5S- Refresher course

5S Implementation

Introduction
• 1S
• 2S
• 3S
• 4S
• 5S
 What is each S?
• SORT (SEIRI)
• SET IN ORDER (SEITON)
• SHINE (SEISO)
• STANDARDIZE (SEIKETSU)
• SUSTAIN (SHITSUKE)
First ‘S’

1S
 First ‘S’

The Definition of Seiri

•Sort (SEIRI)

Distinguish between what is needed

and what is not needed
 Categorizing Things

Can be used

Things Cannot be used

Unlikely to be used
 Red tag strategy

5S red tag
Can be used

Things Cannot be used

Unlikely to be used
 Red tag strategy

RED TAG TARGETS

?
 Red tag strategy

Red tag targets-----

•At storage sites for parts and Inventory

•At storage sites for jigs, tools,Cutting bits, Dies, Etc…
•Floors, Walkways and work areas
•Walls, Signs and Management boards
•Outdoor sites
•Offices
 Red tag strategy
Raw materials, Processing parts, assembly
Inventory parts, Semi-finished products & Products

Factories Machines,Jigs,Tools,Cutting
(Workshops) Equipment bits,Gauges,Dies,Carts,Conveyors,worktables,Ca
binets chairs, desks

Floors, Walkways, walls

Spaces

Red –tag
targets Notices,MOMs,Clericalreports,Estimates,Contracts
Documentation Memos

Computes,Fax machines,Printers and other office

Offices Equipment automation equipment

Folders, Binders,File boxes,Cabinets Desks,chairs

Supplies

Stationery
Pens,Pencils, Markers,Erasers,staplers,memo pads
Supplies
Vouchers, Business cards, Magazines,
others Newspapers, Drawings & Pamplets
 Sort – (Seiri)
An effective visual method to identify these unneeded items is called
red tagging. A red tag is placed on all items not required to complete
your job. These items are then moved to a central holding area. This
process is for evaluation of the red tag items. Occasionally used items
are moved to a more organized storage location outside of the work
area while unneeded items are discarded.
Sort – (Seiri)

If you don’t use it,

move it!
 RED
Sort – (Seiri) TAG

For wavering items

• PLACE THE SUSPECTED ITEMS IN THE RED

TAG AREA FOR ONE WEEK
• ALLOW THE TEAM/ASSOCIATES TO
REEVALUATE THE NEEDED ITEMS
• AT THE END OF WEEK THOSE WHO NEED
ITEMS SHOULD BE RETURNED
What is 1S ?
 Benefits of 1S

•Space saving
•Value realization through sale of items
2S
 Second ‘S’

The Definition of Seiton

•Set in order (SEITON)

A place for everything

&
everything in its place
 2S- Implementation Methodology

Prepare 5S Layout
In the 5S Layout, indicate the following
• Bay marking
•All permanent locations
•All temporary locations
•Fire fighting equipment locations
•GCC, Rough area, Finish area, WIP area, NC area & Red tag area
•Emergency exit
•Dust bins

Divide the areas into different zones & identify the process owners
for each zone
5S layout - Sample
 Second ‘S’

SET IN ORDER-TARGETS

?
 2S- Targets

Category Set in order-Targets

Floors,Walkways,Operation
Spaces
areas,Walls,Shelves,Warehouses

Raw materials,Procured parts,Parts for

machining, Inprocessinventory,Assembly
Products
parts,Semi-finished Products & Finished
products
Machines,Equipment,Jigs,Tools,Cutting
bits,Gauges,Dies,Flow cars,Material
Equipment
handling trolleys,Work tables,chairs &
Cabinets
 For Efficient
Set in Order – (SEITON) &
Effective
Storage methods
The second S focuses on efficient and effective storage methods.
You must ask yourself these questions:

1. What do I need to do my job?

2. Where should I locate this item?
3. How many do I need?
 How to SEITON Your Workplace

Stratification Required Action

Items Must be placed near

SEITON frequently used the point of use

Items Items Can be placed

Necessary sometimes used farther away

Items Must be stored

not used at all separately with
SEIRI but must be kept clear identification
Estate Maint/ AM /23.04.08
 Seven Seiton Principles


Follow the first-in-first-out (FIFO) method for
storing items.

