5S TRAIN - THE -TRAINER

PROGRAMME
 5S TRAIN - THE -TRAINER PROGRAMME
Contents:
• Objective
• What is expected of you!
• What is 5S?
• 5 S LEADERSHIP OF THE CEO & MANAGEMENT
• SEIRI
• SEITON
• SEISO
• SEIKETSU
• SHITSUKE
 WHAT IS EXPECTED OF YOU!
• Be a Leader – Not a follower
• 5 S Concept manual – Read and Understand
• Take notes before they disappear from mind
• Understand, Gain knowledge, ask Questions
• 5 S in every department/Section with full
participation
• Involvement, Commitment & Dedication
• Be a 5 S Consultant**
 WHAT IS 5S?
• SEIRI SORTING

• SEITON SET IN ORDER (ORGANIZE)

 
• SEISO SHINE (CLEANING)

• SEIKETSU STANDARDIZE

• SHITSUKE SUSTAIN (TRAINING AND SELF-CONTROL)

 How to structures
5S Implementation ?
 5S Leadership of the CEO & Management

 Role & Commitment of the top management

 Sustainability of 5S activity
 Educate and reinforce the importance of 5S for
middle Mgt.
 Setting up 5S Committees
 5S campaigns
 Reward and recognition for the jobs well done
 5S Leadership of the CEO & Management

Visible commitment by management to sustaining the

program.
As leader,

 you need to strongly encourage your senior management to

make regular visits, communicate, show interest, promote and
participate in the activities that form part of the ongoing 5S
program.
 Ensure senior management reacts quickly to problems and
participates in the resolution of them.
 Senior management needs to empower their organization to
improve and maintain their workplace.
Main 5S Committee / Steering Committee

Advisor
(CEO/Director)

Chairman
(SM who can
command the
respect of others)

MR
(Executive with Committee
Authority & Members (Business
Leadership Unit Directors)
qualities)
 Main 5S Committee / Steering Committee

 By Monthly progress Review meeting Minutes

 Main 5S committee meetings – ones in 2 or 4 week
 Minutes communicate by MR within 2days (48 Hrs.)
 Minute book or file to be maintained.
 5S Committee

Advisor
(Head of the
Factory)

Chairman
(SM/SE who can
command the
respect of others)

MR
(Executive with Committee
Authority & Members (Head of the
Leadership Dept.)
qualities)
 5S Committee

 5S committee meetings – ones in 1 or 2 week

 Minutes communicate by MR within 2days
 Minute book or file to be maintained.
 Form a Petrol team for Audit 5S practices
 5-7 Senior staff members from different department
 Even 3 members should have to participate for an
audit.
 Committee members should have to get a discussion
for 15 minutes once a week with Sub committee
members
 5S Sub Committee

Advisor
Committee Member (Head of the Department)

Chairman (SE/SM who can command the respect of others)

 5S Sub Committee

 Every department should have one or more sub

committee
 Secretary should have record minutes & trainer’s
instructions on a register
 Use 3W (What, Who & When) method for record
 Sub committee members should get a discussion for
5-10 mints once in one or two day (Floor, Standing)
 5S Progress Review

 Initial Stage - Once in two week

 After maintained in credible stage – Once in four
week
 Maximum 60 minutes take for a meeting

 Team – Steering committee members/Member

Committee members
Sub committee members
 5S Audit

 Conduct monthly MOCK Audits

 Review audit progress by weekly
 Conduct internal audits
 Do a Mock audit with Petrol team
 Petrol team represent by committee members
 Minimum 3 members should involve for an audit
 Display audit results in a common notice
 Recognize best dept. that has done well at each
audits
 Reprimands dept. who has not progressed
 5S Manual
 Prepare by the MR/Secretary
 MR to compile all data in his/her computer and later
take hard copies to prepare the 5S manual
 Relevant data such as
• Pre-5S and post 5S Photographs
• Main committee meeting minutes
• Sub committee meeting minutes
• Other activities etc..
• Vision & mission
 Every steps taken in the implementation of the 5S
concept should be record
 In sub sequence years manual would be the
reference to related activities
 SEIRI – (SORTING)

Clutter free Environment in Premises,

inside offices and Workplace etc.
Evidence of removal of unwanted
items should be evident all round.
• Outside & Inside area of the premises free of clutter
• Unwanted items removed from Premises, Office, and Workplace etc.
• Top and insides of all cupboards, shelves, tables, drawers etc. free of unwanted
items.
• Walls are free of old posters, calendars, pictures.
• Notice Boards – Current Notices with removal instruction.
• Rules for disposal with Red Tags etc.

