To

5S
Training Program
PRIME CONSULTANTS

TRAINING PROGRAMME
ON
AWARENESS OF ISO/TS 16949

R.S.No. 887/2, Plot No. 11,

Behind Mohite Colony,
Ganapati Nagar, Kalamba Road,
Kolhapur-416007
Ph. No. 0231-2325204 / 9822800416
5S Training Program

5S Principles
Elimination of waste
Every body is involved,
Co-operative effort
Attack root cause
Human being is not infallible
(reliable, sure)
5S Training Program

5S Objectives
Improve housekeeping
Make every individual responsible for
housekeeping
Beautify by simple means
Productivity improvement by saving time,
space etc.
Elimination of waste
5S Training Program

5S Steps
Seiri - Sorting
Seiton - Systematic arrangement
Seiso - Cleaning & Inspection while cleaning
Seiketsu - Standardization
Shitsuke - Self Discipline
5S Training Program

Seiri – Sorting Out

Meaning
Distinguish between necessary and unnecessary
items and eliminate the unnecessary items

Activity
Establish a criteria for eliminating unwanted items.
Eliminate unwanted items either by disposing them
or by relocating them.

Success
Area saved or percentage of space available
Indicator
 5S Training Program

Frequency of use Storage Method

*Things you have not used Throw them out
in the past one year
W
LO

*Things you have used once Store at distance OR

in the last 6-12 months Keep in store

*Things you have used only Store it in central place

GE

once in the last 2-6 months in your zone

RA

*Things used more than once Store it in central place

VE

a month in your zone

A

*Things used once a week Store near the workplace

H

*Things used daily or hourly Store near the workplace

IG
H
5S Training Program

Identify unnecessary………..

1. Parts & Work in Process (WIP)

• Things fallen back behind the machine or rolled under it
• Broken items inside the machine
• Things under the racks/ platform
• Extra WIP
• Stock of rejected items
• Items accumulated over period for rework
• Material awaiting disposal decision
• Material brought for some trial, still lying even after trial
• Small qty of material no longer in use
5S Training Program

Identify unnecessary………..
2. Tools, Toolings, Measuring devices
• Old jigs, tools not in use are lying
• Modified tools, tooling for trial, are lying after trial
• Worn out items like bushes, liners, toggles etc. lying
• Broken tools, bits, etc. may be lying
• Measuring equipment not required for the operation
being performed , is lying
3. Contingency Parts
• Many times storage place for contingency parts become
a last refuge for broken parts, surplus items and things
nobody is likely to use
5S Training Program

Identify unnecessary………..
4. Shelves and Lockers
• Shelves and lockers tends to collect things that nobody
ever uses , like surplus, broken items etc.
5. Passages and Corners
• Dust, material not required seem to gather in corner
6. Besides Pillars and under the stairs
• These places tends to collect junk, spittoon etc.
7. Walls and Bulletin Boards
• Old out dated notices which have lost their relevance
• Posters or bulletins on wall
• Dust, remains of torn notices, cell tape pieces
5S Training Program

Identify unnecessary………..
8.Floor, Pits, Partitions
• Defective parts
• Protection caps, covers
• Packing material
• Hardware items , small items
• Even tools, tooling, items dropped on the floor are never
picked
9.Computer Hardware
• Many unwanted, outdated, temporary files pile up
5S Training Program

Dealing with papers………..

How to reduce papers
on your table ?

1. Make a single pile of papers

2. Go through them and sort in
following categories

a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information
5S Training Program

Seiton – Systematic Arrangement

Meaning
To determine type of storage and layout that will
ensure easy accessibility for everyone .

Activity
- Functional storage
- Creating place for everything and putting
everything in its place

Success
- Time saved in searching
- Time saved in material handling
5S Training Program

How to achieve Systematic Arrangement ?

Decide where things belong

- Standardize Nomenclature
- Determine an analytical method of storage
5S Training Program

How to achieve Systematic Arrangement ?

Decide how things should be put away

- Name & locations to everything.

