Prepared by

M.Ganesh Murugan
9715447621
MGM 1
 Necessity of 5S

Productivity
improvement

Quality assurance
Cost reduction
Job satisfaction

Deadline observation Happy workplace Secure production

volume

Workplace improvement
SEIRI SHITSUKE

SEITON SEIKETSU
SEISO
MGM 2
The 5 Words
5S is a method that uses five
Japanese words which start
with the letter S

MGM 3
5S
5 Steps to a Better Workplace

MGM 4
Why 5 S?
The Purpose of 5S is to promote a safe
and efficient work environment
 Not just a cleaning campaign, 5S is a way
to set a new standard that we all agree on
and help us get the discipline we need to
maintain it.
By Implementing the 5S
 Opportunity to improve the own
workplace
 Team involvement & Problem solving
opportunities appears.
5S gives visible and Motivating
Results
 First step in the implementation of Lean
Manufacturing, TPM an Kaizen.

MGM 5
Reasons to implement 5S
Improved Safety
 No items on the floor
 Therefore fewer slips or falls
 Safety device in their right places
 Less dust

MGM 6
Reasons to implement 5S
Improved Safety
Fewer break downs
 Fewer “strange ” errors from electronic
systems
 Less wear from dust or grit in moving
parts

MGM 7
Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
 A clean & well functioning workplace
 Fix the unsafe & cluttered work
stations

MGM 8
Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
 Leakages such as oil will easily be
spotted
 Using less floor space may reduce
energy consumption

MGM 9
Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
 Easy to do it right than wrong
 Safety guards placed properly
 Less clutter, fewer visual distractions&
easy access to tools and materials

MGM 10
Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
 When you do 5S , you inspect the
same

MGM 11
Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
No searching
 Effective tools at the right place

MGM 12
Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
No searching
Higher morale
 Through teamwork and visible results

MGM 13
Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
No searching
Higher morale
Goodwill
 Helpfulness to create an
impression.
MGM 14
The 5 phases in 5S

MGM 15
Step 1 - Sorting
Sorting is a team activity that
will be carried out by the
production an d maintenance
personnel together
Sorting has two purposes
Remove unnecessary objects
Reduce waste

MGM 16
Remove unnecessary Objects
Go through the whole plant
Look for
Materials
 Behind or under machines
 Rejects
 Forgotten materials

MGM 17
Remove unnecessary Objects
Go through the whole plant
Look for
Materials
Tools
 Not in use
 Worn out or broken
 “Custom-made” tools (made
of steel wire/tape/etc-Replace
by real tools

MGM 18
Remove unnecessary Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
 Broken
 Surplus Inventory
 Spare parts for machines no
longer in use

MGM 19
Remove unnecessary Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
Out-of-date Documentation
 Instructions
 Binders
 Manuals

MGM 20
Remove unnecessary Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
Out-of-date Documentation
Bulletin board
 Outdated notices
 Irrelevant information

MGM 21
Remove unnecessary Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
Out-of-date Documentation
Bulletin board
Other stuff
 Outdated computer hardware
 Packing Material
 Outdated protective equipment
MGM 22
Remove unnecessary Objects ?
Look at each object
Ask yourself, Do we need it at all?
If not – Discard it or sell it
Ask yourself, Will we need it
soon?
If not – Put it in proper storage
eg:- spare parts, etc.
Is it working , but..
Too difficult to use
In correct design
Too time consuming to use
Has a high risk for injury/quality?
MGM 23
Remove unnecessary Objects ?
Each item to be discarded or
corrected is marked with a red tag

MGM 24
Waste elimination
The second purpose of sorting is
to reduce waste and generate
ideas for improvements
We will try to identify every thing
that is hindering us from working
safely and efficiently

MGM 25
Waste elimination
Try to identify every thing that is
hindering us from working safely
and efficiently
Work instrutions
Do we have them?
Are they up-to-date?
Are they in use? If not – why not?

MGM 26
Waste elimination
Try to identify every thing that is
hindering us from working safely
and efficiently
Work instructions
Safety
What measures should we take to
eliminate the risk of fire and
accidents?
 Remove clutter
 Improve unsafe electrical
installations
 Replace broken safety devices
MGM  Repair broken components 27
Waste elimination
Try to identify every thing that is
hindering us from working safely
and efficiently
Work instructions
Safety
Environment
What measures do we need to
minimize or prevent damage to
the environment?

MGM 28
Waste elimination
Try to identify every thing that is
hindering us from working safely
and efficiently
Work instructions
Safety
Environment
Tools and equipment
Anything missing ?
Anything not working properly ?
Anything in need of improvement?

MGM 29
Waste elimination
Try to identify every thing that is
hindering us from working safely
and efficiently
Work instructions
Safety
Environment
Tools and equipment
Inconvenient work positions
Seat & work s/f’s at the right
height
Awkward angles for moving
MGM materials 30
Waste elimination
Try to identify every thing that is
hindering us from working safely
and efficiently
Work instructions
Safety
Environment
Tools and equipment
Inconvenient work positions
Deferred maintenance
Temporary repairs/not properly
secured
MGM 31

Waste elimination
Try to identify every thing that is
hindering us from working safely
and efficiently
Work instructions
Safety
Environment
Tools and equipment
Inconvenient work positions
Deferred maintenance
Improvement Proposals
Review prior suggestions
MGM 32
Waste elimination
All identified waste items are
marked with an red tag

Machine tagged with errors and improved suggestions

MGM 33
5S Sort list
Every tag refers to a 5S Sort list

Think break
• Do we have any examples of deferred maintenance in our
plant?

Tag no Item description Session tagged Date Tagged by Responsible Due date

MGM 34
Question yourself – Seiri
• Do you find items scattered at your
place?
• Are any items left in disorganized
way?
• Are all item sorted and kept in
designated place?
• Are tools and stationeries properly
sorted and stored?

MGM 35
Step 2 – Set in Order
Every tag refers to a 5S Sort list

MGM 36
Missing letter ?
Every tag refers to a 5S Sort list

MGM 37
Why-set in order?
• The purpose of Seiton – set in order
is that everything that we regularly
use should have a convenient
placement
• Tools should be kept at the point
of use
• No bending to pickup or move
materials
• Alter flow paths to improve
efficiency

MGM 38
Placement

MGM 39
Efficient layout and color coding
• Make a drawing of the current
situation
• Brainstorm to find an optimal
layout
• Agree the color code
• Mark the location(removable tapes
preferred) of all objects
• Move the equipments if necessary

MGM 40
Question yourself – Seiton?
• Are passages and storages clearly
indicated?
• Commonly used tools &
stationeries separated from the
seldom used?
• Are containers, boxes, materials
and fire extinguishers stocked up
properly?
• Are there grooves, cracks or bumps
on the floor which hinder work or
safely?
MGM 41
Step 3 – Shiny clean
Next step in 5S is to carry out a Shiny clean event

MGM 42
Shiny clean
• To keep your area clean on a
continuing basis
• Clean all machines thorough
• Clean all equipments,
fixtures, and tools
• Clean the floor, walls,
cabinets, shelves etc.

MGM 43
Why – Seiso?
• To prevent the area from getting
dirty in the first place, so we
don’t have to clean it up
afterward
• A clean workplace is indicative of
a quality product and process
• Dust and dirt cause potential
health hazards
• Things to remember :-
• Sweep/Vacuum
• Dust / Mop
MGM 44
Guidelines – Seiso?
• Divide areas into zones

• Define responsibilities for cleaning

• Tools and equipment must be owned by an individual

• Focus on removing the need to clean

MGM 45
Question yourself – Seiso?
• Are machines and equipments dirty?

• Are pipes dirty and corroded?

• Are nozzles dirtied by lubricants and

ink?
• Are shades, lights, bulbs, and light
reflectors dirty?

MGM 46
Step 4 – Standardized cleanup
Continue sorting, storing and cleaning to maintain serene
atmosphere at all times

MGM 47
Why – Seiketsu?
• Prevents regression back to an unclean/disorganized
environment
• Things to remember :-
• Develop schedules, checklists
• Periodically evaluate area using 5”S” Audit sheet
• Continually improve neatness

MGM 48
Phases of Seiketsu?
• Clarification of vital points for management Things to
remember :-
• What are the minute defects?
• Basic conditions: Cleanliness, refueling, replace tightly bind
fast, dirt, looseness
• Operating conditions: pressure, temperature, time, flow
volume, weight, Equipment, jigs and tools, sub-materials
1

MGM 49
Phases of Seiketsu?
• Prepare standards for the conditions
• Objectification of judgment standards for normal versus
abnormal
• Judgment without using measurement, knowledge, intuition
and knack

MGM 50
Phases of Seiketsu?
• Judgment standards for abnormalities
• Inspection methods that can be used by anybody
• Methods for actions against abnormalities

MGM 51
Question yourself – Seiketsu?
• Are there sufficient light?
• Is there noise/light in your place
causing discomfort?
• Do people work at designated
way?
• Is there any leakage?

MGM 52
Step 5 - Shitsuke

MGM 53
Shitsuke
• To maintain discipline, we need to
practice and repeat until it
becomes a way of life

MGM 54
Shitsuke
• Make sure you stick to standard procedures
and make them a habit
• Be disciplined to follow rules and regulations to
maintain standards

MGM 55
Why – Shitsuke?
• To build “housekeeping” into every day process
• Makes the 7 wastes visible
• Gets everyone involved
• Things to remember :-
• Training everyone is vital
• Involvement from all is necessary
• Commitment and discipline toward housekeeping is essential
in taking the first step in being World Class
• 5 “S” RATING
• 0= Poor (Unacceptable)
• 2= Satisfactory
MGM• 4= Excellent ( World Class Environment) 56
Question yourself – Shitsuke?
• If 4S done?
• Are regular 5s check conducted?
• Do people involved without
reminder?
• Do assemble at time?

