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Business Excellence
Approach for 5S – Tool For improvement
BY
Q FACTOR CONSULTING PRIVATE LIMITED
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5S Philosophy

 5S is not just about the cleaning

 5S is not just the steps, it is how you go about your job – are you a Lean
thinker?

 Think about the 5Ss as being attributes of the type of person you would
want to hire
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5S

Generally Understood as either a

“HOUSEKEEPING TECHNIQUE” or

“PRODUCTIVITY AND SAFETY ENHANCEMENT TECHNIQUE”

But in reality

It is Cultural Transformation
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What is 5S and why do we want to do it?

5S is short for: Sort, Set in Order, Shine, Standardize and Sustain

5S represents 5 disciplines for maintaining a visual workplace
(visual controls and information systems).
These are foundational to Kaizen (continuous improvement)
and a manufacturing strategy based "Lean Manufacturing"
(waste removing) concepts.
5S is one of the activities that will help ensure our company’s
survival.
 5S 5

1. Sort - All unneeded tools, parts and supplies are removed from the area
2. Set in Order - A place for everything and everything is in its place
3. Shine - The area is cleaned as the work is performed
4. Standardize - Cleaning and identification methods are consistently
applied
5. Sustain - 5S is a habit and is continually improved

Also - Work areas are safe and free of hazardous or dangerous conditions
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THE 5S PRINCIPLES
 SEIRI – Organisation/Sort out
 SEITON – Orderliness/Systemize
 SEISO – The Cleaning/Shining
 SEIKETSU – STANDARDIZE
 SHITSUKE - Sustain/Discipline
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DISCOVERY OF 5S
 Thirty years ago researchers started studying the secret of
success of Japanese manufacturing companies
 5S turned out to be the most impressive "secret“
 The factories were so well organized that abnormal situations
were readily apparent
 Equipment's were so clean and well maintained that any
problem such as a loose bolt or leaking oil could be easily seen
 This passion of cleanliness and orderliness became a hallmark
of Japanese organizations
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DISCOVERY OF 5S

 Equipments were so clean and well maintained

that any problem such as a loose bolt or leaking
oil could be easily seen
 This passion of cleanliness and orderliness
became a hallmark of Japanese organizations
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ADVANTAGES OF 5S
 If tools and materials are conveniently located in
uncluttered work areas

 Operators spend less time looking for items

 This leads to higher workstation efficiency, a
fundamental goal in mass production
 ADVANTAGES OF 5S 10

 TIME SAVING

 QUICK RETRIEVAL

 ACCIDENTS & MISTAKES MINIMIZED

 INCREASES SPACE

 CREATES WORKPLACE OWNERSHIP

 ADVANTAGES OF 5S 11

 FOUNDATION OF ALL QC TOOLS

 CONTINUOUS QUALITY IMPROVEMENT

 LEAN MANUFACTURING

 KINDERGARTEN OF QUALITY TOOLS & TECHNIQUES

Advantages of 5S 12

 15% increase in throughput

 70% cut in materials handling
 60% decrease in floor space
 80% decrease in flow distance
 68% reduction in rack storage
 45% decrease in number of forklifts
 12% decrease in engineering cycle time
 50% decrease in annual physical inventory time
 96% decrease in defects
 ADVANTAGES OF 5S 13

 VISUAL MANAGEMENT SYSTEM

 VISUAL CONTROL TO SEE THE ABNORMALITIES

 SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE

CONDITION( NORMAL/ ABNORMAL)

 A LOOK AT THE PROCESS REVEALS ITS DIRECTION

(RIGHT/WRONG)
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KINDERGARTEN OF ALL THE QC TOOLS

 5S IS THE STARTING POINT OF ALL THE QC
TOOLS

 COULD BE SAID AS THE PRE- REQUISITE OF ALL

QC TOOLS
5 S Approach 15

Phase Module 1
Target Audience Management
Activities  Formal Start of Project
 Selection of team for 5 S project Initiations
Team shall be comprising of the persons from Different Production areas and
shop floor activities like Maintenance / Housekeeping

