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5S

The Benefits of 5S Program


Improved profitability and efficiency by reducing

time wasted looking for tools and equipment.


Improved quality.
Achieve work standardization.
Decreased changeover time.
Improves daily and shift startup times.

The Benefits of 5S Program


Improved safety.
Reduced space requirements and storage costs.
Reduced cycle times.
Reduced machine down time.
Simplified work environment.
Improved employee moral and pride by creating
a pleasant workplace.

The 5S Benefits
Sales - Increase sales (market share).
Savings - Save costs.
Safety - Provide a safety working environment.
Standardization - Standardize the operating
procedure.
Satisfaction - Employees and customers
satisfaction.

The PQCDS Benefits


P - Increase productivity.
Q - Improve product quality.
C - Reduce manufacturing costs.
D - Ensure on-time delivery.
S - Provide a safety working environment.

What will It cost us?


Realistically you will need to spend some extra
money to get your Five S program going.
There will be training time;
man-hours spent to get your facility cleaned up
and organized;
equipment purchases, such as buying a quality
labeling system; and
time spent on sustaining your Five S program
once it is in place.

What will It cost us?


Your actual costs will depend on where you are
now - for example what is the condition of your
facility? The further you are from meeting the
goals of a Five S program, the more it will cost
to implement one and the greater the benefits
you'll see as a result of your Five S program.

WHAT IS 5S ?

Does this describe your work areas?


Space is crowded with parts and tools.
Unneeded items are stacked between
workers

Excess inventory on the floor

Does this describe . . .


Excess items and machines make it difficult

to improve process flow


Equipment is dirty and a collection point for
miscellaneous materials
Needed equipment such as tools are difficult
to find.

5S
is one of the most basic tools
for improving productivity!

Five Japanese words beginning with


'S; it focuses on effective work place
organization and standardized work
procedures.

It simplifies the work environment,


reduces waste and non-value activity
while improving quality efficiency and
safety

Japanese

English

Explanation

SEIRI

SORT

Take out unnecessary


items and dispose.

SEITON

SYSTEMATIZE

Arrange necessary items


in good order for use.

SEISO

SWEEP

Clean your workplace

SEIKETSU

SANITIZE

Maintain high standard of


housekeeping.

SHITSUKE

SELF-DISCIPLINE

Do things spontaneously
with out being told so.

Deploying 5S

Two ways of implementing 5S :


Quick hits
A high density approach
deploying the whole 5S principles
in a very short period of time,
generally 3 to 5 days. Its a kind of
tidal wave starting with a cleaningsorting-disposing initial phase

Two ways . . .

5S workshop
Done over a longer period of
time and addresses the
several principles in gradual
way

Two ways . . .

Both ways have advantages and

inconveniences. The choice depends


on management targets and
companys culture.
In any case, regardless of the way it is
conducted, the 5S implementation
must be managed like a project

Key Points in the


Implementation of

5S

Key points

1. Start small and easy, proceed slowly but


steadily.
IF YOU MAKE HASTE, IT IS EASY TO
FAIL
For big organization, start with a pilot
area.
Trial practice at model area and model
machine.

2. Start with the most suitable S

For messy workplace, start from first


S - Seri

For troublesome machine, first


conduct SEISO then do SEISO
inspection.

Everyone can participate in SEISO


But they need to be familiar with
machines, proper cleaning
procedures and tools.

SEISO inspection requires

specialists.

3.Only 1,2 ,& 3 S are enough


for the initial practice, not
all 5S.

First 3S ( SEIRI, SEISO, SEITON) are

ACTION WORDS.
4th S- SEIKETSU is a CONDITION
5th S- SHITSUKE is accordingly

CULTURE

4. Set simple, easily achievable and


step-by-step targets
Themes are helpful to concentrate
effort and achieve greater results.

Practice 5S together with other


movements.
Integration through selection of
common themes.

5. Everyones participation is
important

Two heads are better than one


Four eyes see more than two.

Encourage participation first by


EDUCATION then by DEMONSTRATION,
later through ACTUAL PRACTICE, and of
course RECOGNITION.
Set aside a day launching (e.g. BIG CLEAN
UP DAY).

Implementation of
5S Plan

1. CEOs Commitment
Understanding 5S concept and benefits by

CEO
CEOs visit to 5S Model Companies
CEOs commitment to 5S Implementation
Organize 5S Working Committee
Appoint 5S facilitator(s)
Train facilitator(s) practitioner

2. Information Campaign
CEOS Official Announcement
Officially announces implementation
of 5S to all 5S program
Explains the objectives of 5S to all
colleagues

Publicize 5S Organization chart


and layout
Workout various promotion tools

3. BIG Day
Organize a BIG Cleaning Day
after 5S implementation
announcement by CEO

Divide company premises into


small areas and assign small
group of people for each area.

3. BIG Day

Provide enough cleaning tools


and materials.

This big cleaning include public


areas including gardens, canteen
and car park

Everybody must participate in this

BIG CLEANING DAY!

4. Initial SEIRI
Establish disposal standards for
unnecessary items.
Apply Disposal Notices to all
questionable items
Carefully examine contents of responses
to Disposal Notices.

4. Initial SEIRI

Dispose unnecessary items according to


Disposal Standards.
A company- wide SEIRI should be
planned and practiced annually.

5. SEITON and SEISO


Identify areas for improvement and
work out priority listing by colleagues.
Select untidy, inconvenient, unsafe
areas.

5. SEITON and SEISO

Select activity for 3-6 months


Organize presentations by small groups
Standardize good 5S practices visibly
Motivates colleague for creative
improvements

6. Periodic 5S AUDIT
Establish 5S evaluation and incentive
plan
Conduct 5S evaluation inspection
regularly
Organize 5S inter-department
competition

6. Periodic 5S AUDIT

Periodically award groups and


individuals
Organize tours to other companies
Organize 5S inter-company competition