INTERNATIONAL BUSINESS CENTRE (IBC)

ONE DAY TRAINING PROGRAMME ON

at : M/s. BRITACEL SILICONES LTD. ,

GOA
ON 2 ND MARCH- 2010
IBC-098241 13673 /

 Having total 26+ years experience in the corporate fieldWas

working with Bajaj Auto, Kabra, Cadila & Siddhivanayak group
SINCE 12YEARS AS A GOVT.APPROVED SENIOR
MANAGEMENT CONSULTANT
Have conducted more than 2000+trg.programmes , workshops,
seminars & trained more than 50,000+ Employees / Participants
in India & Abroad
Transformed more 1000+ peoples life due to effective & quality
training on attitude, behavior ,discipline & culture
More than 5000 + people left guthka , bidi , cigarette as a personal
mission & social activities.
Planted & arranged to planted more than 10000 + trees to save
environment .
Official Visited at: UAE, New Zealand , Bangkok (Thailand) &
Hong Kong
Expertise in ISO, HRD, TQM, Marketing - Training and
Development.
Life member and Associated with :
1) National HRD Network, Hyderabad
2) ISTD, New Delhi
3) Hare Rama Hare Krishna International (ISKON), Mumbai
4) Art of Living , Bangalore IBC-098241 13673 /
5) Brahmakumaris and many National & Intl. organizations.

AJAY B. DESAI
National Trainer
& Lead Auditor IRCA UK
B.Com, LLB, MBA &
MPhil (TQM)
Approved by
2
QCI &TEX.Mini.Delhi

LOCATIONS OF IBC

CORPORATE OFFICE: 109/110, 1ST FLOOR, EMERALD 7 JEWELS BLDG, RLY STATION
ROAD, VAPI (E)- 396191, GUJARAT STATE, INDIA. TEL: (0260) 2421099 / 2422283 MOB: 98241
13673

SURAT & ANKLESHWAR : 540, GOLDEN POINT, NEXT TO BSNL BHAVAN / PARK INN, RING
ROAD, SURAT - 395007 MOB:9377890287

SURENDRANAGAR & RAJKOT: JANTA ICE FACTORY ROAD, BEHIND JAWAHAR SOCIETY,
SURENDRANAGAR - 363001
TEL: (02752) 222849 MOB: 98258 99360
MUMBAI : TEL: 28699059/ MOB: 9920687074

E-MAIL: info@ibciso.com / ibc7ajay@rediffmail.com

WEBSITE: www.ibciso.com

GOVT. RGN. NO. : 3950201107 MC/MR/ST/47/2001-2002

IBC-098241 13673 /

WHAT IS 5S ?
5S

IBC-098241 13673 /

 5S IS A SYSTEMATIC APPROACH USING FIVE

IMPORTANT STEPS TO CREATE A CONDUCIVE (COOPERATIVE) WORK ENVIRONMENT.
5S IS A PARTICIPATIVE PROGRAM INVOLVING EVERY
ONE RIGHT FROM TOP MANAGEMENT TO JUNIOR
MOST PERSON OF THE ORGANIZATION.
5S CREATES SOUND FOUNDATION FOR CONTINUOUS
IMPROVEMENT AND WORLD CLASS
MANUFACTURING PRACTICES.
5S CAN BE GAINFULLY ADOPTED BY EVERY
INDIVIDUAL AT HIS/HER WORKPLACE, OFFICE, OR
HOME TO MAKE IMPROVEMENT
IBC-098241 13673 /

WHAT 5S STANDS FOR?

5S STANDS FOR 5 INITIALS OF THE
FOLLOWING JAPANESE WORDS (RELATED
ENGLISH WORDS)

1.
2.
3.
4.
5.

Sei -ri
Sei-ton
Sei-so
Sei-ke-tsu
Shi-tsu-ke

(Sort)
(Set in order)
(Shine/ Cleanliness)
(Standardize)
(Sustain)

5S

5S
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OVERVIEW OF 5S
Sr.NO

5S

SEI-RI

5S

SORT

BRIEF DESCRIPTION

ORGANIZATION:
CLEARLY
DISTINGUISH BETWEEN NECESSARY &
UNNECESSARY. GET RID OF UNNECESSARY

SEI-TON

SEI-SO

SET IN
ORDER

ORDERLINESS:

SHINE

CLEANLINESS:

KEEP NEEDED ITEMS IN A SPECIFIC

PLACE FOR EASY ACCESS WHEN
NEEDED
KEEP THE WORKPLACE AND ITEMS
CLEAN AND SHINING

SEI-KE-TSU STANDARDIZE STANDARDIZE:

MAKE STANDARDS FOR MAKING &
MAINTAINING EVERYTHING CLEAN
AND IN PLACE

SHI-TSU-KE SUSTAIN
IBC-098241

SELF-DISCIPLINE:
MAKE A HABIT OF MAINTAINING
ESTABLISHED STANDARDS AND
PROCEDURES
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BENEFITS OF IMPLEMENTING 5S