MGM 57
Action Plan for Implementing 5S
 Awareness programme of 5s for all employees, supervisors, engineers and

managers.
 Form steering committee

 Application programme on 5S for all Employees

 Steering committee periodically evaluates all cells, scores displayed on the

display board
 Display posters on house keeping, distribute cards on 5S to all employees

 Annual award for the best cell

MGM 58
Advantages of 5S
 If tools and materials are conveniently located in uncluttered work areas

 Operators spend less time looking for items

 This leads to higher workstation efficiency, a fundamental goal in mass production

 A clean and tidy workplace leads to greater well being and increased motivation

 Company image improves

 Time saving

 Quick retrieval

 Accidents & mistakes minimized

 Increases space

 Creates workplace ownership

 Foundation of all qc tools

 Continuous quality improvement

 Lean manufacturing

 Visual management system

 Results in a place easier to manage

 Smooth working no obstruction

MGM 59
Checking System

MGM 60
5S Audit
Three purposes of conducting regular 5S Audit reviews are:

• Review compliance to the 5S standards for your factory

• Note and address non-compliance – to fix what is wrong!

• Provide a formal opportunity to suggest improvements

MGM 61
The Basic Steps
• Plan for the audit by dividing the workplace into various
areas, probably the same ones where different teams
conducted the various 5S stages.
• Make a checklist for each area, based on the standards that
were set during 5S.
• Find out the list of known problems in each area. From the
initial 5S sweep, this may include:
• Machines needing repair
• Tool racks
• Signage on tool racks or cabinets or storage shelves; warning signs;
“keep clear” markings for corridors; or instruction pages
• Surplus equipment or materials which were not immediately removed
MGM 62
During the audit, three key tasks
ONE
• Determine whether known problems have been addressed:
• Does this machine still leak lubricants?
• Has the required tool rack been installed in this area? Is it labeled? Is
it full? Are tools still left on workbenches?
• Is the warning sign in place so people will not walk under this crane?
• Why is this outdated drill press still in the corner?

MGM 63
During the audit, three key tasks
TWO
• See that standards are being met:
• Are tools left on workbenches?
• Is something missing from a tool rack?
• Is dirt accumulating somewhere?
• Are existing labels still visible and easily read? (This is especially
important for signs that may be obscured by dust, and for lines
painted on floors where they can be scuffed)
• Are there new sounds or smells that indicate that gears are grinding
or fluids are leaking?

MGM 64
During the audit, three key tasks
THREE
• Note what has not yet been standardized – this is the most
creative and difficult part, because it may involve seeing what
is missing in an area that seems tidy:
• Why is there no sign over the neat stack of work-in-process materials
on that shelf? (How will the next shift know what is there, or what
should go there?)
• Tools that are not yet labeled
• Is there a limit to how high those barrels can be stacked? Why don’t
we show that information on the sign for that storage area?
• Do we need all those cans of wing nuts in this assembly area? How
many are used in one day? Should the rest of the month’s supply be
stored elsewhere?
MGM 65
Safety infractions should also be part
of the 5S audit
• Are WHMIS (Workplace Hazardous Materials Information
System) labels used properly?
• Are fire exits visible and clear? Are the fire extinguishers
charged and inspected on schedule?
• Are stairs and ladders safe?
• Do we notice unsafe behavior regarding heights and falls?
Climbing a ladder without maintaining three points of
contact? Working on a height without the required safety
tether?

MGM 66
To follow up on each 5S audit
• Write up a work order to deal with each deficiency
• Update the next check list:
• Check off what was corrected
• Add new deficiencies to be reviewed
• Determine the score:
• Deduct for each deficiency
• Add a point for each correction
• Add a point for each suggestion for improvement
• If the previous audit had found deficiencies, the goal is to
eradicate them
• The ultimate goal is to regularly achieve zero outstanding
MGM deficiencies 67
How often should audits be Performed?
Regular audits lead to the best results:
• Weekly “self-check” audits by teams of workers, reviewing
their own areas
• This might be the best way to generate suggestions for
improvements
• Monthly audits by the area supervisor
• Ensure that the weekly audits catch any problems with the daily
or weekly cleanups
• Pay special attention to the less-frequent cleaning tasks
• Try to notice what is missing: new tools that do not yet have a
place in a rack; materials stored neatly but not well-labeled
MGM 68
How often should audits be Performed?
• Quarterly audits by the plant manager
• Ensure that standards are being met
• If there are deficiencies, ask “why”: try to determine the root
causes
• Ensure that resources are allocated to repairs and to making the
long-term improvements
• Without audits, it is impossible to ensure compliance.

MGM 69
5S Audit check sheet

Model follows

MGM 70
MGM 71
 Prepared by
M.Ganesh Murugan
9715447621
MGM 72