutter, unnecessary
tools, scrap materials and unused supplies. It organizes, labels and places close at
hand those tools and materials that are needed on a regular basis. The result is
that more time is spent productively and less time is wasted finding needed tools
and materials.
Less Space Used For Storage Equals Reduced Costs
By eliminating unused materials, tools and equipment, and getting rid of clutter, a
surprising amount of space will be freed up. There is a cost associated with
space, not only in the rental or lease costs, but in heating/cooling, cleaning and
maintaining of that space.

13. Clean Equals Improved Maintenance & Less Down Time
When machines, equipment and tools are kept clean and free from clutter, it is easier to
spot defects, part failures, and problems such as an oil leak. This allows preventative
maintenance to address the problem before it becomes a more serious problem.
For example, if a machine is kept clean, an oil leak would immediately be noticed. The
source and cause of the leak can be quickly identified and the problem fixed, before low oil
levels lead to more serious damage to the machine.
Improved Moral Equals Greater Commitment To Job
When your employees see you care about them, their work area, and that you value their input,
they care more about their job. 5S naturally leads to this result.
5S is dependent on employee participation. 5S leads to employees being more engaged with
their job.
The clean, organized workplace that results from 5S is a more pleasant workplace that leads to
improved employee attitudes. The focus on cleanliness, organization, labor-saving efficiency,
having the right tools, and using quality standards leads to an increased pride in workmanship.
Add in the improved safety (lower numbers of injuries) resulting from 5S and you get a
workforce that is happier (less turn-over), more motivated, is getting more done with less effort,
and is interested in further improving their workplace and your products.

14. Implementing 5S Equals Improved Safety
• Clean means that spills get cleaned up ASAP, eliminating the potential for slips and
falls.
• Clean means clutter is removed, revealing hidden electrical, chemical or
mechanical hazards.
• Having needed tools, materials and supplies close to where they are needed
greatly reduces travel (movement) and as a result reduces the potential for injury.
• Standardization means that unsafe practices are eliminated because those
practices are not a part of the standards.
• Employees who have their eyes open for spotting ways to improve using 5S
principles will also be more aware of their surroundings and potential safety
hazards.

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5 Levels of housekeeping
LEVELS :
1. Horizontal surfaces/floor full of unwanted material.
2. Vertical surfaces / areas near walls having clutter.
3. Horizontal ,vertical surfaces clean and have no unwanted
items.However,storage areas, record rooms disorganised.
4. Storage areas ,machines,offices are clean.All materials ,furtinuture,documents
properly organised,labelled and numbered.
5. Factory/office is immaculate at all times.

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Level 1 of Housekeeping
Work area is in level 1 of housekeeping if,
 Cigarette butts/Gutkha pouches
 Scraps of paper
 Tools (Used or Unused)
 Packing and clamping materials
 Support structures
 Left -over raw material
 Obsolete documents
 Bulky files
 Unused equipment, machine etc
are scattered around all over the workplace.

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Corrective action for level 1
• Look at all horizontal surfaces
• Examine the entire work floor. Eliminate all garbage and
non- essential items on floor,shelves,tabletops etc
• Remove unnecessary papers from files
• Discard old files, stationery etc
• Make a definite place for all tools/documents,files and parts that are lying on the
floor tabletops
HINTS FOR IMPROVEMENT
 Do not put anything directly on the floor
 As much as possible, throw/dispose off things that have no clear foreseeable use.

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Level 2 of housekeeping
Work area is in level 2 of housekeeping if there is no litter or unused material on
the floor/horizontal surface, but
 Clutter is found by the walls
 The passage ways are not clear
 Unused items,documents,furniture etc are leaning against the walls or columns
 Unused tools and equipment ,paper left beneath or beside the equipment

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Corrective action for level 2
• Look at vertical surfaces
• Examine walls and columns
• Eliminate all garbage and non- essential items leaning against the walls/columns
• Paint all walls and columns that can be reached by hand
Hint for improvement
 Divide responsibilities (For area and walls)