Assign each item a dedicated location.

All items and their locations should be
indicated by systematic labeling.

Place items so that they are visible to minimize
search time. How to

Place items so they can be reached or handled
easily.
Seiton

Separate exclusive tools from common ones.

Place frequently used tools near the user.
2S- Implementation Guidelines

ALLOCATE PLACE:
(a) Worktable / workbench
(b) Open racks
(c) Open cupboard
(d) Closed cupboard
(e) Trays
(f) Pallets / boxes
(g) Trolley
(h) Stands
(i) Dust bins
(j) Essential maintenance tools
(k) Rejected items
(l) Rework items
(m) Cleaning tools etc.
 2S- Implementation Guidelines

MARKING
(a) Permanent Storage area
- Yellow solid line with 5cm thick
(b) Gangway / walkway / aisle
- Yellow solid line with 10 cm thick
(c) Traffic flow line – Arrows
- Yellow solid with 5 cm thick
(In the case of light colour floor, use yellow arrow over Dark blue colour
rectangle)
(d) Door openings
- Yellow and black stripes with 2.5 cm thick
- Push – Pull stickers for doors
(e) Steps front face
- Yellow and black stripes (RHS) with 5 cm thick
(f) All non-movable items legs / base
- Yellow solid corner lines with 1.0 cm thick
 5S Marking

Temp parking slots marking for Trolleys, ladders , Flow cars

Marking on wall for all Fire fighting equipments and

other caution areas

Marking on Floor for all Fire fighting equipments and

In front of Electrical control panel

Marking for hazardous areas like LPG cylinders etc.

Permanent location Marking for Worktables, Cupboards, Racks

And other Machine accessories like Burr trolley
 5S Marking

GCC – Green with yellow boundary

Marking for Red tag area

 5S – Inventory locations Marking

RM Rough material( Input material )

MAX QTY : NOs

RM Finish material( Output material )

MAX QTY : NOs

RM WIP material

MAX QTY : NOs

NC area

MAX QTY : NOs

 2S- Implementation Guidelines
(g) Moving trolleys and lifting devices
- Yellow and black stripes (RHS) with 5 cm thick in the
back and front.

(h) Temporary parking slots for moving items (Trolleys, container with
wheels, cranes etc)
- Sky blue and white stripes (RHS) with 5 cm thick

(i) Front area of Electrical Control panels, Fire extinguishers, fire hose,
emergency exits and First aid box
- Postal red and white stripes (RHS) with 5 cm thick
j) Hazardous area (Gas cylinders, Flammable items, explosive items,
Acids)
- Postal Red and yellow stripes (RHS) with 5 cms thick

k) Red Tag area (To keep unwanted good condition materials)

- Red line with 5 cm thick

l) Table top surface (to keep telephone, books, registers and files)
- Green or Yellow line stickers with 5 mm thick.
 2S- Implementation Guidelines

NAMING

(a) All machines

White colour 5 cm letters in blue board , depending on the
requirement. (use stand or fix it in the machine)

(b) All work flow lines / areas

Black or Dark blue colour 10 cm letters in white board / plate
depending on the requirement (Preferably hang this from
top)

(c) All storage areas

white colour 7.5 cm letters in blue board / plate, depending on
the requirement (Hang this from top or use stand
 2S- Implementation Guidelines

(d) Number the following items using 2.5 cm letters

(preferably black or dark blue colour over the light colour
background)
(i) Worktable / workbench
(ii) Open racks
(iii) Open cupboard
(iv) Closed cupboard
(v) Trays
(vi) Pallets
(vii) Trolley
(viii) Stand
(ix) Boxes
(x) Dust bins etc.
 2S- Implementation Guidelines

LABELING

(a) Racks – items name (may be removable) and location mark (A1,
A2, A3)
(b) Cupboard – items name or list
(c) Machines – Crucial points to be checked
(Lighting and ventilation facilities to be checked and improve if
necessary)

GROUPING
a) Tools grouping
b) Spares grouping
c) Oil & Grease grouping
d) Waste grouping (Dust bin)
 2S- Implementation Guidelines

VISIBLE AT A GLANCE
a) Transparent door or cover
b) Shadow board
c) Picture display
b) Keeping them open

FREQUENCY OF USAGE
a) Frequently used items - Yellow colour sticker or paint mark
b) Less frequently used items – Blue colour sticker or paint mark
c) Rarely used items – Green colour sticker or paint mark
Example:
Necessary items can be reached at all times .
Very frequently used items shall be placed within 15 to
25 cm of reach.

