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5s

Key to work place improvement
Kaizen Institute Africa Asia Pacific
402, Abhishek 72, B.M.M. Society Ellis Bridge Ahmedabad –380006 - India Tel: + 91 –79- 6588634 / 9562 / 5616 Mobile: (0) 9825073146 Email: jmurthy@kaizen-institute.com

Lead By: Jayanth Murthy

www.kaizen-institute.com
KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Putting 5s to Work
Who does not like a -Clean -Orderly -Disciplined Environment ? At home & At work !!!

5s AIMS at achieving this state

Mess ?!

Clean & Organized – Puts A Smile On Your Face !

One Way to Do It !! .

The 5s Way To Do It !! .

One to Keep Files ! .

The 5s Way To Do It !!

The 5s Way To Do It !!

The 5s Way To Do It !!

The 5s Way To Do It !!

5-S • Seiri .Scrub clean.Self-discipline (Follow rules) KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN . Spic & Span • Seiketsu – Standardize .State the rules • Shitsuke .sort out • Seiton -systematic arrangement • Seiso .

Step Zero .of 5s Identify strategic Spots & take Photos / Video – To Capture Current Status 1st Step of 5s SEIRI •Sorting of all items •Segregate Necessary from Unnecessary •Take action on Unnecessary • Red Tagging & Red Tag Areas (set Rules first) • Heaps to Come out – 10 trucks (in a factory) .

Throw It Out ! . •Stock •Facilities •Locations / Space •Documents •Computer Files •Machines •Stationary •Not People !! When In Doubt.Red Tag To.

? and unwanted • Discard unwanted • Create red tag area for ? •Wanted but not here items •Wanted but not in this Qty • Move ? Items to red tag •Wanted but not now area •Not Wanted at all • Put red tag on unmovable ? items KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .Seiri • Classify into: wanted.

Before Seiri .

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Where. labels etc) . find.Can Return It . take & put back •Everything to have a place & label This Leads To Standardizing Of Storage. What.2nd Step of 5s SEITON Systematic Arrangement A Place For Every Thing & Every Thing In Its Place •Arrange Necessary Items Systematically •Easy to identify.Can Take out it fast (less than 30 sec) . Any Body Can : .See Things (floor lines. How Many ? (Define & label) . door opening lines.

Seiton • • • • • Make Place for all wanted items Target: Max searching time: 30 seconds Sign boarding/labeling Outlining Color Coding Visual Controls KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .

Does It Ring A Bell ? .

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The 5s Way To Do It !! .

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3rd Step of 5s SEISO Spic and Span – Collective Cleaning Autonomous Cleaning •Cleaning is Inspection •Cleaning with meaning • Seiso Boards (tools) • Seiso calendar & responsibility charts • Decide What. Who and How to clean . When.

Seiso COT •Cleaning with meaning •Seiso calendar/map KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .

Cleaning using your own hands .

Cleaning using your own hands .

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Seiso Board .

Seiso Board .

Dirt • Make the rules & Follow them • SDCA •5 min / 10 min 5s •Setting Standards .4th Step of 5s SEIKETSU Standardization (so that first 3 ‘S’ is maintained AND… No – Unnecessary items pile up No – Mess / out of place items No .

Seiketsu Setting up of Rules: • Place token when tool (or file) is taken • Make schedule to restore basic conditions • Establish measures to track adherence to rules • answer the 5w1h as regards first 3 S KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .

Token System For Tracing Tools .

Token System For Tracing Tools .

Standardize First Aid Point. Emergency Tel No & the Telephone next to it !! .

5th Step of 5s SHITSUKE •Self Discipline •Training & People Involvement • Follow the rules set (if not use ..Retraining / Disciplinary Measures !) •Photo Gallery • Slogans • Audit • Radar Charts .

Shitsuke Self Discipline of adhering to Rules: • Adhere to rules yourself • Post adherence on visual displays • Spread rules and adherence by teaching others and tracking everybody’s performance on visual displays KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .

For Office Environment 5s Audit .For Production / Factory Environment 5s Audit .Audit Format .Casting a Radar Chart & Keeping it Updated .

Some More Cases On 5s .

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take & put back Everything to have a place & label Seiso – Spin & Span Everything to be clean Use cleaning as inspection Seiketsu – Setting Standards Set standards & rules 5 min / 10 min 5s Audit Shitsuke – Self Discipline Training & People Involvement . find.What is 5s ? Seiri – Sorting of all items Segregate Necessary from Unnecessary Take action on Unnecessary Seiton – Systematic Arrangement Arrange Necessary Items Systematically Easy to identify.

5s Requires Team Work .

Three More Things 1 Top management Commitment 2 Top management Commitment 3 Top management Commitment .

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Africa S. Dev): Africa-Asia-Pacific: Masaaki Imai Bud H.Gondhalekar.Founder: Head (Bus.Grover.V.Durairajan.K. Mumbai Jayanth Murthy. Chennai . Pune Kristianto Jahja . Cox S. Jakarta Over 160 consultants worldwide. KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .

Kenya Taj group of hotels Milton Plastics Bombay Oil Industries • Rallis.Uganda / Zambia / Kenya • Comcraft Group Of Companies • Power techniques . KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .Consulting Clients in Africa-Asia Pacific: • • • • • • Bidco. Kenya Superfoam Ltd. India & Hitech Gears (supplier to Honda) Latest additions (from March 2000): • Spencon . Nairobi Spinners and Spinners.

Unique Features of Consultancy: • • • • • • • Hands-on consultants Implementation in shortest time Cash-stingy solutions Energizing people Release of latent capabilities Human development Learning organization KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN .