5s

Key to work place improvement

Kaizen Institute Africa Asia Pacific
402, Abhishek 72, B.M.M. Society Ellis Bridge Ahmedabad 380006 - India Tel: + 91 79- 6588634 / 9562 / 5616 Mobile: (0) 9825073146 Email: jmurthy@kaizen-institute.com

Lead By: Jayanth Murthy

www.kaizen-institute.com
KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Putting 5s to Work
Who does not like a -Clean -Orderly -Disciplined Environment ? At home & At work !!!

5s AIMS at achieving this state

Mess ?!

Clean & Organized Puts A Smile On Your Face !

One Way to Do It !!

The 5s Way To Do It !!

One to Keep Files !

The 5s Way To Do It !!

The 5s Way To Do It !!

The 5s Way To Do It !!

The 5s Way To Do It !!

5-S
Seiri - sort out Seiton -systematic arrangement Seiso - Scrub clean, Spic & Span Seiketsu Standardize - State the rules Shitsuke - Self-discipline (Follow rules)
KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Step Zero - of 5s Identify strategic Spots & take Photos / Video To Capture Current Status

1st Step of 5s

SEIRI
Sorting of all items
Segregate Necessary from Unnecessary Take action on Unnecessary

Red Tagging & Red Tag Areas (set Rules first) Heaps to Come out 10 trucks (in a factory)

Red Tag To, Stock Facilities Locations / Space Documents Computer Files Machines Stationary Not People !!

When In Doubt, Throw It Out !

Seiri
Classify into: wanted, ? and unwanted Discard unwanted Create red tag area for ? Wanted but not here items Wanted but not in this Qty Move ? Items to red tag Wanted but not now area Not Wanted at all Put red tag on unmovable ? items
KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Before Seiri

Before Seiri

Before Seiri

After Seiri

2nd Step of 5s

SEITON
Systematic Arrangement A Place For Every Thing & Every Thing In Its Place Arrange Necessary Items Systematically Easy to identify, find, take & put back

Everything to have a place & label

This Leads To Standardizing Of Storage. Any Body Can : - See Things (floor lines, door opening lines, labels etc) - Can Take out it fast (less than 30 sec) - Can Return It - Where, What, How Many ? (Define & label)

Seiton

Make Place for all wanted items Target: Max searching time: 30 seconds Sign boarding/labeling Outlining Color Coding Visual Controls

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Does It Ring A Bell ?

Before

Before

Before

After Seiton

After Seiton

Before

After Seiton

After Seiton

After Seiton

After Seiton

The 5s Way To Do It !!

After Seiton

After Seiton

After Seiton

After Seiton

Before Seiton

After Seiton

After Seiton

After Seiton

After Seiton

3rd Step of 5s

SEISO
Spic and Span Collective Cleaning
Autonomous Cleaning
Cleaning is Inspection Cleaning with meaning Seiso Boards (tools) Seiso calendar & responsibility charts Decide What, When, Who and How to clean

Seiso

COT Cleaning with meaning Seiso calendar/map

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Cleaning using your own hands

Cleaning using your own hands

After Seiton

Before

After Seiton

After Seiton

Before

After Seiton

Seiso Board

Seiso Board

4th Step of 5s

SEIKETSU
Standardization (so that first 3

S is maintained AND

No Unnecessary items pile up No Mess / out of place items No - Dirt Make the rules & Follow them SDCA
5 min / 10 min 5s Setting Standards

Seiketsu
Setting up of Rules: Place token when tool (or file) is taken Make schedule to restore basic conditions Establish measures to track adherence to rules answer the 5w1h as regards first 3 S

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Token System For Tracing Tools

Token System For Tracing Tools

Standardize First Aid Point, Emergency Tel No & the Telephone next to it !!

5th Step of 5s

SHITSUKE
Self Discipline Training & People Involvement Follow the rules set (if not use ..Retraining / Disciplinary Measures !)

Photo Gallery
Slogans Audit Radar Charts

Shitsuke
Self Discipline of adhering to Rules: Adhere to rules yourself Post adherence on visual displays Spread rules and adherence by teaching others and tracking everybodys performance on visual displays

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Audit Format

- For Office Environment 5s Audit

- For Production / Factory Environment 5s Audit

- Casting a Radar Chart & Keeping it Updated

Some More Cases On 5s

Seiton

Seiton

Seiton

Seiton

Seiton

Seiri

Seiton

Seiso

Seiton

Seiton

What is 5s ?
Seiri Sorting of all items Segregate Necessary from Unnecessary Take action on Unnecessary

Seiton Systematic Arrangement Arrange Necessary Items Systematically Easy to identify, find, take & put back Everything to have a place & label Seiso Spin & Span Everything to be clean Use cleaning as inspection
Seiketsu Setting Standards Set standards & rules 5 min / 10 min 5s Audit Shitsuke Self Discipline Training & People Involvement

5s Requires Team Work

Three More Things

1 Top management Commitment

2 Top management Commitment 3 Top management Commitment

KAIZEN INSTITUTE OF AMERICA KAIZEN INSTITUTE OF EUROPE KAIZEN INSTITUTE: AFRICA-ASIA-PACIFIC

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Founder:
Head (Bus. Dev): Africa-Asia-Pacific:

Masaaki Imai
Bud H. Cox

S.Gondhalekar, Mumbai Jayanth Murthy, Africa S.Durairajan, Chennai ,V.K.Grover, Pune Kristianto Jahja , Jakarta

Over 160 consultants worldwide.

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Consulting Clients in Africa-Asia Pacific:

Bidco, Nairobi Spinners and Spinners, Kenya Superfoam Ltd, Kenya Taj group of hotels Milton Plastics Bombay Oil Industries

Rallis, India & Hitech Gears (supplier to Honda) Latest additions (from March 2000): Spencon - Uganda / Zambia / Kenya Comcraft Group Of Companies Power techniques .
KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Unique Features of Consultancy:

Hands-on consultants Implementation in shortest time Cash-stingy solutions Energizing people Release of latent capabilities Human development Learning organization
KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN