“5-S METHODOLOGY”

• 5S is an approach originally developed in Japan for better house keeping. Now it is been utilized for keeping better work place.It includes 5 steps which are to be followed sequentially.

• Following Japanese terms collectively are as called 5S• 1S - Seiri or Sort • 2S - Seiton or Set In Order• 3S - Seiso or Shiny Clean up • 4S - Seiketsu or Standardize • 5S - Shitsuke or Sustain

• By Implementing 5S one will get to know how cleanliness, orderliness, safety practises and better work environment results in increased free space, higher yield and transparency in work.

REQUIREMENTS OF 5S• To implement 5S following are the requisites

1. Consciousness fora. Strong determinationb. Trainingc. Constant Efforts

2. Ability toa. Judge what is importantb. Attention to details

3. Continuous implementation through total employee participation and better communication

1ST ‘S’ – SEIRI OR SORT

Step 1 : Tagging the followinga. Not needed at allb. Needed But Not Nowc. Needed But Not Hered. Needed But Not So

Much QuantityStep 2 : Entry in Red tag Register Step 3 : Assign Red Tag area and dump the scrap

It aims at taking out unnecessary items and dumping it into garbage(i.e Red Tagging)

Action during Seiri

KEY INDICATORSIndicators of success1. Decrease in unnecessary items and reserved

stocks2. Reduction in sq.ft area consumed

Checklist – • Do you find items scattered in your workplace?• Are the boxes ,papers and other items left in a

disorganized manner?• Are there equipment and tools on the floor ?• Are all items sorted out and placed in designated

spots?• Are tools and stationary properly sorted and stored ?

RESULT FROM SEIRI

Created free space

2ND ‘S’ – SEITON OR SET IN ORDER

• It aims at arranging the necessary items in proper order so that they can be easily picked up for use• Steps for Seiton1.Systematic Arrangement is a form of

standardization2.3 Keys are the basic rules for Storage3.Fixing Position4.Fixing Quantity5.Signs for Storage of Work-in Progress

SYSTEMATIC ARRANGEMENT

KEYWORD 3 POINTS 3 KEYS

- Anybody - Immediately

1. Can see

2. Can take out

3. Can return

1. Where?.. Fix position

2. What? …Fix items

3. How many? Fix quantity

3 KEYS

It answers the question

What items are to be kept ,where and in how much quantity ?

RULES FOR STORAGE1.Search – Free2.Count – Free3.Air – Free4.Climb – Free5.Bend – Free6.First – In, First – Out7.Heavy/ Tall Things On Bottom Shelves8.Fast Moving Materials Close To Point-of-use/ Point-of-

issue9.Adequate Lighting10.Adequate Ventilation

Street numbers

Address of bin:A32=Block A, Street 3, House 2

House numbers

Block tables

Fixing Position

TOOLS• For Eg. Colour coding for files/tools, tool

organizer to organize tools, shelf colour/tagging etc.• The purpose of 5S Seiton is to find a place for

everything within your working area, everything should be located as close as possible to where it is needed and at a location that is both safe and easily reached• Following are few eg.

EXAMPLES

Before After

Seiton for Store

Make your Store:• Search free• Air free• Climb/Bend free• Count free• FIFO

• Warehouse is where material is dumped in any quantity.• Store has Reserved Seats.

Two-Bin System

Kanban card

When bin is empty, card is placed here, to be picked up periodically by Purchase

Seiton

SEITONSuccess Indicator• Reduction in handling/searching timeChecklist• Are passage ways and storage places clearly

indicated?• Are commonly used tools and stationery

separated from those seldom used?• Are containers and boxes stacked up properly?• Are fire extinguishers and hydrants readily

accessible?• Are there grooves, cracks or bumps on the floor

which hinder work or safety?

3RD ‘S’- SEISO OR SHINY CLEAN UP 1/2

• Clean your workplace so that there is no dust. In workplace, it becomes easy to trace leaks, cracks etc.• This stage has two goals:1. Determine and gain agreement on the

desired level of cleanliness2. Learn how to make new routines so this will

become standardized (in the Seiketsu stage)• Several questions help this stage to be more than

just "polish until it shines for inspection":a. How much cleanliness is required for safety,

for ease of use, and to minimize equipment breakdown?

b. How clean should the environment be for comfort and morale?

SEISO 2/2c. How will cleanliness improve product

quality?d. While cleaning, do we notice maintenance

issues that should be addressed?

1. Surroundings2. Equipment3. Storage Areas

Cleaning Targets

Surroundings : What to Clean ?

1. Are there any unnecessary items around you ?

2. Are all files & folders immediately accessible ?

3. Is cleaning done every morning ?4. Is clearing up done every day

after work ?

Maintaining A Spotless Workplace

Example of ‘3S’

Factory Surroundings

FACTORY ENTRANCE SCRAP YARD

Front area and Scrap yard are comparable

SEITONIndicators of Success• Reduction in machine downtime• Increased life of machine parts• Reduction in number of accidents• Reduction in rejection/reworkChecklist• Are the floor surfaces dirty ?• Are machines and equipment dirty?• Are wires and pipes dirty or stained?• Are machine nozzles dirtied by lubricants and ink ?• Are shades, light bulb and light reflectors dirty?

4TH ‘S’- SEIKETSU OR STANDARDIZE

• This phase draws on the notes from the Seiso stage• A practical target is to have all workers

take five minutes every day to tidy up after themselves including the time to complete and sign the checklists• By dividing the work among all the

employees:a. No-one has a huge burdenb. No-one seems unproductivec. Morale improves because everyone has a

common purposed. Supervisors should monitor compliance with

Seiketsu. The checklists make this both important and achievable.

What Is To Be Standardised

• Workstation layout, work area layouts.• Work in Process (WIP).• Sequence of work.• Cycle time of work .• Material and tools used.• Machines and their process parameters.• Quality parameters, methods of measurement,

reaction plan and reporting method. • “ What, Where, When, Who & How ” of work .

METHODOLOGY TO PRACTICE ‘4S’

• Preparation of S.O.P.( Standard Operating Procedure) for all the activities to be carried out to maintain 1S,2S, & 3S.

• Following areas shall be covered while preparing S.O.P. : • Machine & Equipment maintenance.• Manufacturing Processes maintenance.• Work Place maintenance.• Quality Standards and Procedures maintenance.

SEIKETSUIndicators of Success• Number of areas/cover made transparent• Number of new problems exposed & solvedChecklist • Is the standardization system company-wide ?• Is the setting, revision , and abolition of

standards encouraged ?• Have official procedures been laid down for

setting, revising, and abolishing standards ?• Is accumulation of technology promoted ?• Are standards being utilized ?• Are standards up to-date and capable of being

put into practice

5TH ‘S’- SHITSUKE OR SUSTAIN 1/2

• Clear deliverables & communication.• Score Keeping• Continuous improvement

with cyclic mini-5S events.

Tools:• Training and Awareness of

5S• Dedicated 5S team• Clear 5S Map and

Responsibilities/Ownership.

SHITSUKE• Indicators of success• High Employee morale• Involvement of people in the movement• Checklist • Are regular 5S checks conducted?• Do people clean without reminder?• Do people follow rules & instructions?• Do people wear their uniforms & safety gear

properly?• Do people assemble on time?

THANK YOU