RED TAG NOTICE

What:………………………………….

Why:……………………………………

Who:…………………………………..

When:…………………………………

Remarks:……………………………..
• Maintenance / Prevention of Seiri Projects established with Mechanism to
reduce paperwork, stocks etc.
Drama #1
 SEITON – (ORGANISATION)

Ability to find whatever is required

with the least possible delay.
Evidence of eliminating the waste
of time throughout the Institute /
Organization.
• Photographic evidence of Pre 5S Implementation and afterwards.
• Visual control methods adopted to prevent mix-up.
• Directional Boards to all facilities from the Entrance onwards.
• All machines/Rooms/Toilets have identification labels.
• All Equipment/ Tools/ Files etc.., arranged according to ‘Can See’, ’Can Talk Out’
and Can Return’ principle.
• X- Axis, Y- axis alignment is evident everywhere.
• Gangways clearly marked with Passageways / Entrances & Entrances & Exit
Lines / Curved door openings/ Direction of travel.
• Parking areas specified for Vehicle, Pallets, Trolleys, and Garbage Bins etc.
• Parking areas specified for Vehicle, Pallets, Trolleys, and Garbage Bins etc.
• Cables /Wires/Pipes etc. are laid Neat/Straight & color coded.
• Cables /Wires/Pipes etc. are laid Neat/Straight & color coded.
• Electrical Lights, Switches, Fans Regulators etc.. labeled
• Storage area maintained with Racks/Bins and clearly marked.
Drama #2
 SEISO – (Cleanliness)

The cleanliness all-round the Institute

/Organization should have been
carried out according to the 5S
concepts, as if an Inspection is to take
place.
Floors, Walls, Windows, Toilets, and Change rooms in working order & clean.
• Daily self – Cleaning (5 min) has to be practiced.
• Cleaning responsibility Map and Schedules Displayed.
• Waste bin strategy is implemented.
• Use of adequate Cleaning Tools is evident.
• Storage of Cleaning Tools- Brooms/Map/Other equipment.
• Machines /Equipment/Tools/Furniture at a high level of Cleanliness & maintenance
schedules displayed.
• General appearance of cleanliness all round.
Drama #3
 SEIKETSU-(STANDARDISATION)

High level of standardization in all

activities carried out in SEIRI, SEITON,
and SEISO and the evidence of such
standards being practiced all round.
• 5S procedures adopted & standardized on Check List & Labels.
• 5S procedures adopted & standardized in Corridors/Isles & Gangways.
• Orderliness in the use of Corridors/Isles/Gangways by Pedestrians.
 • Visuals on Danger, Open & Shut directional Labels on Valves/Doors etc.

EXAMPLE
EXAMPLE
• Standardized Visuals on Oil/Lubricant Containers & Fire Extinguishers etc.
• Pipes/Cables etc., color coded according to the international standard.
Machine / Document Table

Floor Colour

Walk Way

passenger crossing

Hazard or Hazardous Area / Gantry Columns up to 5’ from

the floor
Electrical Wiring

Main Panel (Toyota White)

Main Panel (Toyota White)

Oil lines / Tanks

Air lines
Floor Demarcations

Water lines

Ovens / Steam lines (Silver)

Racks

Safety bar / Safety Guards /

Emergency Switch

/////////////////////////////////////
///////////////
Emergency Rope
 Area demarcation

Raw Material (Dark Blue Boarder)

Racks

Quarantine Area

Finish good

Rejected material storing area

• Innovative Visual Control methods implemented.
• Maintenance/Storage of files/Records in offices/Workplace etc.
• Standardization/Orderliness in kept in furniture/Equipment.
• Standardize check list for common Administrative Procedures.
COMPUTER WIRE MANAGEMENT SYSTEM
Standard Color

From To Colour
Power UPS
Network Cable
UPS CPU
CPU Monitor
CPU Mouse
CPU Key Board
CPU Printer
CPU Scanner
Power Printer
Drama #4
 SHITSUKE – (SELF DISCIPLINE)
Evidence of a disciplined approach to all 5S activities through proper
training and development, which shows the sustainability in the long
term.

• Evidence of regular training program for all categories of employees.

• Evidence of 5S group activities and promotion of KaiZen Schemes.

• Evidence in carrying out internal audits by patrol teams.

• Self-Discipline amongst Workforce/Good & Bad Point Stickers etc.

• Evidence of 5S slogan & poster competitions among Employees’ Families.

• Evidence of self-discipline among Visitors to the Institution.

• Evidence of Self-Discipline in the overall institution.

Drama #5
THANK YOU