5S Role in Achieving Quality

5S
A STRATEGY FOR
PERFORMANCE
EXCELLENCE
5S
 What is 5S ?
 An essential step required for Waste
Elimination
Systematic Cleanup
Orderliness Cleanliness
Organization “Seiketsu”
“Seiri” “Seiton” “Seiso”

Cleanup
Standardization/Perseverance
“Seiketsu”
“Shitsuke”
 An integral step in Kaizen
 A required element to achieve Lean-site
Manufacturing.
 The Five Elements of 5S
Self-Discipline/Control- Systematic Systematic
Ensuring that Systematic Organization- Identifying what
Organization, Visual items are required and which
Placement & Cleanliness are not.
are maintained.

Standardizing Control- 5S Improvement in Performance

Maintain and continually
improve the previous
improvements.
Sorting Visual Placement-
Items should be easily
Scrubbing Clean-Keep the area free from debris, retrievable, easy to get, and
dirt, oil, items not needed. visual-easy to see.
Why 5S

•To eliminate the wastes that result from

“uncontrolled” processes.
• To gain control on equipment, material &
inventory placement and position.
• Apply Control Techniques to Eliminate
Erosion of Improvements.
• Standardize Improvements for
Maintenance of Critical Process
Parameters.
The Nine types of wastes.

 Overproduction
 Delays (waiting time)
 Transportation
 Process
 Inventories
 Motions
 Defective products
 Untapped Resources
 Mis-used Resources
 Elimination of Waste
5 S Element Waste/ Improvement Item Deliverable

Systematic Elimination of finding. Reduced Costs

Reduction of part selection errors. Improved Quality
Organization Increased Product Options

Sorting-Visual Elimination of finding. Reduced Costs

Elimination of nonconformances. Increased Safety
Placement Elimination of motion. Improved Quality
Reduction of part selection errors. Increased Product Options.

Scrubbing Clean Increased safety. Increased Safety

Preventive maintenance. Improved Quality
Increased equipment knowledge.

Standardization Increased equipment life. Improved Quality

Higher morale. Consistent Delivery
Control Clean environment. Improved Safety
Increased visibility of nonconformances.
 5S Implementation Plan
Step 1 Step 2 Step 3
Step 4
Develop Specific Develop Communication
Step 5
Establish 5 S
Develop 5 S Training Plan
Implementation Plan Plan Implement 5 S
Implementation Team

Systematic
Organization Progressive
Standardization
Enhancements

Cleanliness
Visual Placement

Step 6
Verification of Effectiveness
Key to successful Implementation of 5S
Some evidence of standardized work areas

•Clear, shiny aisle ways

•Color coded areas
•Slogans, banners

•No work-in-process ( WIP )

•One-Piece Flow
•Standardized Work Sheets
 Visual Color System Implementation

• Develop a map identifying the “access ways”(aisles, entrances, walkways etc.)

and the “action” areas.
• Perform any necessary realignment of walkways, isles, entrances.
• Assign an address to each of the major action areas.
• Mark off the Walkways, Aisles & entrances from the action areas.
• Apply flow-direction arrows to aisles & walkways
• Perform any necessary realignment of action areas.
• Mark-off the inventory locations
• Mark-off equipment/machine locations
• Mark-off storage locations( Cabinets,shelves,tables)
• Color-code the floors and respective action areas
Cleanliness involves cleaning every aspect of
the Organization and the removal of dirt,
dust,oil, scraps on the floor, & garbage.
Key Deliverables

Increased
Efficiency
Increased
Safety
5S Action Items
 5S Action Items
Table of Contents
Section 1 Development of 5S “To Do” Plan: Establishment of the 5S team focused on
the development, training, and implementation of the company’s 5S program.
Deliverable includes action plan and associated tasks with the 5S
implementation. ………………………………………………………………………… 4
Section 2 Waste Identification Map: Identification of the 9 wastes associated with
production of products and services. A detailed map of each major work area is
developed describing the major types of wastes in each area. These wastes are
the improvement opportunities that exist prior to 7
5S………………………………...

The overall wastes is calculated for all the work areas and identified on the 9
Waste Radar Chart

Section 3 5S Action sheet: Establishing baseline key performance metrics in terms of

key deliverables, photographs, and current conditions of the “before” 5S
implementation phase. Deliverable includes the 5S action 11
sheet………………….

Red Tag Strategy: The utilization of “Red Tags” to visually identify items which
are not needed or used infrequently…………………………………………………..
14
Section 5 Visual Color Sheets: Utilization of colors to identify specific work actions,
inventory locations, access areas within the work environment. Initialization
begins with development of Visual Color 17
Sheets…………………………………….
Section 6 Visual Sign Sheets: Utilization of signs to identify machine, equipment, tooling,
inventory, safety, hazard and work center locations. Sample Sign 20
Sheets……….

Section 7 Standard Cleaning Work Sheet: A cleaning matrix identifying the work area
responsibilities, supplies, and schedules for cleaning. …………………………….. 23

Section 8 Cleaning “To Do List”: A action list identifying specific cleaning tasks for each
work area identified on the Standard Cleaning Work Sheet……………………….. 27

Section 9 5S Status Report: A report identifying implementation effectiveness of each 5S

steps applied. A variable metric ranging from 0-5 is established for each step
implemented…………………………………………………………………………….. 30

Section 10 Waste Identification Map: Identification of the 9 wastes associated with

production of products and services. A detailed map of each major work area is
developed describing the major types of wastes in each area. These wastes are
the improvement opportunities that exist prior to 5S……………………………
33
9 Wastes Radar Chart: After the completion of 5S, the results of the waste reduction
is recorded, charted and compared to the initial 9 Waste Radar Chart.
THANK
YOU