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 WORKPLACE BECOMES CLEAN & BETTER

ORGANIZED.
SHOP FLOOR AND OFFICE OPERATIONS BECOME
EASIER AND SAFER.
TIME LOST DUE TO UNNECESSARY SEARCHING ARE
MINIMIZED.
MACHINE BREAKDOWNS ARE REDUCED.
CONSUMABLES AND MATERIAL WASTAGE ARE
MINIMIZE.
RESULTS ARE VISIBLE TO EVERYONE - THE INSIDER
AND OUTSIDER.
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 PEOPLE DEVELOP SELF-DISCIPLINE AND POSITIVE

ATTITUDE.
EMPLOYEES DEVELOP TEAM SPIRIT AND SENSE OF
ACHIEVEMENT.
COMPANY IMAGE AND EMPLOYEES MORALE
ENHANCED.
OVERALL QUALITY OF PRODUCTS AND PROCESSES
CONTINUOUSLY IMPROVE.
QUALITY OF YOUR LIFE AT WORKPLACE & HOME
BECOMES BETTER & BETTERAND SO MANY..
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HOW TO IMPLEMENT 5
S ?

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11

THE FOUNDATION FOR

LEAN MANUFACTURING
STEP 1: ROADMAP &
PROMOTION PLAN
STEP 2: INITIAL AUDIT
STEP 3: IMPLEMENT SEIRI
STEP 4: IMPLEMENT SEITON
STEP 5: IMPLEMENT SEISO
STEP 6: IMPLEMENT SEIKETSU
STEP 7: IMPLEMENT SHITSUKE

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1
ROAD MAP &
PROMOTION
PLAN

STEP-2

STEP-3

INITIAL
AUDIT

1ST S
SEIRI

2ND S
SEITON

STEP-5

SEVEN STEPS
PROMOTION PLAN
INITIAL AUDIT
SERI
SEITON
SEISO
SEIKETSU
SHITSUKE

STEP-4

3RD S
SEISO
STEP-7
5TH S
SHITSUKE

STEP-6
4TH S
SEIKETSU

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STEP1 :
5S ROAD MAP &
PROMOTION PLAN

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1: ACTIVITIES
STEP-1

ESTABLISH 5S POLICY

PROMOTION
PLAN

ESTABLISH COMPANYS OBJECTIVES

ESTABLISH A 5S STEERING COMMITTEE
DEVELOP A WORK PLACE AREA MAP

STEP-1: PROMOTION PLAN

DEVELOP A 5S IMPLEMENTATION PLAN

OBJECTIVE:
TO PROMOTE 5S IN WORKPLACE

ORGANIZE RESOURCES

TOOLS:
5S IMPROVEMENT PLAN
5S AREA MAPS

TRAIN THE TEAM MEMBERS

FORM AREA TEAMS

AUDIT

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STEP2 :
INITIAL AUDIT

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1

STEP-2

STEP-3

STEP-4

PROMOTION
PLAN

INITIAL
AUDIT

1ST S

2ND S

SEIRI

SEITON

STEP-5

STEP-2
OBJECTIVE:
TO IDENTIFY CURRENT STATE
TO DEVELOP AREA SPECIFIC 5S
IMPROVEMENT PLAN
TECHNIQUES:
CURRENT STATE PHOTOGRAPHY
AUDIT SHEETS

3RD S

SEISO

STEP-7
5

TH

SHITSUKE

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STEP-6
4TH S

SEIKETSU

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OBJECTIVE OF INITIAL AUDIT?

THE PURPOSE OF INITIAL AUDIT IS TO ASSESS
HOW BAD YOUR WORKPLACE IS?

THE 5S AUDIT SURVEYS THE CURRENT

CONDITION OF WORKPLACE. IT USES
FOLLOWING TECHNIQUES:
- 5S AUDIT SHEET
- PHOTOGRAPHY/VIDEO BEFORE STARTING
AND AFTER 5S ACTIVITIES
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STEP 3:
IMPLEMENT SEIRI SORT
st
- 1 S

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1

STEP-2

STEP-3

STEP-4

PROMOTION
PLAN

INITIAL
AUDIT

1ST S

2ND S

SEIRI

SEITON

STEP-5

STEP-3

3RD S

SEISO

OBJECTIVE:
GET RID OF UNWANTED ITEMS
TOOLS:
CLASSIFICATION
RED TAGGING

STEP-7
5

TH

SHITSUKE

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STEP-6
4TH S

SEIKETSU

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SEIRI: SORT
THE VERY FIRST S OF 5S ACTIVITY

SORT ACTIVITY MEANS GET RID OF ALL SUCH

ITEMS FROM THE WORK PLACE, WHICH ARE
NOT NEEDED FOR CURRENT PRODUCTION (OR
OFFICE) OPERATIONS

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STEP 4:
IMPLEMENT SEITONSET IN ORDER- 2 nd S

