5S

WORKPLACE ORGANIZATION

Engr. Motahar Hosen

B.Sc. in IPE(SUST), MBA(EWU),
MEcon in Environmental Economics(DU)
Introduction to 5S

5Sis the workplace organization method

Method is composed of five pillars and pillars

name starts with S

Sort, Set in order, Shine, Standardize and Sustain

Japanese words: seiri, seiton, seiso, seiketsu, and

shitsuke.
 What Is 5S?

A process and method for creating

and maintaining a safe, organized,
clean and high-performance
workplace.
The Origins of 5S

5S was developed in Japan and was identified as

one of the techniques that accelerated Just in
Time manufacturing.

Just-in-time (JIT) manufacturing, also known as

just-in-time production or the Toyota production
system (TPS)

It is a methodology to reduce flow times???

within production.
The 5 Steps are as follows:

 Sort: Sort out & separate items that is needed & not
needed in the area.
 Set in order : 1. Arrange needed items so that these would
be easy to use. 2. Clearly define locations for all items so
that anyone can find them & return them after completing
the task.
 Shine: Clean the workplace & equipment on a regular
basis.
 Standardize: Revisit the first three of the 5S on a frequent
basis and confirm that 3S are working at defined procedures.
 Sustain: Keep to the rules to maintain the standard &
continue to improve every day.
THE 5 PILLARS OF WORKPLACE ORGANIZATION

SORT SET IN ORDER. SHINE

STANDARDIZE SUSTAIN
Objectives of 5S

5 Pillars of the Visual work place leads to make your

company more
Pleasant work place
Greater job satisfaction and
An opportunity to provide creative input to the way
your work should be done.
FIRST PILLAR: SORT
Sort means that you remove all items from the
workplace that are not needed for current
production operations.
Example
 Remove unneeded equipment, trims and others tools for current
production helps to avoid obstacle to production activities.
 Large quantity of inventory requires more space and management.
Implementing 1st Pillar: Sort

1. Setting up the 5S Core Team

Prior to commencement of the 5S project, a 5S
team and one leader of this team is needed

2. Training the Core Team

To understand what the 5S core team must cover

How to manage the project and communication across
the organization?
 Implementing 1st Pillar: Sort
3. Implement the Red tagging project
 Mapping the selected workplace to identify potentially unneeded
items in the factory, and evaluation of it’s usefulness

Steps:
 Launch the red tag project
 Identify the red tag targets
 Set red tag criteria
 Make red tags
 Attach red tags
 Evaluate red tagged items
 Document the results (goals) of red tagging
Red Tag Area

 The red tag area is simply a storage location

for red tagged items that is segregated from the
production areas.
 RED TAGGING PROCESS
CATEGORY: 1. Raw material 5. Machine or other eqp.

2. In-process stock 6. Folder or attachment

3. Semi-finished goods 7. Tools and supplies

4. Products 8. Other

ITEM NAME:

MNF. NO:

QTY: Units Units value Total cost ?????????

REASON

MNGD BY

EVAL DATE

MOVEMENT WHERE WHO WHEN HOW MANY

Red Tag
when a person finds an item either don’t
know about it , or is not needed in a
process, they tag it.
Floor 5 S Tag Number
Line Red T ag
Ca te gory
1.Raw Material 5.W IP 10.Others
2.Finished Good 6.Tools
3.Equipments 7.Supplies
4.Office Materials 8.Furnitures
Tag Date
Item Name
Quantity
Reason Tagged
Action to be Ta ke n
1. Discard 4. Reduce
2. In floor storage 5. Transfer
3. Send to Store 6. Organize
7. Others (Specify)

Action Ta ke n Date
W ho:
Description:
Unneeded Item - Suggestion

4. Accumulation of unneeded items

Certain types of unneeded items tend to accumulate in

factories and warehouses in predictable places.

Ithas to take the decision how to dispose the recognized

unwanted .(Throw it away, Sell, Return, Lend out,
Distribute, Central red tag area)
Types of unneeded items
 Defective or excess quantities of small parts and
inventory
 Finished thread cones
 Unneeded fabric pieces
 Broken tools
 Empty oil bottles
SECOND PILLAR: SET IN ORDER
Set in order can be defined as arranging needed items in
such a way so that it can helps to use and find those items
easily. Give focus on following two

1. 1. Arrange items as it’s demand and frequency of need

2. 2. Labeling the them so that they are easy to find and put
away.

