5S : JAPANESE METHODOLOGY

PRESENTED BY: AGUILA, EDELYN A.

BANASTAS, DANIEL MARK M.
BELO, VERONICA B.
WHAT IS 5S?

 5S is a method of creating a self-sustaining culture which

perpetuates a neat, clean, efficient workplace; a method for
removing all excess materials and tools from the workplace and
organizing the required items such that they are easy to find, use,
and maintain.
WHAT IS 5S?
 5S is a workplace organization method that uses a list of five Japanese
words: seiri (整理), seiton (整頓), seisō (清掃), seiketsu (清潔), and
shitsuke (躾). These have been translated as "Sort", "Set In order",
"Shine", "Standardize" and "Sustain".The list describes how to organize a
work space for efficiency and effectiveness by identifying and storing the
items used, maintaining the area and items, and sustaining the new order.
The decision-making process usually comes from a dialogue about
standardization, which builds understanding among employees of how
they should do the work.
WHAT IS 5S?
WHY IMPLEMENT 5S?
 Improves safety and ergonomics
 Promotes flow
 Reduces searching
 Reduces unplanned downtime
 Improve quality
 Encourages visual control
 Enhances teamwork
WHY IMPLEMENT 5S?
 Improves productivity
 Eliminates distractions
 Reduces inventory and space
 Instills the discipline to follow standard work
 Exposes problems
 Tackles waste
 Enhances self-management
THE 5S

 Sort (Seiri)
No unnecessary items at the workplace: “When in doubt, throw it
out!”
 Set in Order (Seiton)
Anyone can instantly find, take, and return any needed item: “A
place for everything, and everything in its place”
THE 5S

 Shine (Seiso)
Deviations become visual by cleaning: “Cleaning = inspection;
Cleaning with meaning”
 Standardize (Seiketsu)
Visualize the 5S standards in the workplace: “Make the best way
the easiest way”
THE 5S

 Sustain (Shitsuke)
Everybody follows the standard until we have a better one:“Stick
to it!”
SEIRI (整理) : SORT
• Sort means that you remove all items from the workplace that are
not needed for current production or transactional operations.
• Distinguishing between necessary and unnecessary things, and getting
rid of what you do not need
• It does not mean that you only remove the items that you know
you may never need.
• It does not mean that you simply arrange things in a neater fashion.
HOW TO IMPLEMENT?

•Remove items not used in area – outdated materials, broken equipment,

redundant equipment, files on the computer, measurements which you no
longer use
•Ask staff to tag all items which they don’t think are needed – this improves
understanding about need and use
•Classify all equipment and materials by frequency of use to help decide if it
should be removed – place ‘Red Tag’ on items to be removed
•Establish a ‘holding area’ for items that are difficult to classify – hold item
for allotted period to enable others not on 5S team to review
EXAMPLES

• Defective or excess unneeded items that accumulate

• Outdated or broken jigs and dies
• Worn-out bits, inserts
• Outdated or broken tools or inspection equipment
• Old rags and other cleaning supplies
• Electrical tools/equipment with broken cords
• Outdated posters, signs, notices, and memos
RED TAG

• The red tag system is simply a communication tool used to identify

items that a person has flagged for removal from a work area.

• When a person finds an item that they either don’t know what it is, or
is not needed in a process, they tag it. The red tag acts as a signal to
everyone else in the area that someone intends to move the item out
of the work area at some point in the future. This leads to a discussion
about the item, and ultimately, a decision about whether or not the
item stays or goes.
RED TAG
 RED TAG METHOD
Red tag method is a method of identifying and removing all unneeded
items from the workplace through the use of red tags as a visual control.

•Attach a red tag to each item that is unneeded or does not belong in
the area.
•Attach a red tag to each item that belongs in the area but DOES NOT
have an identified storage area.
•Fill out each tag to describe what each item is and why it was tagged.
•Record all the tags and their description in the “5S Tag Log.”
SEITON (整頓) : SET IN ORDER

• Set in order means that you arrange the items that are needed in the
area and identify them or label them so that ANYONE can find them or
put them away

• The practice of orderly storage so the right item can be picked efficiently
(without waste) at the right time, easy to access for everyone.A place for
everything and everything in its place.
 HOW TO IMPLEMENT?

