Training

On
5- “S”
Housekeeping &
Workplace Organization
 Background
Since The Early 80’S
Japanese Industries Widely
Practiced
5 S as a Powerful Technique
To Improve Productivity
And Quality
Today
5S
Is used in Many Countries
Including India
 What is 5 S?
A Systematic And
Rational Approach
To Workplace organization
And Methodical Housekeeping
With a Sense of Purpose
5-S is more than house keeping
"Mess is like gas, it takes all available
space".

“5-S is the foundation of all improvement

activities".
 Introduction To 5S

5S is a method for achieving and

sustaining efficiency and
effectiveness through organization and
standardization in
the workplace.
5-S workplace organization & standardization

• 5-S is a process of workplace organization and house keeping

which is carried out gradually and systematically.
• The 5-S method is a structured program to implement
workplace organization and standardization. A well
organized workplace motivates people, both on shop floor as
well as others. 5-S improves safety, work efficiency. improves
productivity & establish a sense of ownership.
 What are the 5S’ s?
• It is a set of 5 Japanese words
– Seiri - Sort - Eliminate from the work area anything
that doesn’t belong in it
– Seiton - Set in place - Assign one logic place for each
tool or material that belongs in the area and have it
always in its place
– Seiso – Shine - Clean the area as never before
– Seiketsu – Standardize - Establish new conditions as
the standard
– Shitsuke – Sustain - Sustain the effort so you do not
lose what you have achieved
 What is 5-S

1st “S” Seiri - Sorting, Segregate

2nd “S” Seiton - Systematic arrangement,
Set in order
3rd “S” Seiso – Spic & span, Shine,
4th “S” Seiketsu – Standardize
5th “S” Shitsuke – Sustain, Self discipline
 5-S develops in Japan and stands for

• Seiri – Clean-up: remove what is not needed and keep what

is needed.
• Seiton – Organizing: Place things in such a way that they
can be easily reached whenever they are needed.
• Seiso – Cleaning: Keep things clean and polished, no trace
or dirt in the work place.
• Seiketsu – Standardization: Maintain cleanliness after
cleaning – Perpetual cleaning.
• Shitsuke – Self discipline: Commitment, a typical teaching
and attitude towards any undertaking to inspire pride and
adherence to standards established for the four components
 WHY 5 - “S”

1. To eliminate the waste that results from “uncontrolled processes”

2. To gain control on Equipment, material & inventory placement &
position.
3. Apply control techniques to eliminate erosion of improvements
4. Standardize improvements for maintenance of critical process
parameters.
 Key to successful implementation of 5-S
• Get every one involved.
• Get company authorization.
• Final responsibility rest with the top
management.
• Make your self understood and aware
• Do it all the way.
• The president should inspect the Gemba (Shop
floor) personally.
• Do not stop halfway in establishing 5-S
• 5-S is halfway towards other improvements.
 SEITON
Orderliness
 Put things in right order in
SEIRI designated areas
 Store all materials and information
Arrange Properly in an orderly fashion at all times
 Distinguish between those things that  Organized according to frequency
are needed and not needed  Place for everything and everything in its SEISO
 Keep only needed materials at place
the job site Cleanliness
 Throw away all unneeded  Problems are more visible when
items immediately everything is neat and clean
 Find minor defects while

5s
"sweeping clean”

SEIKETSU
SHITSUKE
Always Clean
Discipline  Clean tools, equipment and
 Use and follow standard job site immediately after use
procedures  Equipment that is kept clean
 Follow company rules and runs better
regulations
 Follow safety procedures at all
times
 1st “S” - S E I R I - Shorting
Short all the items & Arrange Properly
Distinguish between those things that are
needed and not needed
 Distinguish between those things that are
Ok and not OK, Repaired & to be repaired
Keep only needed materials at
the job site
Throw away all unneeded
items immediately
 The Sort Process

"Sort" (Seiri) means removing all supplies,

materials, tools, and paperwork not required for
current production ... also all waste, by-
products, empty containers, and papers
generated by current production activity but no
longer needed
 The Sort Process

"Sort" Phase - the

sorting process and
the "red-tag" method
used to identify and
remove unnecessary
material from the
workplace.
 Step 1 – Sorting
Identify And Sort To Segregate Usable From Non – Usable Items
SORTING

SCRAP IN WORKING
NOT IN WORKING ORDER
ORDER

REWORKABLE REJECTED
NECESSARY UNNECESSARY

REWORK DISCARD
NO POTENTIAL POTENTIALLY REQ SPL
USE USEFUL DISPOSAL

REPAIRABLE UNREPAIRABLE
MOVE TO ARRANGE
REQ LOCATION DISPOSAL

REPAIR DISCARD DISCARD DISCARD

USABLE ITEMS
 2nd “S” - S E I T O N – Systematic arrangement
Orderliness
Put things in right order in designated areas
Store all materials and information
in an orderly fashion at all times
Organized according to frequency
Place for everything and everything in its place
 Seiton

The Goal is to
have a place for
every thing and
every thing in
the place
(PEEP)
 PLACEMENT ON THE BASIS OF
FREQUENCY OF USE

Usable items

Things constantly Things occasionally Seldom used

in use used but still needed
(Hourly, Daily, Weekly) (Monthly) (Quarterly)

PLACE CLOSE TO PLACE IN PLACE IN

MACHINE WORK AREA STORES
 HOW AND WHERE TO
STORE
Brainstorm On The Following:
How and where can it be:
Easily stored?
Easily identifiable?
Easily retrievable?
Easily returned to original location?

