Module Objectives

By the end of this module the participant will be able to:

• Understand what each of the 5S’s stands for and

its true meaning.
• Understand how 5S is the foundation for many
other improvements.
• Understand how each “S” create a systematic
method to improve a work area.

03/19/23 BPASCUA BPASCUA

12345

Welcome to 5 `S’
Program

03/19/23 BPASCUA BPASCUA

03/19/23 VENVI FEEDMILL CONFIDENTIAL BPASCUA
03/19/23 VENVI FEEDMILL CONFIDENTIAL BPASCUA
03/19/23 VENVI FEEDMILL CONFIDENTIAL BPASCUA
03/19/23 VENVI FEEDMILL CONFIDENTIAL BPASCUA
03/19/23 VENVI FEEDMILL CONFIDENTIAL BPASCUA
03/19/23 VENVI FEEDMILL CONFIDENTIAL BPASCUA
03/19/23 VENVI FEEDMILL CONFIDENTIAL BPASCUA
In this changing scenario, we must change:

• Our way of thinking

• Our way of working

BPASCUA
The Changing Scenario
• Customer Expectations
• Product Quality Perceptions
• Employee & Employers’ expectations
• Competition
• Government Rules & Regulations
–- Liberalization

BPASCUA
What is Workplace Organization

• A Systematic and rational approach

to a clutter free, safe workplace
with the objective of reducing waste
and preparing the ground for
further improvement.

BPASCUA
5S Background
BACKGROUND
• Since the early 80’s Japanese
industries widely practiced 5S as a
powerful technique to improve
productivity and quality.
• Today, 5 S is used worldwide to
prepare the ground for improvement

BPASCUA
3Different Types of Workplaces

BPASCUA
Levels of Workplace Organization
• Following the 5 S principles and
reducing waste
• Extending the 5 S concept to include
ergonomics
• Extending the 5 S concept to include
aesthetics
• Maintaining records and educating
others

BPASCUA
Elements of 5S

BPASCUA
Elements of 5S
• Comprises of 5 simple steps:
• 1. SEIRI Sorting Out
• 2. SEITON Systematic
arrangement
• 3. SEISO Spic and Span
• 4. SEIKETSU Standardization
• 5. SHITSUKE Self Discipline

BPASCUA
Elements of 5S

BPASCUA
1 - SORT
• Segregating necessary from
unnecessary and throwing away what
is not required at all.

(Done with the objective of saving and

recovering space)

BPASCUA
1 - SORT
• Segregating necessary from
unnecessary
• Discarding what is not
required
• Deciding on a frequency of
sorting

BPASCUA
Sort it out!

BPASCUA
Premix Room

BEFORE: Chaos laboratory and stock room AFTER: Organized micro lab and stock room

03/19/23 BPASCUA BPASCUA

Maintenance Bay

BEFORE: AFTER:

03/19/23 BPASCUA BPASCUA

Segregation Flow
SO RTING

SCRAP NO T IN W ORKING ORDER IN W O RKING O RDER

Reworkable Rejected Necessary Unnecessary Usable Item

Rework Discard Repairable Unrepairable No Potential Use Potentially Useful Req Spl Disposal

Usable Item Repair Discard Discard Move to Req Arrange

Location Disposal

Usable Item Usable Item Discard

BPASCUA
What do you sort? And How often?
Mail
files
Equipment
Memos
Floppies
Left over course material
Stationery
Notices
Records

BPASCUA
What do you sort? And How often?
• Documents Electrical Equip Ducts
• Forms AC filters
• Furniture Inside machinery
• Meetings Around the machinery
• Cabinet contents Packing boxes
• Desk drawer contents Shelves/Cabinets
• Bills Trolleys
• Indents Pipes/Wires
• Telephone Calls Computers
• In & Out tray Fire Extinguishers
• Reference Books Telephones
• Things to do today Light/Fans

BPASCUA
Elements of 5S

BPASCUA
2 - Set in Order

• A rational, orderly and methodical

arrangement of all items we use, re-

work or write off

BPASCUA
2 - Set in Order
Putting things in order after
Analyzing why
Getting things out and putting them back
takes so long

(Done with the objective of minimizing search time

and errors)

BPASCUA
2 – Having a place for everything and everything in it’s place

• Prevent floppy disks from getting bent

• Categorization of files, mails, papers etc.
• Binders kept vertically, not laid out
• Compartmentalization of desk drawers/ shelves/cabinets
• Designating responsibilities for files in shared use
• Prioritizing the things to do - planning a sequence
• Labeling/identifying drawers
• Color coding
• Decide `how much’ of what is needed