- Label both item and location
- Store material functionally
- Prevent mistakes with coding by shapes & colour
- Follow first in first out rule
- If two identical items are to be located, then
store them separately, colour code them.
5S Training Program

How to achieve Systematic Arrangement ?

Obey the Put away rules

- Put the things back to their location after their

use
5S Training Program

How to achieve Systematic Arrangement ?

Obey the Put away rules

- Put the things back to their location after their

use
5S Training Program

How to achieve Systematic Arrangement ?

USE :

1 ) Signboards

2) Colour codes

3) Outline markings

4) Labels
5S Training Program

How to achieve Systematic Arrangement ?

Functional Storage

Usage Frequency
Store frequently used material near the workplace
and less frequently at some distance

Weight & Shape of the material

Heavy material should be stored at lower levels/
layers or place directly on the material handling
device for ease of handling
5S Training Program

How to achieve Systematic Arrangement ?

Functional Storage

Category
Same category of material may be stored in one
location.
Eg. Allen Screws, Oil Seals

Operation wise
All items required for an operation may be stored
in one location.
Eg. Allen key, spanner etc hand tools required for
setting m/c
5S Training Program

Seiso – Cleaning
Meaning
Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection

Activity
- Keep workplace spotlessly clean
- Inspection while cleaning
- Finding minor problems with cleaning inspection

Success
- Reduction in machine down time
- Reduction in no. of accidents
5S Training Program

How to do cleaning………….
- Here cleaning means more than just keeping
things clean. Cleaning should be viewed as a
form of Visual Inspection

- Preventive measures should be taken to tackle

problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated
5S Training Program

How to do cleaning………….
5 Minutes Every day for cleaning

- Devote 5 minutes everyday for cleaning your

work area

- Participation of everyone is required

- Attack hard to clean places regularly

5S Training Program

Cleaning/Inspection points……
Oils
No oil, Low oil, leakage, filter clogging, dirty oil,
dirty or bent oil lines, clogged drainage, oil
spillage, worn& torn ports etc.

Tightening
Loose bolts, welding detachment, loose parts,
vibration or bumping noise, friction

Heating
Oil tanks, motors, heater, axles, control panels,
washing/ cleaning water, bearing, wiring etc.
5S Training Program

Cleaning/Inspection points……
Breakage / Cracks
Breakage, cracks, dent on sliding parts, handle has
come off, broken switches, wire joints come off,
wires are broken or crack, crack dial of various
pre. gauges, meters etc.

Pneumatics / Hydraulics
Compressed Air lines, air valves, connections,
meters, filters, reservoirs etc.
Hydraulic oil tank, oil valves, filters, pumps, hoses,
gauges, cylinders etc.
5S Training Program

Seiketsu – Standardisation
Meaning
Setting up standards / Norms for a neat, clean,
workplace and details of how to maintain the norm

Activity
- Innovative visual management
- Colour coding
- Early detection of problem and early action

Success
- Increase in 5S indicator
5S Training Program

Standardisation……
• Make it easy for everyone to identify the state
of normal or abnormal condition

• For maintaining previous 3S, deploy visual

management

• It has been estimated by scientific study that

60% of all human activities starts with sight

• 5S is easy to do once. It is consistency that is

difficult. That is why Visual Management is so
important.
5S Training Program

Standardisation……

What visual control communicates ?

It grabs one or more of our senses in order to

Alert us to an abnormality
Help us recover quickly
Promote adherence and prevention
Enable successful self management
5S Training Program

Standardisation……

Some methods for visual communication

 Colour coding
 Use of Labels
 Danger alerts
 Indication where things should be put
 Directional arrows/ marks
 Transparent covers
 Performance indicators
5S Training Program

Shitsuke – Self Discipline

Meaning
Every one sticks to the rule and makes it a habit

Activity
- Participation of everyone in developing good
habits
- Regular audits and aiming for higher level

Success
- High employee morale
- Involvement of all people
5S Training Program

Self Discipline……

Activities :

5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.