Management Support Manpower selection & motivation for new project

Deliverables at end of 5 S Team

Phase/ Step
5 S Approach 16
Phase Module 2
Target Audience Management
Activities  Brief Presentation to Management for
o 5 S project familiarization comprising of Concept, Steps,
Implementation Plan & their role
Management Support Time for presentation and Training Arrangements

Deliverables at end of Basic Concept of 5 S

Phase/ Step Signing off Model Plan for Implementation

Phase Module 3
Target Audience 5S Team
Activities  Facilitators Training Programme for 5 S
 Introduction to 5S: work place organization and Standardization:
 Awareness on 5S Implementation Plan to all the departments and initiation of 1S
activities
 What is 5S, principles of 5S,
 5S Performance,
 Excellence Model ,
 Five elements of 5S,
 Types of waste and their elimination

Management Support Training Arrangements & Availing Team

Deliverables at end of Teams ready with knowledge and workshop experience with Model Plan
Phase/ Step activities
Formats / basic steps to start project
5 S Approach 17

Phase Module -4

Target Audience 5 S Team

Activities  Selection of Area for 5 S Start
 Area Inspection with Management member & Team
 Demonstration by consultant for 1st, 2nd & 3rd Step of 5 S
 Workshop for team members for model area activities
 Identification & Segregation of the relevant inputs/ consumable
& Wastes around model area

Management Support Model area for 5S

Working time for 5S team
Deliverables at end of 1st 3 step working for model area,
Phase/ Step Controlled formats for team working
Query resolution of team members
Review of activities done.
5 S Approach 18
Phase Module -5
Target Audience 5 S team
Activities  Brainstorming on 1st, 2nd, 3rd Step of Implementation for Model Area
 Standardization practice for Model Area
 Development of Knowledge sharing signage, Visual Aids to maintain the
model area
 Brainstorming of challenges and ensuring sustainable practice in Model area
 Library of lessons / control practices for model area

 Self Audit of area with Team & Operators

 Review of progress of team and updation of Activity Display Board

Management Support Provision of Resources for Display boards

Deliverables at end of Phase/
Step
Working time of team
Controlled formats for working customized for team
Control measures and Visual Aids for Model Area
Activity Display Boards
Engaged team for workshops
5 S Approach 19

Phase Module -6
Target Audience 5 S team
Activities  Brainstorming on 4S , Standardizing Implementation
 Standardization practice for Model Area
 Development of Knowledge sharing signage, Visual Aids to maintain the
model area
 Developing standards for step 1, 2,3
 Roles, Responsibilities of the persons are clearly identified

 Self Audit of area with Team & Operators

 Brainstorm ideas for making the 5S changes standard operating procedure. That
may mean updating workplace procedures, checklists, job aids, diagrams and
the like.
 Update documentation to reflect the changes. If your company has an ISO
Coordinator, get the person involved to assure compliance with ISO
requirements.
 Make sure all stakeholders are aware of the new standard – inform and educate.

 Review of progress of team and updation of Activity Display Board

Management Support Provision of Resources for Display boards
Working time of team
Deliverables at end of Phase/ Standard Method and Clearcut designation of responsibilities to individual
Step
5 S Approach 20
Phase Module -7
Target Audience 5 S team
Activities  Action steps for implementing S5 - Sustain
 Audit to ensure that processes established during S4–
Standardization continue to be maintained.
 Use the phase 1 work area as a model for other areas to match, and
have the original 5S team share their
 insights and experiences with employees in other work areas.
 Use newsletters, displays and other communication tools to publicize
successes and reward strong efforts with recognition.
 Evaluate 5S effectiveness and continue to improve. Conduct regular
review meetings to identify additional 5S opportunities.
Management Support Audit by Management and recognition of efforts by the team

Deliverables at end of Phase/ Sustained Cultural change

Step