BPASCUA
2 – Categorizing of Files

• By Project
• By Titles
• By document type
• By subject
• By client

BPASCUA
2 - Set in Order
No Step Probable Problems Remarks

1. Name of item a. Donot know what it is called

b. Find out

2. Retreival a. No prefixed location

b. Storage in far away location
c. Storage location are scattered
d. Too many repeat trips
e. Hard to get out
f. Too big to carry
g. Need to set or assemble
3. Search a. Difficult to find because of lot of
things are there
b. Not labelled
c. Not there, but not clear whether
somebody is using it
d. One brought was defective
4. Bringing the item No way of transport

BPASCUA
2 - Set in Order

BPASCUA
2 - Set in Order

BPASCUA
2 - Set in Order

BPASCUA
2 - Set in Order

BPASCUA
Elements of 5S

BPASCUA
3 - Shine
• Understanding how to prevent things
from getting dirty and ensuring tip top
condition

(Done with the objective of inspecting for

problems and taking faster corrective actions)

BPASCUA
3 - Shine
• Steps to be followed during or after
major housekeeping
• Do a survey of the origins of grime & Leakage
• Set priorities for cleaning where grime is most
• study why things are dirty
• study possible plan of action
• Decide on action steps/ responsibility/ timeframe

BPASCUA
Ensuring cleanliness and tiptop conditions
Type of grime in office Tick if applicable Source

Dust

Dirt

Water

Fittings

Temperature

Litter

BPASCUA
3 - Shine

• If there’s Lesser number of items, there

is lesser to clean
• One is best
– One page memo
– one day processing
– one location files
– one copy filing

BPASCUA
Elements of 5S

BPASCUA
4 - Standardization
• Following of earlier 3 S’s, standardized work
procedures, maintaining safe & hygienic
conditions in work place contribute to a
serene atmosphere
• Standards for My job-Product &
Processes
My machine
My work area

BPASCUA
4 - Standardization

• Ensuring conducive and safe working

Environment

(Done with the objective of Achieving higher

productivity and better quality through higher
employee morale)

BPASCUA
4 - Standardization

BPASCUA
4 - Standardization

BPASCUA
4 - Standardization

BPASCUA
5 - Sustain

BPASCUA
5 - Sustain

• Training, Evaluation and Follow-up

Actions

(Done with the objective of Achieving constancy

of Purpose)

BPASCUA
5 - Sustain
• Introduce 3 min 5 S activity system
• How often
• Introduce 5 S Activity Evaluation system
• Train Evaluators
• Train Implementers on
• Problem solving steps
• What defects to look for
• Preparing and using implementation checklist

BPASCUA
5 – S Evaluation
• What is it?
• An activity or related activities to determine
whether there is an existence of a system &
the system is in operation as per established
norms. It also verifies whether the system &
results are taking the organization towards
the desired objectives.

BPASCUA
 Sample Checklist for Audit
Committee
Dept……………………………………………………….Total score: …………………..
1. Hard Disk:
a. Files should be in various folders
1 2 3 4 5
b. Virus Scan date
1 2 3 4 5
c. Recycle Bin
1 2 3 4 5
II. Desk Surface:
a. Unwanted loose papers
1 2 3 4 5
b. Wires hanging around
1 2 3 4 5
 Contd.…..
C. Softboards only have what is relevant
1 2 3 4 5
III. Backups:
1 2 3 4 5
IV. Unlabelled Floppies
1 2 3 4 5
V. Bootable disk:
1 2 3 4 5
 Attributes of an Evaluator
• One who believes in 5 S
• Strict, Fair and Tactful
• Must be able to do it in an competent manner
• Willing to go to the workplace, offer advice and
point out problems when necessary
• Should be able to comment on successes and
shortcomings clearly
 Implementing 5S-Methodology
• All employees to undergo workplace trg
• A vision statement to be evolved & started with all employees
• Divide the orgn into convenient zones
• Divide each zone into convenient sub-zones
• Decide dates for launching in each zone/sub zone
• Take pledge
• Apply 5 S principles, step by step
• Form audit teams
• Carry out audits
 Advantages of 5 S
• Nice to work in a clean, beautiful, organized
workplace
• Time taken to reach things minimized
• Lesser time wasted in information handling
• Problems detected fast
• Customer Response time reduced
• More usable space
 Advantages contd...
• Better preventive maintenance
• Higher employee involvement
• Reduction in errors/defects due to standardized
procedures
• Consistent & better customer handling
• Higher productivity
• Higher employee morale
• More time for improvement activities
 5 S is TRANSFORMATION
“If we fail to improve 5 S, what makes us think
that we can do anything else?”
On the other hand we know that if we can do 5
S, we can do anything. 5 S is fundamental, so
it gives us the power to build out capabilities
to meet the BIG CHALLENGES. That is why 5 S
is transformational’.
 bpascua

03/19/23 VENVI FEEDMILL CONFIDENTIAL