Is The Storage Area Easily Identiable?

5S - The Set In Order Process
"Set In Order" (Seiton) is equivalent to orderliness, or organizing those
items that truly need to be in the workplace (those remaining after "Sort")
so that everything has a place and everything is in its place.
The Set In Order Examples :
BENEFITS OF SYSTEMATIC ARRANGEMENT

 Materials easily available.

 Materials easily retrievable.

 Lesser Production downtime

 Machine Breakdowns handled fast.

 Time taken to search minimized.

 3rd “S” - S E I S O – Spic & Span

Cleanliness
Problems are more visible when
everything is neat and clean
Find minor defects while "sweeping
clean”
 STEP III - SPIC AND SPAN

 Cleaning not for beautification alone but with a

sense of purpose.
 Keep Own machines and workplaces clean through:

 Sweeping floors & surroundings.

 Dusting to make dirt free, cobweb free.
 Wiping to make oil, grease, moisture free.
 Polishing & Painting.
 Maintaining sparkling cleanliness.
 Inspections for any problems.
 Identification root causes and establishing
corrective action.
 STEPS TO SPIC AND SPAN
 Develop standards of cleaning.
 Clean up workplace after use.
 Clean up machines and tools after use.
 Clean up supply lines (No leakage, Blockage, clogging with oil/dirt).
 Assign clear responsibilities and schedules for cleaning.
 Clean waste bins at end of shift/day.
 Clean light bulbs, fans, shades, reflectors.
 Pay special attention to scrapyard, gardens, godowns.
 Scrap and chips from machines could fall directly into collecting
bins.
 5S - The Shine Process
This 5S module explains "Shine" - the role of cleaning in
maintaining quality and throughput.
 BENEFITS OF SPIC AND SPAN
 Clean machines and floor expose problems like machine cracks/
oil leakage fast.
 Fast corrective action.
 Tools well laid out.
 Smoother material flow
 Inventory levels can be found visually.
 Lesser production downtime.
 Pride to employees.
 Greater confidence of customers.
 High product quality achieved.
 4th “S” - S E I K E T S U

Always Clean
Clean tools, equipment and
job site immediately after use
Equipment that is kept clean
runs better
 SERENE ATMOSPHERE &
STANDARDIZATION

FOLLOWING OF EARLIER 3S’s,

STANDARDIZED WORK PROCEDURES,
MAINTAINING SAFE AND HYGIENIC
CONDITIONS IN WORK-PLACE
CONTRIBUTE TO A SERENE
ATMOSPHERE
STEPS TO SERENE ATMOSPHERE & STANDARDIZATION

IDENTIFY 5`S’ AREAS

DEVELOP STANDARDS / EVALUATION CRITERIA

WITH WORKMEN (SOP’s’, HOUSEKEEPING
STANDARDS)

ESTABLISH CHECK
PROCEDURE 5W + 1H

ESTABLISH FEEDBACK PROCEDURES 5W +

1H
 STEPS TO SERENE ATMOSPHERE

 WEAR NEAT AND CLEAN UNIFORM.

 WEAR PROTECTIVE CLOTHING.
 PROVIDE ADEQUATE LIGHTING, VENTILATION,
EXHAUST.
 CHECK ELECTRICAL WIRING, CABLES, SWITCHES.
 MAINTAIN SANITARY / HYGIENIC CONDITIONS IN
WASHROOMS, LOCKER ROOMS, CANTEENS AND
KITCHEN.
 EARMARK SMOKING AND EATING AREA.
 STEPS TO SERENE ATMOSPHERE

(Contd.)

 LOOK FOR HEAVY NOISE, VIBRATION AND HEAT IN

MACHINES, ANALYSE FOR ROOT CAUSE AND
TAKE ACTION.
 CREATE VISUAL CONTROL SYSTEMS.
 DEVISE WAYS TO EXPOSE HIDDEN PROBLEMS.
 CREATE STANDARDS.
4th S - The Standardize Process:
 4th S - The Standardize Process
This 5S module describes the "Standardize" phase, which includes the
creation and use of procedures, practices, policies, and job aids associated
with the first 3 of the 5S activities.
 4th S - The Standardize Process
The "Standardize" phase develops controls and checks to
ensure that procedures, practices and activities are
executed consistently and at regular time intervals.
 BENEFITS OF STANDARDIZATRION
& SERENE ATMOSPHERE

 STANDARDIZED PROCEDURES MINIMISE ERRORS.

 PRODUCTIVITY INCREASES AS DEFECTS GO DOWN.
 EASIER WORKING CONDITIONS.
 SAFER WORKING CONDITIONS.
 NUMBER OF NEW PROBLEMS EXPOSED AND SOLVED.
 MORE OPPORTUNITIES TO MAINTAIN AND IMPROVE
QUALITY.
 OWNERSHIP AND SENSE OF PRIDE AMONG
EMPLOYEES.
 5th “S” - S H I T S U K E

Self Discipline
Use and follow standard procedures
Follow company rules and regulations
Follow safety procedures at all times
 5S - The Sustain Process
This 5S module describes the roles and functions of company personnel in the
5S "Sustain" phase - the ongoing monitoring of, and improvement to, the 5S
process.
 5S - The Sustain Process
To create and maintain a favorable 5S atmosphere in the workplace means
creating a 5S culture.
In the 5S Sustain phase, you put in place mechanisms that support, enhance,
and extend the practice of 5S.
Thank “U”