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5S BACK GROUND
5S-PRACTICE
SINCE THE EARLY’80’SJAPANESE INDUSTRIES
WIDELY PRACTISED 5S AS A POWERFUL
TECHNIQUE TOIMPROVE PRODUCTIVITY
& QUALITY. TODAY 5S IS USED IN MANY
COUNTRIES INCLUDING INDIA.
WHAT IS 5S?
5S-PRACTICE
A SYSTEMATIC AND RATIONAL APPROACH TO
WORKPLACE ORGANIZATION AND METHODICAL
HOUSEKEEPING WITH A SENSE OF PURPOSE
ELEMENTS OF 5S
5 COMPRISES 5 SIMPLE STEPS
5S-PRACTICE
1. SEIRI -- SORTING
2. SEITON -- SYSTEMATIC ARRANGEMENT
3. SEISO -- SPIC AND SPAN
4. SEIKETSU -- SERENE ATMOSPHERE/
SANITISING
5. SHITSUKE -- SELF DISCIPLINE
STEP-1 -- SORTING
5S-PRACTICE
IDENTIFY AND SORT TO SEGREGATE
USABLE FROM NON-USABLE ITEMS
SORTING
NOT IN WORKING IN WORKING
SCRAP ORDER ORDER
REWORKABLE REJECTED NECESSARY UNNECESSARY
REWORK DISCARD
NO REQ.SPL.
POTENTALLY
POTENTAL
USEFUL DISPOSAL
USE
REPAIRABLE UNREPAIRABLE
MOVE TO
ARRANGE
REQUIRED
DISPOSAL
REPAIR DISCARD DISCARD LOCATION
DISCARD
USABLE ITEMS
STEPS FOR SORTING
• REMOVE ALL GARBAGE AND UNNECESSARY
5S-PRACTICE
TOOLS FROM SHOP-FLOOR
• REMOVE UNNECESSARY PAPERS FROM FILES
•DISCARD OLD FILES ,STATIONERY NOT IN USE
• GIVE A HORIZONTAL & VERTICAL LOOK
(WALL&FLOOR) TO REMOVE ALL UNNECESSARY
ITEMS
•CLEN WALKWAYS
BENEFITS OF SORTING
•SAVES FLOOR SPACE
5S-PRACTICE
•HELPS TO GET RID OF OBSOLETE ITEMS
•GIVES A CLEAR IDEA OF MATERIALS IN STOCK
•PREVENTS INCIDENCE OF UNNECESSARY BUYING
•BETTERUTILIZATION OF EXISTING MATERIAL.
STEP-II
SYSTEMATIC ARRANGEMENT
5S-PRACTICE
A RATIONAL ,ORDERLY AND METHODICAL
ARRANGEMENT OF ALL ITEMS WE USE,
RE-WORK OR WRITE OFF.
STEPS FOR SYSTEMATIC ARRANGEMENT
•ENSURE RATIONAL LAYOUT OF MACHINES,EQUIPMENT,
5S-PRACTICE
CABINETS.
•PLACE FREQUENTLY USED ITEMS AT THE POINT OF USE
•PRE-FIX A PALCE FOR EVERYTHING AND PUT EVERYTHING
IN PLACE
•USE LABLES ,COLOUR CODES TO IDENTIFY
•USE INDEX FOR FILES,RECORDS,DRAWINGS
•PLAN STORAGE WITH EASY RETRIEVABILITY
5S-PRACTICE
•MIXED UP ITEMS IN CABINETS SHOULD BE
ORGANISED
•MAKECABINETS,SHELVES,RACKSSELF EXPLANATORY
THROUGH IDENTIFICATION AIDS
•HAVE VISUAL CONTROLS FOR CHECKING MISSING
ITEMS
PLACEMENT ON THE BASIS OF FREQUENCY OF USE
USABLE ITEMS
THINGS CONSTANTLY THINGS SELDOM USED BUT
INUSE STILL NEEDED
OCCASIONALLY
(HOURLY,DAILY,WEEKLY) (QUARTERLY)
USED(MONTHY)
PLACE CLOSE PLACE IN PLACE IN
TO MACHINE WORK AREA STORES
HOW AND WHERE TO STORE
BRAIN STORM ON THE FOLLOWING:
5S-PRACTICE
HOW AND WHERE CAN IT BE:
•EASILY STORED?
•EASILY IDENTIFIABLE?
•EASILY RETRIEVABLE?
•EASILY RETURNED TO ORIGINAL LOCATION?
IS THE STORAGE AREA EASILY IDENTIFIABLE?
BENEFITS OF SYSTEMATIC ARRANGEMENT
•MATERIALS EASILY AVAILABLE
5S-PRACTICE
•MATERIALS EASILY RETRIEVABLE
•LESSER PRODUCTION DOWNTIME
•MACHINE BREAKDOWNS HANDLED FAST
•TIME TAKEN TO SEARCH MINIMISED
STEP-III
SPIC & SPAN
•CLEANING NOT FOR BEAUTIFICATION ALONE BUT WITH A
SENSE OF PURPOSE
5S-PRACTICE
•KEEP OWN MACHINES AND WORKPLACES CLAEN THROUGH
•SWEEPING FLOORS AND SURROUNDINGS
•DUSTING TO MAKE DIRT FREE,COBWEB FREE
•WIPING TO MAKE OIL,GREASE,MOISTURE FREE
•POLISHING AND PAINTAING
•MAINTAINING SPARKLING CLEANLINESS
•INSPECTING FOR ANY PROBLEMS
•IDENTIFYING ROOT CAUSES AND ESTABLISHING CORRECTIVE
ACTION
STEPS TO SPIC & SPAN
• DEVELOP STANDARDS OF CLEANING
5S-PRACTICE
• CLEAN UP WORLPLACE AFTER USE
• CLEAN UP MACHINES AND TOOLS AFTER USE
• CLEAN UP SUPPLY LINES (NO
LEAKAGE,BLOCKAGE,CLOGGING WITH OIL/DIRT)
• ASSIGN CLEAR RESPONSIBILITIES AND SCHEDULES
FORCLEANING
• CLEAN WASTE BINS AT END OF SHIFT/DAY
•CLEAN LIGHT BULBS,FANS, SHADES,REFLECTORS
• PAY SPECIAL ATTENTION TO SCRAPYARD,
5S-PRACTICE
GARDENS,GODOWNS
• SCRAP AND CHIPS FROM MACHINES COULD FALL
DIRECTLY INTO COLECTING BINS
•USE BRAIN-STROMING AND PROBLEM SLOVING
TECHNIQUES TO IDENTIFY ROOT CAUSE
PROBLEMS FOR CORRECTIVE ACTION.
BENEFITS OF SPIC & SPAN
• CLEAN MACHINES AND FLOOR EXPOSE PROBLEMS
LIKE MACHINES CRACKS /OIL LEAKAGE FAST
5S-PRACTICE
• FAST CORRECTIVE ACTION
• TOOLS WELL LAID OUT
• SMOOTHER MATERIALS FLOW
• INVENTORY LEVELS CAN BE FOUND VISUALLY
• LESSER PRODUCTION DOWNTIME
• PRIDE TO EMPLOYEES
• GREATER CONFIDENCE OF CUSTOMERS
• HIGH PRODUCT QUALITY ACHIEVED
STEP-IV
SERENE ATMOSPHERE/STANDARDIZATION
5S-PRACTICE
FOLLOWING OF EARLIER 3S’s,STANDARDIZED
WORK PROCEDURES,MAINTAINING SAFE AND
HYGIENICCONDITIONS IN WORK - PLACE
CONTRIBUTE TO A SERENE ATMOSPHERE
STEPS TO SERENE ATMOSPHERE
IDENTIFY 5S AREAS
5S-PRACTICE
DEVELOP STANDARDS/EVALUATION CRITERIAWITH
WORKMEN (SOP”S”,HOUSE KEEPING STANDARDS)
ESTABLISH CHECKING PROCEDURE 5W+1H
ESTABLISH FEEDBACK PROCEDURES 5W+1H
STEPS TO SERENE ATMOSPHERE
• WEAR NEAT AND CLAEN UNIFORM
• WEAR PROTECTIVE CLOTHING
5S-PRACTICE
• PROVIDEADEQUATELIGHTING,VENTILATION,
EXHAUST
• CHECK ELECTRICALWIRING,CABLES,SWITCHES
•MAINTAIN SANITARY/HYGIENIC CONDITIONS IN
WASHROOMS,LOCKER ROOMS,CANTEENS AND
KITCHEN.