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Level 3 of housekeeping
Work area is in level 3 of housekeeping if the walkways are clear and the
factory/office is clean,but the tools,materials,papers and files are still
disorganised in the storage areas,record rooms,drawers,filing racks etc.
 Tools ,parts,clamps are all mixed together
 Gloves,shoes etc are thrown in with tools in the toolbox
 Drawers,shelves are disorganised
 All tools are in locked storage units
 Drawers,shelves are locked and keys are missing
 Unused and worthless items found inside closed cabinets

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Corrective action for level 3
• Look inside the shelves and sort the papers, material ,parts and tools
• Get rid of locked cabinets
• Make separate storages for tools,parts,clamps, documents etc.
• Make the above area distinct and clear
HINT FOR IMPROVEMENT
 Remove the back and sides of all the storage cabinets

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Level 4 of housekeeping
At level 4,the work area will have,
 Machines,equipment,furnitures spotlessly clean
 Storage areas clearly marked and distinguished
 Scrap material found in its designated scrap bin
 Items placed in shelves are properly labelled/ tagged
 Storage areas show many parallel lines and right angles for grid alignment
 Tools/files are colour coded and numbered

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Further improvement at Level 4
 Clean ,straighten and organise automatically
 Storage system designed for “First In First Out” philosophy
 Develop other visual controls
Hints for improvement
 Scrap and chips should fall directly into waste containers/dust bins
 Make a model line with super market type display of parts and tools
 Well defined scrap & waste collection & disposal system

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Level 5 of Housekeeping
At level 5,the work place is immaculate at all times. It witnesses,
 Constant and continual cleaning by all employees
 Origins of rubbish are removed so that dirt, clutter and garbage are eliminated
at source
 Tools, items and materials can be found at a glance
 Inventory levels can be found visually
 Production runs smoothly
 High product quality achieved

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What does 5(S) require?
Consciousness revolution through :
1. Perseverance, determination
2. Training
3. Constant efforts
Abilities :
1. To see / judge what is important
2. Attention to details
Continuous implementation through :
1. Total participation by all employees

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Crucial points for successful
implementation of 5S
PARTICIPATION BY ALL PEOPLE :
• 5S programme should be participated by all People in the organization.
• 6 objectives or why’s of 5S programme should be understood by all people in the
organization :
1. A clean workplace is high in PRODUCTIVITY
2. A clean workplace has high QUALITY
3. A clean workplace keeps COST down
4. A clean workplace ensures DELIVERY on time
5. A clean workplace is SAFE for people to work
6. A clean workplace is high in MORALE
REQUIRE FULL SUPPORT FROM ALL EMPLOYEES.

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Tangible results expected from 5S
practice
From People
• Employees will be disciplined to be more aware of untidy workplace and motivated
to improve the level of cleanliness.
• Greater team spirit and co-operation can be built up through involvement of all
within an organisation.
• Employees will be disciplined to follow safer and better ways of work,resulting in
lesser risks to accidents.
• Employees would be more conscious of improvement which leads to greater
efficiency and effectiveness.

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From Machines and Tools :
• Machine troubles can be detected at an earlier stage to prevent a major
breakdown, when machines are cleaned daily by people operating them.
• Daily cleaning of measuring instruments will ensure accuracy and reliability.
• Life of machines and tools can be extended significantly when they are handled
with care and placed in the designated locations.
From Materials and Work –in –Progress :
• Flow of materials and work-in-progress will become smoother.
• Floor space will become organized and possible areas for improvement can be
easily identified by quick observation.
• Inventory of materials and work-in-progress will become clearly visible and easily
handled.
• Material yield ratios can be improved

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From Products and Customers :
• Clean workplace will ensure that final products will be free from dust.
• Sales people will be eager to show customers the plant as a marketing tool.

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Housekeeping to Happiness
• Housekeeping means Orderliness
• Orderliness leads to Cleanliness
• Cleanliness leads to Quality
• Quality leads to Productivity
• Productivity leads to Prosperity
• Prosperity means Happiness

31. Thank You