5S

TRAINING
 MODULE STRUCTURE
Session Duration
1. Session 01 - Importance of Target and Our Vision 15 Minutes
2. Session 02 - An Over-view of 5S 15 Minutes
3. Session 03 - 1S - SEIRI 30 Minutes
4. Session 04 - Genba Exercise (1S Master list) 15 Minutes
5. Session 05 - Genba Exercise (1S Master list-Distinguish) 15 Minutes
6. Session 06 - 2S - SEITON (Examples) 30 Minutes
7. Session 07 - 2S - Genba Exercise 30 Minutes
8. Session 08 - 3S - SEISO 15 Minutes
9. Session 09 - 3S - Check sheet 15 Minutes
10. Session 10 - 4S - SEIKETSU 15 Minutes
11. Session 11 - 5S - SHITSHUKE 15 Minutes
12. Session 12 – SUMMARY 5S 30 Minutes

MODULE DURATION : 04 HOURS

 SESSION 1
Importance of Target and Our Vision

DURATION : 15 MINUTES
Nothing is impossible……………..
IF YOU WORK WITHOUT TARGETS, IT WILL BE LIKE…

WITHOUT A LIGHT HOUSE

SHIP

WITHOUT WICKETS

CRICKET
IF WE DON’T FIX TARGET, WE DON’T KNOW WHERE WE HAVE TO GO
IF YOU WORK WITH TARGETS, IT WILL BE LIKE…

MOVING TOWARDS

SHIP LIGHT HOUSE

WITH

CRICKET WICKETS
FIX THE TARGET
BE CLEAR ABOUT YOUR TARGET
EVERYTIME WE FIX HIGHER TARGET, WE
WILL STRETCH OURSELF AND
PERFORM BETTER
TARGET

TARGET STOPS US FROM

DOING UNPRODUCTIVE JOBS

TARGET PREPARES US TO
GO AHEAD TO REACH THE
SET GOAL

TARGET GIVES US A GREEN

SIGNAL IF WE ARE ON THE
RIGHT PATH
What is important to construct a
strong building ?
 Strong, Good
Foundation
is the basic criteria to construct
a rigid structure !
What is our Company’s vision ?
Building
Infrastructure
Globally
Is the foundation
What is 5S ?

NEXT SESSION
 SESSION 2
An Over-view of 5S

DURATION : 15 MINUTES
 5S
5S
1S-SEIRI 2S-SEITON

5S-SHITSHUKE

ETPL

3S-SEISO
4S-SEIKETSU
 Visual Factory
• “Ability to understand the status of a production area
in 5 minutes or less by simple observation without use
of computers or speaking to anyone.”
 Objectives of 5S
1. VISUAL WORKPLACE

2. SAFE WORKPLACE

3. PRODUCTIVE WORK PLACE

4. STANDARDISED WORK
PLACE

5. PLEASANT WORK PLACE

What we do on BHOGI festival ?

•Segregate unwanted things.

•Keep it away. Why ?
•Burn / throw out.
 But what about our working area ?
In the following pictures, identify some of the”
Abnormalities”

Abnormalities

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 Tomo Sugiyama’s wisdom
People leave trash. People tolerate it. No one step to
pick up.
 Tomo Sugiyama’s wisdom
People leave trash , some do not tolerate it , pick it up
 Tomo Sugiyama’s wisdom

People do not leave trash , people do not tolerate it ,

Everyone picks it
 SESSION 3
1S - SEIRI

DURATION : 30 MINUTES
How to get first level?

MR.DOUBT
 Key 1: Seiri (Sorting)

Distinguish
Distinguish Between
Between What
What Is
Is Needed
Needed And
And Is
Is Not
Not
Needed
Needed
 Before starting 1S,

Let me tell you a story…

I am the goddess who give you all the
below things. Who am I ?
I am the goddess who give you all the
below things. Who am I ?

                               
 I am the
goddess of
good fortune &
wealth .
I am the goddess who gives you all the below
things. Who am I ?
I am the goddess who gives you all the below
things. Who am I ?
I am the goddess who gives you all the below
things. Who am I ?
 I am the
goddess of
poverty &
odium
Once upon a time…..
 Both the goddess had a competition of who is

beautiful among them and they went to Narada for

judgment
Narada, tell me
who is beautiful
among us ?
 Lakshmi, you are beautiful
when you ENTER & Moodevi,
you are beautiful when you
You both are
EXIT
equally beautiful…..
 Theme
Good
Good
things
things are
are
beautiful
beautiful
when
when they
they enter
enter
and
and bad
bad things
things
when
when they
they exit
exit
Now what do you want ?