•EARMARK SMOKING AND EATING AREA
5S-PRACTICE
•LOOK FOR HEAVY NOISE ,VIBRATION AND
HEAT IN MACHINES ,ANALYSE FOR ROOT
CAUSE AND TAKE ACTION
•CREATE VISUAL CONTROL SYSTEMS
•DEVISE WAYS TO EXPOSE HIDDEN PROBLEMS
•CREATE STANDARDS
BENEFITS OF SERENE ATMOSPHERE
• STANDARDIZED PROCEDURES MINIMISE ERRORS
5S-PRACTICE
• PRODUCTIVITY INCREASE AS DEFECTS GO DOWN
• EASIER WORKING CONDITIONS
• SAFER WORKING CONDITIONS
• NUMBER OF NEW PROBLEMS EXPOSED AND SLOVED
• MORE OPPRTUNITIES TO MAINTAIN AND IMPROVE
QUALITY
• OWNERSHIP AND SENSE OF PRIDE AMONG EMPLOYEES
STEP-V
SELF DISCIPLINE
5S-PRACTICE
TRAINING,SINCERITY AND
CONSTANCY
OF PURPOSE IN THE FOLLOWING
THE RULES AND STANDARDS
DEVELOPED IN THE EARLIER 4S’s
STEPS TO SELF DISCIPLINE
• CREATE AWARENESS OF 4S
• DEVELOP ACTION DETAILS FOR MAINTAINING
STANDARDS
5S-PRACTICE
• MAKE THEM EASILY UNDERSTANDABLE
• GIVE SPECIFIC DIRECTIONS
• DISPLAY CORRECT WORK PROCEDURES ON THE FLOOR
• CORRECT DEVIATIONS ON THE SPOT
• MAINTAIN PUNCTUALITY
• CONDUCT AUDITS
• DEMONSTARATE SINCERITY IN FOLLOWING RULES
• SHARE SUCCESS TO ENTHUSE OTHERS
ADVANTAGES OF 5S
• NICE TO WORK IN A CLEAN,BEAUTIFUL,ORGANISED
WORKPLACE
5S-PRACTICE
• TIME TAKEN TO REACH THINGS MINIMISED
• LESSER TIME WASTED IN MATERIAL HANDLING
• PROBLEMS DETECTED FAST
• MACHINE/PRODUCTION DOWN-TIME REDUCED
• LOWER COST OF PRODUCTION
• MORE USABLE SPACE
• BETTER PREVENTIVE MAINTENANCE
• HIGHER EMPLOYEE INVOLVEMENT
•REDUCTION IN ERRORS/DEFECTS DUE TO
STANDARDIZED PROCEDURES
5S-PRACTICE
•CONSISTENT AND BETTER QUALITY PRODUCT
•HIGHER PRODUCTIVITY
•LESSER ACCIDENTS
•HIGHER EMPLOYEE MORALE
•MORE TIME FOR IMPROVEMENT ACTIVITIES
CRITICAL FACTORS /STEPS IN IMPLEMENTING 5S
•TOP MANAGEMENT COMMITMENT
•LEADERSHIP BY LOCATION HEAD
5S-PRACTICE
•AWARENESS TRAINING PROGRAMME FOR ALL
EMPLOYEES (CONCEPTS,RULES,STEPS,BENEFITS)
•LAUNCHING OF 5S PROGRAMME,PROMOTION
THROUGH BADGES,POSTERS,BOOKLETS,BANNERS
•ALLOCATION OF FUNDS
•IDENTIFICATION ON 5S AREAS
•TEAM FORMATION INVOLVING WORKMEN
•DEVELOPING STANDARDS
•DEVELOPING CHECKLISTS
•GUIDANCE,TRAINING,SORTING OUT PROBLEMS
5S-PRACTICE
•DEVELOPING AUDIT CHECKLISTS
•PUBLISHING AUDIT RESULTS
•REVIEWING AUDIT FINDINGS,FOLLOW UP,
CORRECTIVE ACTION
•HOLDING COMPETITIONS-AWARDS.
METHODOLOGY
•ALL EMPLOYEES TO UNDERGO HOUSE KEEPING TRAINING
•A VISION STATEMENT TO BE EVOLVED AND STARTED
5S-PRACTICE
WITH ALL EMPLOYEES
•DIVIDE THE ORGANISATION INTO CONVENIENT ZONES
•DIVIDE EACH ZONE INTO CONVENIENT SUB-ZONES
•DECIDE ON DATE(S)FOR LAUNCHING HK IN EACH
ZONES/SUB ZONES
•TAKE PLEDGE
•APPLY 5S PRINCIPLE ,STEP BY STEP
•FORM AUDIT TEAMS
•CARRY OUT AUDITS.
IMPLEMENTATION OF 5S
IDENTIFY EXISTING STATUS TAKE PREVENTIVE
UNDER 5S CONCEPT ACTION
5S-PRACTICE
IDENTIFY SPECIFIC ASSIGN RESPONSIBILITY
WEAKNESSES THROUGH 5W+1H
DETERMINE ROOT VERIFY WHETHER
CAUSES OF EACH ACTIONS ARE EFFECTIVE
DETERMINE SOLUTION REVIEW PERIODICALLY
TAKE REMEDIAL ACTION THINK & LOOK FOR
BETTER IDEAS
DETAILS OF 5S OPERATIONS IN A ZONE
1) EACH ZONE TO BE SUB DIVIDED INTO
SUB-ZONES
5S-PRACTICE
2) EACH SUB-ZONE TO HAVE A MAIN
COORDINATOR.ALL OTHERS WORKING IN
THAT SUB-ZONE TO WORK JOINTLY WITH
THE MAIN COORDINATOR
3) EACH MEMBER TO THE SUB-ZONE MAY BE
ASSIGNED A SPECIFIC TASK BASED ON
MUTUAL CONSENT/CONVENIENCE.