Example
 All trims must be uniquely placed away in an identified and organized place.
For exm: Rack, Drawers, etc.
 Documents, Metals parts as trims, etc.
SECOND PILLAR: SET IN ORDER

 The second pillar, Set in order can be implemented only when

the first pillar is in place.

 Similarly, if sorting is implemented without Setting in order, it is

much less effective. Sort and Set in order work best when
they are implemented together.
Implementing 2nd Pillar: Set-In-Order

Step 1
Before you arrange the best place for the separated needed items
you must aware of the below principles.

Locate items in the work place according to their frequency of

use???

 Store items together if they are used together, and store them in
the sequence in which they are used
Implementing 2nd Pillar Set-In-Order

Step 2

Once best location have been decided, we need a way to

identify these locations so that everyone will know what
goes where and how many of each item belong in each
location.

 The signboard strategy uses signboards to identify what, where

and how many.

 The painting strategy is a method for identifying location on

floors and walkways.
Sign Board Strategy
The signboard strategy uses signboards to
identify what, where and how many.
 Factory - work place - line - process
 Large and clear signs
 Use Colors to distinguish
 All machines identified by name and number
 All assets to have inventory number but placed
discreetly not like the government dept. method
 All employees to have name tags
 Sizes should be appropriate
Floor Painting Strategy
The painting strategy is a method for identifying
location on floors and walkways.

 Working areas - green

 Aisles - orange
 Rest areas - Blue
 Warehouses - Gray
 Types of lines and sizes
 Door opening lines
 Storage space lines
Examples: Floor Marking Color Codes
Color Designation

Red  Flammable area

 Nonflammable corrosive / unstable
material container storage area
 Physical hazard
 Rejected material

Green Location of first aid and safety

equipment, Working areas
Blue Materials management (e.g. shipping,
receiving, kanban, SWIP, etc.)

Yellow Aisles and walkways

Safety Signs
 “Don’t do “ signs
 “Must do” signs
 Warning signs
 Safe way signs
 Different colors
THIRD PILLAR: SHINE
Shine means sweeping floors, wiping off machinery and
generally make sure everything on the floor stays clean.
However, maintenance tasks must be taken daily through
defined checkpoints.

Example
 Machineries dust off and maintained.
 Floor are free of any object could create obstacles
and danger to employees and the product.
Problems avoided by shine
 Windows are so dirty that very little sunlight filters
through. This leads to poor morale and inefficient work.
 Defects are less obvious in dark, messy factories
 Puddles of oil and water cause slipping and injuries
 Machines do not receive sufficient check up maintenance
and tent to breakdown frequently.
 Machines that do not receive sufficient maintenance tent
to operate incorrectly at times, which can be hazardous
 Filthy work environments can be lower morale
Implementing the 3rd Pillar: SHINE
Step 01:
Set the target (area, item) for the cleaning activities
 Nominate the subordinates for the cleaning activities
cleaning activities on three categories: Inventory items,
equipment and space.

Step 02:
Assign the specific areas to individuals.
It includes who is responsible for cleaning for which
areas, in which days and for what times.
Planning the 3rd Pillar SHINE
Step 03:
It is important to set aside times for these shine activities so that
they eventually become a natural part of the workday.
 Define times for common shine activities????
Ex: We can ring a bell 5 minutes time per day or play music to
clean the individual’s working environment by them.

.
Planning the 3rd Pillar SHINE
 Step04: Cleaning tools should be stored in the
places where they are easy to find, use and
return
FOURTH PILLAR: STANDARDIZE

The first three pillars are activities to organize the

workplace.
But standardize is the method are used to maintain the
first three pillars Sort-Set in order and Shine.
Implementing 4th Pillar: STANDARDIZE

1. Assign 3S responsibilities

 If people are not given clear 3S job assignments based

on their own workplaces then the Sort, Set in order and
Shine activities will not have much meaning.
 5S team has to make the 5S checklist showing clearly
who is responsible for each job, which area, what to do,
and when to do it.
Implementing 4th Pillar: STANDARDIZE
2. Integrate 3S Duties into regular work duties

 Maintenance of 3S must become a natural part

of everyone’s regular work duties.
 Launch of “5 minutes 5S” program for every
day. It will cover all three pillars (Sort, Set in
order and Shine)
 Need to evaluate how well the three pillars are
being maintained.
 5S Team has to make the Standardization-level
check list to evaluate the maintenance level.
 Supervisor's Daily 5S Checklist
Factory: Section/Line: Duration:
Check Point Sat Sun Mon Tue Wed Thu
Unnecessary items removed from working area

Materials in the supermarket & station are organized & labeled

All materials are in designated place

All materials are in required quantity

Standard WIP is at designated level (per documentation)

Carts & pallets,etc, should keep in designated place

All tools are in place and functional

Air pressure should keep in a designated place

Brooms & dustpans in designated areas, keep the garbage bin

clean in time
Floor clean & free of debris, thrums, water, oil, gum, defect
sticker, etc

Equipment clean & functional

Standard Operation & SQCD board are in place and updated

Keep windows, door, lights, machine been closed berore leaving

Remark:Use√and ╳ to check, for any special issue

should write remark
Checked by:

Remarks: Line Supervisor should check before starting the work

FIFTH PILLAR: SUSTAIN

i. Sustain making a habit of properly maintaining correct

procedures.

ii. The first four pillar can be implemented without any

difficulty if the workplace is where employees commit to
sustain the 5S conditions

iii. Without Sustain the others four pillars will not last longer.
Implementing 5th Pillar : SUSTAIN
Factory must create conditions or structures that will help to
sustain a commitment to the five pillars such as:
Awareness: You and your employees need to understand what the five pillars are and
how to important to sustain them.

Time: You need to give time in your work schedule to perform 5S daily.

Structure: You need to have support for your efforts from management, in terms of
acknowledgment, leadership and resources.

Rewards & recognition: Your effort need to be rewarded.

Satisfaction & Excitement: Implementation of 5 Pillars must be fun and satisfying for
you and the company. Excitement gets communicated from person to person
allowing 5S to build as it involves more people.
Tools & Techniques to
sustain 5S Implementation
There are many tools and techniques your factory can use to help
sustain commitment to 5S implementation. We offer these below so
you will be aware of them. And also 5S team can develop some tools
for the same purpose.

5S Slogans: Communicate the themes of the five pillar campaign in

your factory. They can be displayed on machines,
stickers, flags, or posters
5S Posters: 5S slogans descriptions of 5S activities can be posted
throughout the workplace.
5S Photo: Story board “Picture is worth a thousand words.”
Photo exhibits and Story board showing the before
and after of 5S implementation activities..
Tools & Techniques to
sustain 5S Implementation

5S Maps: Can also be used to get employee involved in

five pillar improvement on an ongoing basis.
Those should be hung in a central location
with suggestion cards attached so anyone can
suggest improvements.

5S Pocket manuals: Can be created that contains five pillar

definitions and descriptions, and is small
enough to fit into the pocket of work clothes.
Tools & Techniques to
sustain 5S Implementation
5S Department tours: When one department in a company has
implemented the five pillars successfully, it can
serve as a model area for other departments to
come visit. Since “seeing is believing,” this
technique is extremely effective for promoting
5S implementation throughout a company.

5S Months: Campaigns should be designate two, three or

four months every year as “5S Months.”
During these months, various activities such as
5S seminars, field trips, and contests can be
carried out to further promote 5S
implementation in the company.
5S Posters
Create the Kaizen Event for 5S
5S Implementation must be done under 3 Kaizen Events
as follows:

Event 1: Covers the 3 Pillars

Red Tagging, Get the requirements such as: Shelves,
tables, set them in order then shine.
If the tools and requirements are on hands then this
event can be 1 week event for one specific area. If
not then it can be 2 weeks event.
Event 2: Covers Standardize – 1 Week
Event 3: Covers Sustain and Consciousness – 2 Weeks
THANK YOU