• Identify and allocate a place for all the materials needed for your
work
• Assign fixed places and fixed quantity
• Make it compact
• Place heavy objects at a height where they are easy to pick from
• Decide how things should be put away, and obey those rules
EXAMPLES
EXAMPLES
BENEFITS

• Person sent to find something, finds it easily

• Time spent looking for things is reduced
• Wrong parts are not retrieved in error
• Adequate space is allocated for storage of items
• Items have “their place” and not not left in walkways,
etc.
SEISŌ (清掃) : SHINE

• Shine emphasizes removing the dirt, grime, and dust

from the work area
• Create a clean worksite without garbage, dirt and dust, so problems
can be more easily identified (leaks, spills, excess, damage, etc)
• This is a program of keeping the work area swept and
clean of debris
• Floors are swept, machinery is clean and wiped off and
everything in the work area is kept clean
HOW TO IMPLEMENT?

•Identify root causes of dirtiness, and correct process

•Only one work activity on a workspace at any given time
•Keep tools and equipment clean and in top condition, ready for use at any
time
•Cleanliness should be a daily activity – at least 5 minutes per day
•Use chart with signatures/initials shows that the action or review has taken
place
•Ensure proper lighting – it can be hard to see dirt and dust
EXAMPLE
BENEFITS

• Defects are easier to see in a well-lit and clean environment

• A work area clean of debris is less likely to cause a tripping hazard
• Machines that are clean and maintained work more efficiently and
break down less often
• A clean work area promotes improved morale and instills pride in
the team members
SEIKETSU (清潔) : STANDARDIZE

• Standardize is setting up standards for a neat, clean,

workplace.
• Means creating a consistent way of implementing the tasks that
are performed on a daily basis including “Sort,” “Set in
Order,” and “Shine”.
• “Do the right things the right way, every time!”
HOW TO IMPLEMENT?

•Standardization of best practices through ‘visual management’

•Make abnormalities visible to management
•Keep each area consistent with one another
•Standards make it easy to move workers into different areas
•Create process of how to maintain the standard with defined roles and
responsibilities
•Make it easy for everyone to identify the state of normal or abnormal
conditions – place photos on the walls, to provide visual reminder
BENEFITS

• Easier to train new employees

• Less room for errors and scrap
• Work area is more organized
• Work area is safer
SHITSUKE (躾) : SUSTAIN

• Sustain is implementing behaviors and habits to maintain the

established standards over the long term, and making the workplace
organization the key to managing the process for success

• Sustain ensures that the company continue to continually improve using

the previous stages of 5S, maintain housekeeping, and conduct audits and
so forth. 5S should become part of the culture of the business and the
responsibility of everyone in the organization.
HOW TO IMPLEMENT?

•Establish and maintain responsibilities – requires leader

commitment to follow through
•Every one sticks to the rules and makes it a habit
•Participation of everyone in developing good habits and buy-in
•Regular audits and reviews
•Get to root cause of issues
•Aim for higher 5S levels – continuous improvement
EXAMPLES
BENEFITS

• Cleaner, safer, working environment

• Detailed tasks are documented to make processes more
efficient
• Work place is maintained in an organized fashion without clutter
• Tools and materials are easier to find
• Higher employee morale
 SUMMARY

• 5S is a process and method for creating and maintaining an organized,

clean, and high performance workplace.
• 5S enables anyone to distinguish between normal and abnormal
conditions at a glance.
• 5S is the foundation for continuous improvement, zero defects, cost
reduction, and a safe work area.
• 5S is a systematic way to improve the workplace, our
processes, and our products through production line employee involvement
• 5S is accomplished by following all of the steps. DO
NOT SKIP A STEP.
• 5S must become part of everyone's job.
• 5S is a team-oriented process between the members of
the work area.
THANK YOU FOR LISTENING!