Good things to enter

Or

Bad things to enter

To receive Lakshmi to our house/ factory /
anywhere , what should we do ?
HOW TO DO 1S?

NEXT SESSION
 SESSION 4
GENBA EXERCISE (1S MASTER LIST)

DURATION : 15 MINUTES
HOW TO DO 1S?

MR.DOUBT
GIVE ONE- ONE IDEA
 ALWAYS KEEP IN MIND-
DO WHAT YOU DOCUMENT,
DOCUMENT WHAT YOU DO

AGAIN GIVE ONE ONE IDEA-

HOW CAN 1S BE DONE WITH
DOCUMENTS
 NEXT SESSION
GENBA EXERCISE
(1S MASTER LIST – DISTINGUISH)
 SESSION 5
GENBA EXERCISE
(1S MASTER LIST-DISTINGUISH)

DURATION : 15 MINUTES
Read 1S List…
One by One
 Now….
Let’s go to Shop floor… &
Distinguish Necessary &
Unnecessary Items…

TIME LIMIT : 10 MINUTES

Share the Learning…
One by One

Height of housekeeping
 Where to keep the
unnecessary items?

MR.DOUBT
 Red Tag
Holding Area
• Temporary storage
• Local holding area
• High Visibility
• Holding area manager
• Timely clearing
WHAT IS 2S?

NEXT SESSION
 SESSION 6
2S - SEITON

DURATION : 30 MINUTES
WHAT IS 2S?
Key 2: Seiton
(Systematic Arrangement)
 For Storing any items, following seven points
should be Considered :

1. Search Free
2. Count Free
3. Air Free
4. Climb Free
5. Bend Free
6. First in First Out
7. Heavy things on Lower Shelves
8. Store should be lighted & ventilated properly.
 44 Good
Good Signs
Signs of
of 2S
2S
1.
1. LOCATION
LOCATION:: Outline,
Outline,Arrows,
Arrows,Separators
Separators

2.
2. IDENTITY
IDENTITY ::Description
Description--“What
“What isisit?”
it?”

3.
3. QUANTITY
QUANTITY::How
Howmany
manyshould
shouldbe
behere
here

4.
4. INSTRUCTION
INSTRUCTION:: What
What do
doyou
youwant
want me
meto
todo?
do?
STILL I AM NOT CLEAR
ABOUT 2S?

MR.DOUBT
1 - PROVIDE Bolts
LOCATION

2 - PROVIDE IDENTIFICATION / NAME

BOARD
Bolts
4
Pallets
1000x4
3 - SPECIFY QUANTITY

Bolts
4
Delivery Time: 9.00 AM Pallets
Daily 1000x4
3 - PROVIDE INSTRUCTIONS
Let us see some
Examples…
 Team Member Area Information Board
All Shift Communication Board

Run Time
Production Log Sheet
Graphs
(Team Member Moulder
Maintained) Setup
Sheets
Team Member Maintenance
Training Log
Request
Sheets
(Team Member Forms
Maintained)
Maintenance
Repair Log

1st Shift 2nd Shift

 To Be
Tool and WIP Board
Ordered Spec Card

In Process

Next Run

Maintenance
Log
&
Maintenance
Request
Forms
Clean-up / WIP Board
To be Ordered

In Process
Next Run

Preventative
Maintenance
Schedule
Calendar
Organize & Demand the Maintenance of Tools

Everything has a Dedicated Home

Seiton workplace example..
 Seiton workplace example..

VCS provided for Inserts / tools stored in bins

component storage with VCS
5S
Point of use tools in Mill Room
What is needed, in reach, ready for use
 Now….
Let’s go to Shop floor… &
Identify Location for
Necessary Items…

TIME LIMIT : 20 MINUTES

Share the Learning…
One by One
WHAT NEXT?

3S
NEXT SESSION
 SESSION 8
3S – SEISO

DURATION : 15 MINUTES
Key 3: Seiso (Cleanliness)

“Cleaning Is Inspection"
• Eliminating all forms of dirt

• Finding ways to keep the workplace clean

• Adopting cleaning as a form of inspection

• Making cleaning part of everyday work

What is the army man standing in front of
before going for war ?

