5S is basically a structured and rational approach to methodical housekeeping built on a sound economic

basis. 5S became a company wide practice in Japanese industries in the early 80s which demonstrated
to be a powerful technique to enhance Productivity and Quality Improvement. This is a Japanese concept
using 5 simple steps involving all employees including top management to create a conducive work
atmpsphere.
By effective use of this technique one can get significant beneficial results in personal life also.
SEIRI - Sorting out
SEITON - Systematic arrangement
SEISO - Spic and span
SEIKETSU - Serene atmosphere
SHITSUKE - Stick to self discipline
SEIRI - Sorting Out
Looking at ones worl place and home we find many things which are not needed are mixed and kept
together with required ones. This occupies valuable space, account for record keeping costs making it
difficult to trace needful things and surroundings become untidy.
SEITON - Systematic Arrangement
Once the things are sorted out a little effort is required in arranging them. Otherwise, out of several needy
things it would consume more time in taking out the thing you need at any point of time. Hence, plan
rationally about the placement, location of each item, properly identify them to reduce the time of searching
and for easy accessibility and traceability during the time of need.
SEISO - Spic and Span
This is basically to keep the place, surroundings and all items belongings there in clean and tip-top
condition for a beautiful outward appearance but also exposes sources of trouble like oil leakage and
cracks on machine, equipment, walls thus enabling immediate corrective action.
This in turn increases the morale, confidence and inculcates a sense of pride in all employees.
5S
SEIKETSU - Serene atmosphere
Serene atmosphere can be established and maintained by following the above three steps along with
maintenance of safe and hygienic work conditions as per norms.
Developing the habit of wearing clean clothes and following safety rules.
All electrical equipments should be in proper working conditions by which safety can be ensured.
Sanitary conditions in wash rooms, locker rooms, canteens, kitchen, should be maintained.
The work place should be clean, orderly and safe.
Stick to SHITSUKE Self-discipline
This is the most important aspect of 5S as the effective implementation of the first 4S depends on how
disciplined an individual is. Thus mathematically we can explain this as: -
SEIRI, SEITON, SEISO, SEIKETSU = f (SHITSUKE)
A self-disciplined individual only can get a cumulative (effect of the 1st 4S. Hence, 1st 4S is a function of the 5th S.
It thus become mandatory to follow the rules for working as per standard, which becomes the key attribute
towards the success should be conducted to detect and correct any deviations from standards.
REDUCTION IN
COST OF
PRODUCTION
BETTER QUALITY
SYSTEM
IMPROVED WORK
HIGH EMPLOYEE
SAFER WORK PLACE
CONDUCTIVE WORK PLACE

SEIRI SORTING OUT
SEITON SYSTEMATIC
ARRANGEMENT
SEISO SPIC AND SPAN
SEIKETSU SERENE ATMOSPHERE
SHITSUKE STICK TO SELF DISCIPLINE
FOUNDATION 80%

The base or foundation of 5S is Shitsuke i.e. Self discipline, which contributes to 80%, this
should be strong and made stronger for effective implementation of the lst 4S which
contributes 20% as cumulative.

By effective implementing the 5S technique with some creativity, common sense and
professionalism one can achieve a Reduction in cost of Production to have a competitive
edge in the market. This indeed the first step towards contineous improvement
DATE : 29, June, 2000
NO
1 5S and Stop Leakage
Due to leakage of CTA from sealing of P-1756, gear box bearing
has been damaged and we shut down both Plant for around half day.
In this connection I would like to emphasize importance of 5s activity
and any leakage of fluid should be stopped or some countermeasure taken
to minimize leakage.
Never ignore leakage, such as acetic acid, PTA, water and steam, any kind of fluid.
If it is impossible to stop perfectly, countermeasure as follows shall be taken :
1) Install backet or hose avoid spread out
2) Install plate to avoid contacting to surrounding devices
All employees are requested to conduct 5S activity 30 minutes in shift from 30th
to 3rd July. Shift engineer is a leader to decide cleaning area and report to
daily report.
1st Shift : 13;00 - 13:30, 2nd shift : 18:00 - 18:30, 3rd Shift : 3:00 - 3:30 (for Example)
All oil gauges should be cleaned and make it easy to find out abnormal oil condition.
OVER N. Fukuda
JOB INSTRUCTION ( CTA / PTA )
INSTRUCTION NOTE
OPERATOR S / I STAFF CHIEF SR MGR