This Presentation covers 5S methodology, implementation technique, example and checklist for implementation

1. 5S Training &
Awareness

2. Thirty years ago, researchers started studying the secret of
success of Japanese manufacturing companies.
It was Hiroyuki Hirano who developed 5s within his overall
approach to production systems.
5s turned out to be the most impressive ‘secret’. Many
western managers coming across the approach for the first
time found the experience to be enlightening.
Hirano provided a structure for improvement programs.
He pointed out a series of identifiable steps, each building on
its predecessor.
Discovery of 5S

3. Objectives
By the end of the module, the participants will be able to:
• Define and understand the importance of the 5s method
• Identify and overcome the barriers to productivity
• Improve QUALITY of work
• Practice efficiency at all times

4. Outline
 Objective
 5S Fundamentals
 Check sheet Understanding
 Before- After Comparison
 Advantages of 5S
 Who to implement

5. Why do we start 5S
The general concept of the 5S is that they are intended to eliminate waste.
Working in disorder is neither productive, nor safe. 5S is a simple and practical
method to instil a quality culture at the work place. It is relatively easy to
undertake, and requires minimal additional resources. The first and small
investment made in time and effort pays off in a much bigger manner when the
results are realized and maintained.
Among the main benefits of implementing 5S are:
• the workplace becomes cleaner, safer, well-organized and more pleasant
• floor space utilization is improved
• workflow becomes smoother and more systematic and non-value added
activities are reduced;
• time for searching tools, materials and document is minimized;
• machine breakdowns are reduced since clean and well-maintained equipment
breaks down less frequently and it also becomes easier to diagnose and repair
before breakdowns occur, therefore extending equipment life;

6. When do we start 5S
If we have growing symptoms of these:
- Poor state of Machines / Equipment / Tools leading to quality deterioration.
- More time is spent in direct and indirect areas by way of searching for Tools /
Files / Documents.
- Poor house keeping leads to unsafe work place & indirect losses.
- Poor material discipline leading to manufacturing delays.
- Poor office upkeep leading to delays in transacting with suppliers & customers.

7. ABOUT 5S
The 5 - S practice is a technique used to establish and maintain
quality and safe environment in an organization.
The 5 Japanese words are :-
1. Seiri (Sort) – Sort out ( )
2. Seiton (Set) – Systematic Arrangement ( )
3. Seiso (Shine) – Spic and Span ( )
4. Sieketsu (Standardize) -- Standardization ( )
5. Shitsuke (Sustain) - Self-discipline ( )

8. SEIRI – Sort out
Segregating the wanted and unwanted items
(workplace - )

9. 1S- SEIRI/ Sorting
The emphasis of Seiri is on stratification management and being able
to spot the unwanted and unnecessary before they become
problematic
Steps for Seiri
Undertake major cleaning up activities
Keep in mind the spirit of waste elimination
Develop specific policy & guidelines on the disposal of
unwanted things and upkeep of necessary things
Devise storage method depending on the priority

10. USABLE / WANTED ITEMS
1S- SEIRI/ Sorting

11. SEITON- Set
Arrange a place for everything and everything in its place.
(
)

12. •Ensure rational layout of machines, equipment, cabinets
•Place frequently-used items at the point of use based on
policy
•Pre-fix a place for everything and put everything in its place
with pre-determined quantity
•Identify useful items with labels/ item name, colour codes and
location etc.
•Use index for files, records, drawings, etc.
•Plan storage with an intent to retrieve easily.
•Have visual controls for checking missing items like an
inclined stripe for files stored which will indicate a missing file,
Shadow graphs for tools storage etc.
Seiton in essence can be defined as neatness, having things in the right places or set up
so that they are readily available for use, eliminating the need to search. Once
everything has a right place so that it’s functionally placed for quality and safety, it can
then be deemed that the workplace is neat. While Seiri helps you to decide what items
are needed, Seiton helps you to decide the way things are to be placed.
Steps for Seiton
2S- SEITON/ Set

13. YES NO
USABLE ITEMS
Is it
identified
Does it have
a storage
space
Will be using
it today
Keep it
closer to
place of use
Mark it up /
identify
Make a
space for it
Put it away /
Stores or
Record
Room
2S- SEITON/ Set

14. Arrangement based on frequency of use
2S- SEITON/ Set

15. SEISO – Spic & Span
Clean your workplace thoroughly.
(workplace )

16. Steps of Seiso
• Identify which parts are to be cleaned each
shift/ twice daily, daily, weekly, monthly, etc.
• Plan for systematic daily or periodic cleaning
of all nooks and corners of the zone / whole
plant
• Ensure cleaning material and cleaning tools
are available at an accessible place cleaning
• Identify and remove the root causes of such
defects/ dust/ dirt
3S- SEISO/ Shine
Seiso places emphasis on cleaning so that things are clean; in other words carrying out
cleaning as a form of inspection i.e. getting rid of waste, and foreign matter. It is
important to note that depending on the circumstance, with higher quality, higher
precision and finer processing technologies, even the minute details may have the
greatest ramifications, hence the importance to carry out cleaning as a form of
inspection

17. Seiketsu - Standardization
Maintain a standard.
( , 1S,2S,3S
|

18. • Identify the way different people are doing an
activity
• Discuss and choose the best way
• Make this the standard method once everyone
accepts it
• Convert this into a written standard, giving a
reference Code number
• Ensure that everyone does the same work only as
per the standard
• After accepting it as the standard, review it from
time to time and improve it as necessary
• Identify the weaknesses in the standard and
upgrade them.
3S- SEIKETSU/ Standardize
This aspect of the 5S focuses on standardization, making the first three S’s, Seiri,
Seiton, and Seiso a constant routine. The emphasis here is on visual management, an
important aspect to attain and maintain standardized conditions to enable the
individuals always act quickly
Steps of Seiketsu

19. Shitsuke : Self-discipline
Train people to be disciplined
( 5S
)

20. Steps for Shitsuke
• Every employee should know 5S and follow it
EVERY DAY from the time of starting to work and
repeating it when he closes for the day.
• One should keep himself tidy and it will make
others to follow
• Should do routine activities as per the standards
only
• One should keep his workplace SPIC & SPAN
• Everyone should strictly follow the safety rules
• One should always search for abnormalities and
solve it
5S- SHITSUKE/ Sustain
Shitsuke places emphasis on being able to forge a workplace with good habits and
discipline. Demonstrating to others what needs to be done and encouraging practice
amongst them. This is mainly a management responsibility.

21. 5S Implementation Structure

22. THE SURE WAY FOR ORGANIZATIONAL
TRANSFORMATION
Education
Development of
checklists
Patrol
inspection
Monthl
y audit
Circulate status zone
wise
Dealing with
individual problems
Assist in
development
of standards
Divide the area into smaller zones
Fix-up the zone-wise responsibility
List out activities to be carried out
SEIRI, SEITON, SEISO, SEIKETSU, SHITSUKE
Prepare standards
Carry out 5S daily
Follow 5S standards
Patrol inspection by Dept. Manager
Monthly Audit
Assess status, develop counter measures
Target for next month
Revise 5S standards, if necessary
Maintain & improve 5S
Adopt some
zones
Participate in
carrying out 5S
Patrol
inspection
Review with
Dept Head
Provide
resources
PL
A
N
D
O
CH
EC
K
AC
T
TQM/OPEX Office Departments

23. Example
NOKIA FACTORY

24. Example- NOKIA Factory

25. Example- NOKIA Factory

26. Example
BENZ FACTORY

27. Example- BENZ Factory

28. Example- BENZ Factory

29. Example- Standardize work Area
• Clear, shiny aisle ways
• Color coded areas
• Slogans, banners
• No work-in-process ( WIP )
• One-Piece Flow
• Standardized Work Sheets

30. 5S Audit worksheet...