Am I
smart
Shine Concept…

• Clean to Inspect
• Inspect to Detect
• Detect to Correct
• Correct to Perfect
WHAT NEXT?
3S – CHECKSHEET

NEXT SESSION
 SESSION 9
3S – CHECK SHEET

DURATION : 15 MINUTES
WHAT NEXT?

4S
NEXT SESSION
 SESSION 10
4S – SEIKETSU

DURATION : 15 MINUTES
Key 4: Seiketsu
(Standardize)
• Check
• Standardize
• Maintain
• Monitor
• Improve

Maintain
Maintain and
and monitor
monitor the
the first
first three
three Keys
Keys
 SESSION 11
5S – SHITSHUKE

DURATION : 15 MINUTES
Key 5: Shitshuke
(Self-Discipline)

“SAY WHAT WE DO
DO WHAT WE SAY"
 Shitshuke (Self-Discipline)

• Correct procedures are • The workplace is well

habitual ordered according to agreed
• Workers are
upon procedures
properly trained
• Managers are committed to
• Everyone has adopted
Visual Factory the 5 Keys as a way of doing
business.
 MANAGERS PROPER
COMMITTED TRAINING
5S
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TO 5-S sdf
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SUSTAIN
PARTICIPATION
CORRECT PROCEDURES FROM ALL
BECOME A HABIT EMPLOYEES

19
 Keys 3, 4, 5: Shine, Standardize,
Sustain
• Summary
– Cleaning serves many functions, including
exposing abnormal and pre-failure conditions and
building pride in the workplace
– Unless changes in work activities are
standardized, things will go back to the way they
were before improvement
– The Five Keys should be implemented on an
ongoing basis, and should involve everyone
– Location Maps facilitate implementation
Benefits of Visual Factory System
 Reduces search time
 Eliminates defects
 Improves product quality
 Improves cost effectiveness
 Improves communication
 Eliminates work frustrations and delays
 Increases workplace safety
 Increases job satisfaction among workers
 . . .And, In Conclusion
• Workplace Organization and
Standardization begins with
Project Identification and
includes five keys:
• Sort, Stabilize, Shine,
Standardize and Sustain
• Red Tagging is a tool for
Sorting
• Location Maps & Indicators
are used in Stabilizing
 5S

Who Gets Most Benefited by 5S?

My Society

MyHouse
MyCompany
 5S

Employees should adhere

Obedience
Discipline
Full – hearted approach towards given goal
 SESSION 12
5S – SUMMARY

DURATION : 30 MINUTES
 A place for Everything,
1S-SEIRI Everything in it’s place 2S-SEITON
1-1
2-1 1-2 1
-3
‚2-2
R-‚P 2-2
2-3 1-4
4-1 3-2
2-4
5-1 4-2 3-3
5-2 4-3 3-4
5-3
4-4

Sorting Out Self-Discipline 5-4

Standardization
RULE 3S-SEISO
4S-SEIKETSU
5S-SHITSHUKE

Cleaning is
Inspection
5S Photo Display ( Fixed Point Photo )

Before After
Our Factory Environment…(Generally)
 After Sorting...
1S
After Systematic Arrangement..
2S
 After Cleaning...
3S
 After Standardising...
4S
 Building the Discipline…
5S
 Morale

In a village there lived an saint old man who was kind hearted,

illiterate and a very good foreteller. Whatever he used to

foretell was final and everyone in the village used to go to him

even for little problems. They treated him next to god.

In the same village there lived an educated man. He was
quite egoistic and never liked the faith people had in that
saint. One day, he planned to make the saint feel ashamed.
As usual, All village people assembled for Saint’s Speech in
the morning. Educated man also joined the crowd. Suddenly,
He said, ”Saint!! In my hand, a small Dove is there. Can u tell
me the fate of this bird? If this bird is going to be dead or shall
remain alive!! Educated man thought if saint tells that the bird
shall remain alive, I’ll kill the bird and if he tells that the bird is
going to be dead, I shall release the bird..
What would have Saint replied..??

The bird live or die is in

your hands
 Like same story
Our Company 5S Implementation
is in our hands only!!!!