4) BASED ON THE AUDITOR’S CHECK LIST,EACH
MEMBER WILL BE REQUIRED TO MAINTAIN A
RETENTION PLAN OF ALL DOCUMENTS.
5S-PRACTICE
DOCUMENTS WHOSE “DESTRUCTION DATE”
CANNOT BE DECIDED,SHOULD BEAR A REVIEW
DATE (e.g:R 30.9.95) .ALL OTHER DOCUMENTS
TO BEAR A REVIEW DATE(D30.9.95)
5) ALL MEMBERS TO MAINTAIN A LIST OF ALL
ITEMS IN HIS/HER CUSTODY AND THEIR
RESPECTIVE LOCATIONS .
6) A PAPER DESTRUCTION DAY TO BE
OBSERVED ONCE A QUARTER
5S-PRACTICE
7) EVERY EMPLOYEE TO SPEND 10-15
MINUTES A DAY TOWARDS HOUSE KEEPING
8) IF NEED BE, A CHANGE IN LAYOUT MAY BE
CARRIED OUT.
9) EMPLOYEES MAY VOLUNTARILY BEAUTIFY
THEIR WORK AREA
10) TO INTRODUCE AS MANY VISUALS AS
POSSIBLE
5S-PRACTICE
11) TO KEEP THINGS IN THEIR ASSIGNED
PLACES
12) AN INTERNAL BULLETIN ON HOUSE
KEEPING IS RECOMMENDED
13) ON-GOING TRAINING PROGRAMMES ON
HOUSE KEEPING
14) COMPETITIVE “BENCHMARKING” AMONG
ZONES.
LEVELS OF HOUSE KEEPING
•HOUSE KEEPING OF ONE’S INNER SELF
5S-PRACTICE
•FOLLOWING THE 5S PRINCIPLES AND REDUCING WASTE
•EXTENDING THE 5S CONCEPT TO INCLUDE ERGONOMICS
•EXTENDING THE 5S CONCEPT TO INCLUDE AESTHETICS
•MAINTAINING RECORDS AND EDUCATING OTHERS
5 STAGES OF HOUSE KEEPING
FLOOR IS DIRTY AND FULL OF UNNECESSARY MATERIALS
5S-PRACTICE
UNNECESSARY MATERIALS AND DIRT IS FOUND SWEPT TO
THE WALLS
SHOP-FLOOR AND OFFICE FLOOR IS CLAEN BUT
TOOLS,PAPRES,FILES,MATERIALS ARE DISORGANISED
STORES,YARDS,GARDEN,M/C.,OFFICE,SHOP-FLOOR ARE
CLEN,FURNITURE,DOCUMENT,MATERIAL ARE ORGANISED
FACTORY,OFFICE,CANTEEN,WASHROOMS,GARDEN ARE
SPIC AND SPAN.
CRITERIA FOR GOOD HOUSE KEEPING
AWARDS
5S-PRACTICE
• SPACE OCCUPIED
•EASE OF RETRIEVAL
•INGENIOUS STRONG METHODS
•WASTE ELIMINATION
•AESTHETICS
5S AUDIT CHECK SHEET:SEIRI
DIVISION: DEPARTMENT: SECTION:
ACT ION T O
T IT LE IT EM CHECH POINT S MARKS
BE T AKEN
LIT T ER ON CLEANED
FLOOR PERIODICALLY
5S-PRACTICE
DUST FREE /NO
MACHINERY
UNUSED MACHINERY
CLAEN /PROPERT Y
FURNIT URE
ARRANGED
NO UNNECESSARY
T OOLS/JIGS
T OOLS AND JIGS
WIP IDENT IFIED
NON IDENT IFIED /NOT
CONFORMING PRESENT IN WORK
SEIRI(SORT ING) PRODUCT S PLACE
IDENT IFIED/NO
RM
UNUSED MAT ERIALS
POST ERS/NO
T ICE CLAEN/UPDAT ED
BOARDS
UNWANT ED PAPERS
FILES/T AGS/
REMOVED. NO
DAT A
OBSOLET E IT EMS
SHEET S
AROUND
MISC.IT EMS IDENT IFIED,ST ORED
T OT AL
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