31. Check sheet- 1S
1. Seiri – Sort out
Stratification management and dealing with the causes
Typical Activities Location Action by
• Throw away things that are not needed
• Deal with causes of dirt leaks and noise
• Organize cleaning the floors and
housecleaning
• Treat defects, leakage and breakage
• Organize the storage of parts and files
• Policy of “One-is-best”
- one set of tools/stationery
- one page form/memo
- one day processing
- one stop service for customer
- one location file

32. 2. Seiton – Systematic Arrangement
Functional storage and eliminating the need to look for things
Typical Activities Location Action by
• Everything has a clearly designated name & place
• 30-second retrieval and storage
• Filing standards and control
• Zoning and placement marks
• Eliminate covers and locks
• First in, first out arrangement
• Neat notice boards (also remove obsolete notices)
• Easy-to-read notices (including zoning)
• Straight-line and right angle layout
• Functional placement for materials, parts, tools etc
Check sheet- 2S

33. 3. Seiso – Spic & Span
Cleaning as inspection and degree of cleanliness
• Individual cleaning responsibility assigned
• Make cleaning and inspection easier
• Regular sparkling cleaning campaigns
• Cleaning inspections and correct minor problems
• Clean even the places most people do not notice
Typical Activities Location Action by
Check sheet- 3S

34. 4. Seiketsu - Standardization
Visual management and 5-S standardization
• Transparency ( e.g. glass covers for see-through)
• Inspection “OK” marks or labels
• Danger zones marked on meters and switches
• ‘Danger’ warning signs and marks
• Fire extinguisher and ‘Exit’ signs
• Directional markings on pipes, gangways etc
• Open and shut directional labels on switches etc
• Colour-coded pipes
Typical Activities Location Action by
Check sheet- 4S

35. Seiketsu - Standardization...
Visual management and 5-S standardization
• Foolproofing (Poka-yoke) practices
• Responsibility labels
• Electrical/telephone wire management
• Colour coding - paper, files, containers etc
• Prevent noise and vibration
• Department/office labels and name plates
• Park-like environment (garden office/factory)
Typical Activities Location Action by
Continued….

36. 5. Shitsuke - Discipline
Habit formation and a disciplined workplace
• All-together cleaning
• Do daily physical exercise all together
• Practice pick-up components and rubbish
• Wear your safety helmet/gloves/shoes etc
• Public-space 5-S management
• Practice dealing with emergencies
• Execute in individual responsibility
• Good telephone and communication practices
• Design and allow the 5-S manual
• Seeing-is-believing: check for 5-S environment
Typical Activities Location Action by
Check sheet- 5S

37. Dept. Asembly Date
Dept.1
Assigned area Entered by: Page No.
No. Process and checkpoint Sort Set in order Shine Total
Previous
total
1 Work at Line A, Process 1 8 6
2 " 8 6
3 " 6 5
4 " 7 7
5 " 10 6
6 " 12 8
7 Average and total for Line A 51 38
Standardization Level Checklist
1111 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4 1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
1 532 4
2.6
2.8 2.8
Standardization Level Cheek Sheet

38. Benefits of practicing 5S
• the workplace becomes cleaner, safer, well-organized and more pleasant
• floor space utilization is improved
• workflow becomes smoother and more systematic and non-value added
activities are reduced;
• time for searching tools, materials and document is minimized;
• machine breakdowns are reduced since clean and well-maintained equipment
breaks down less frequently and it also becomes easier to diagnose and repair
before breakdowns occur, therefore extending equipment life;
• errors are minimized leading to making defect-free products;
• consumables and material wastage are minimized;
• the morale and satisfaction of employees improves; and
• the productivity of the organization improves together with the quality of
products and services.
BENIFITS

39. Identify Red Tag ?
PIC-1 PIC-2

40. Identify Red Tag ?
PIC-3 PIC-4

41. BEFORE- AFTER Comparison

42. BEFORE- AFTER Comparison

43. BEFORE- AFTER Comparison

44. BEFORE- AFTER Comparison
Before 5S
After 5S - Cleaned, organized and drawers
labeled (less time and frustration hunting)

45. BEFORE- AFTER Comparison
1. Sort - All unneeded tools, parts and supplies are removed from the area
2. Set in Order - A place for everything and everything is in its place

46. BEFORE- AFTER Comparison

47. BEFORE- AFTER Comparison

48. BEFORE- AFTER Comparison

49. BEFORE- AFTER Comparison

50. Without 5S

51. With 5S

52. Now Think …
Think about some 5S example, made real life simpler?
How you will contribute ?
Who wants to be Certified by us ?