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1

STEP-2

STEP-3

STEP-4

PROMOTION
PLAN

INITIAL
AUDIT

1ST S

2ND S

SEIRI

SEITON

STEP-5

STEP-4
SET IN ORDER
OBJECTIVE:
TO DECIDE APPROPRIATE LOCATION
FOR SPECIFIC ITEMS
DETERMINE ADDRESS FOR
SPECIFIC ITEMS
TECHNIQUE:
SIGN BOARDS

3RD S

SEISO

STEP-7
5

TH

SHITSUKE

IBC-098241 13673 /

STEP-6
4TH S

SEIKETSU

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2 nd S SEITON:SET IN ORDER
(Better System Better Work)

SEITON MEANS
ARRANGE CORRECTLY IN ACCORDANCE
WITH THE CORRECT METHOD OF DOING
ACTIVITIES.
MAKE THOROUGH PREPARATION SO THAT
ACTIVITIES CAN BE DONE EVEN IF THEY
OCCUR ABRUPTLY.

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STEP 5:
IMPLEMENT SEISO
3 RD S

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1

STEP-2

STEP-3

STEP-4

PROMOTION
PLAN

INITIAL
AUDIT

1ST S

2ND S

SEIRI

SEITON

STEP-5
STEP-5

SHINE & SWEEP

OBJECTIVE:
TO USE CLEANING TO IDENTIFY
ABNORMALITIES
MAINTAIN CLEANLINESS
TECHNIQUE:
VISUAL & PHYSICAL SWEEPING

3RD S

SEISO

STEP-7
5

TH

SHITSUKE

IBC-098241 13673 /

STEP-6
4TH S

SEIKETSU

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3 rd S

SEISO :SHINE & SWEEP

WHY SEISO?

(CLEANING & INSPECTION)

DURING WORK, IN ADDITION TO THE DESIRED

OUTPUTS, CERTAIN SCRAPS, TRASH(JUNK,DEBRIES),
AND DIRT ARE ALSO GENERATED.
THE TRASH AND DIRT GET DEPOSITED ON TOOLS,
MACHINERIES AND OTHER ITEMS. IN ORDER TO
RESTORE THE ITEMS (MACHINE, TOOLS, WORK-PLACE)
IN ITS ORIGINAL CONDITION, UNDESIRABLE SCRAPS,
LEFT OVER MATERIALS, TRASH AND DIRT ARE
REMOVED.
THE SEISO IS A CLEAN-UP ACTIVITY IN ORDER TO CREATE A
SHINING WORK PLACE.

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STEP 6:
IMPLEMENT
SEIKETSU
4 th S

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1

STEP-2

STEP-3

STEP-4

PROMOTION
PLAN

INITIAL
AUDIT

1ST S

2ND S

SEIRI

SEITON

STEP-5
STEP-56

STANDARDIZE
OBJECTIVE:
TO CONSOLIDATE FIRST 3SS
BY STANDARDIZATION
DETERMINE BEST PRACTICES
TECHNIQUE:
VISUAL MANAGEMENT

3RD S

SEISO

STEP-7
5

TH

SHITSUKE

IBC-098241 13673 /

STEP-6
4TH S

SEIKETSU

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OBJECTIVES OF SIEKETSU
TO CONSOLIDATE THE FIRST 3SS BY
ESTABLISHING STANDARD
PROCEDURES
DETERMINE THE BEST WORK
PRACTICES AND ENSURING THAT
EVERY ONE PERFORMS HIS/HER WORK
IN THE SAME BEST WAY

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STEP 7:
IMPLEMENT
SHITSUKE5 th S

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5S: SEVEN STEP IMPLEMENTATION PLAN

STEP-1

STEP-2

STEP-3

STEP-4

PROMOTION
PLAN

INITIAL
AUDIT

1ST S

2ND S

SEIRI

SEITON

STEP-5
STEP-7

SUSTAIN
OBJECTIVE:
TO SUSTAIN IMPROVEMENTS
MADE BY 5S ACTIVITIES
DEVELOP A 5S CULTURE
TECHNIQUE:
5S PROMOTION REWARD &
RECOGNITION

3RD S

SEISO

STEP-7
5

TH

SHITSUKE

IBC-098241 13673 /

STEP-6
4TH S

SEIKETSU

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OBJECTIVES OF SHITSUKE
TO SUSTAIN IMPROVEMENTS AND MAKE
FURTHER IMPROVEMENTS BY ENCOURAGING
EFFECTIVE USE OF 5S
TO CHANGE THE ATTITUDE OF PEOPLE AND TO
MAKE A HABIT OF PROPERLY MAINTAINING
STANDARD PROCEDURES
TO CHANGE THE CORPORATE CULTURE FOR
MAKING PEOPLE-DRIVEN CONTINUAL
IMPROVEMENT
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WHY NOT START 5S

TODAY?

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IBC-098241 13673 /

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