                                                                                                                                           
 Plant : Ennore

Line : ZFGB Shop

Work Station : Shop

AFTER:
BEFORE:

Reserved seat
with capacity
marked

No reserved seat for Finish goods Reserved seat with Capacity

Of Soft stage machining Designated & marked
5S Score = 70 5S Score = 71
 Plant : Ennore

Line : Axle Beam

Work Station :135

BEFORE: AFTER:

Designated place, marking

No Designated place, marking & & Max Quantity indication for rough
Labeling for rough Axle beam area Axle beam area

5S score = 65 5S score =67

 2S Improvements in E135- Navayuga gemba-Shop 7(Axle arm & Axle beam machining)

Before After

No designated place & permanent Designated place & permanent

marking for tool trolley. marking for tool trolley.

5S Improvements- Sep 08
1S,2S &3S Improvements in E111- Gear brain gemba-Shop2 (Timing gears & Axle gears)
2S Improvements – External signage's & Name boards

Direction Signages
At East land gate

Individual name
boards at each dept

Individual name
boards at each dept
 2S Improvements in E134- Creators Gemba( Production stores)

Before After

Imperfect bay marking Perfect bay marking

 Plant : Ennore

Line : Picture = 9
Work Station : E/L Tool room

BEFORE: AFTER:

2’nd level of 2S Trolley

identification and
numbering

5S Score = 65 5S Score = 66
 2S Improvements in E128- Vidivelli gemba Shop 6(H engine component machining)

Before After

Bay with internal signage

Bay with no Internal signages
CYLINDER HEAD LINE
Before After

5S Improvements- Trolley
parking area- CPPS

5S Improvements-
Fork lift area- CPPS

5S Improvements- Press
panel - CPPS

5S Improvements-
Trolley parking area -
CPPS
EXAMPLE : Labelling of storage rack to address Bin locations

Rack address Column address Row address

1 2 3 4 5 6 7
A
1
A42
2

5
 Plant : Ennore

Line : East Land

Work Station : E145

BEFORE: AFTER:

No XY Coordinate system for bins XY coordinate system

implemented for bin with RCR
concept
 Plant : Ennore

Line : East Land

Work Station :E145

BEFORE: AFTER:

Part numbers assigned for each

Bins not having part numbers
bin, improved traceability
 SUPER SEITON
•FIFO - Push out
•Store according to product lines
•Sliding transport

A A A A A A

B B B B B B

C C C C C C

D D D D D D
•Before 5S activity
E E E E E E
 SUPER SEITON
•FIFO - Push out
•Store according to product lines
•Sliding transport

A A A A A A

B B B B B B

C C C C C C

D D D D D D
•Before 5S activity
E E E E E E
•Reserved seats
•Matching names SUPERSEITON

A1 A2 A3 A4 A5 A6 A7

A1 A2 A3 A4 A5 A6 A7

B1 B2 B3 B4 B5 B6 B7

B1 B2 B3 B4 B5 B6 B7

C1 C2 C3 C4 C5 C6 C7

C1 C2 C3 C4 C5 C6 C7
 SEITON
SUPER
•Reserved seats
•Matching names

PD20 PD21 PD22

PD20 PD21 PD22

PD30 PD31 PD32

PD30 PD31 PD32
 SEITON
SUPER •Transparent / no cover
•Stock level indicators

B10-100 B12-100

B10-150 B12-150
 SEITON
SUPER

1 2 3 4 5 6 7 8 9 101112

•Seiri wastes
•No horizontal piling
•Nothing on floor
 SUPER SEITON

•Quick retrieval
•No horizontal piling
•Vertical holders

B20S H B25S H B30S H

B35S H B40S H B50S H

 SUPER SEITON

1 2 3 4 5 6 7 8 9 10 11 12

•Retrieval within 30 seconds

•Labeling reserved seats
•Color identification

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
 SUPER SEITON

•Matching labels
•Color identification
 SEITON
SUPER

•A place for a kind

•Effective use of space

CL10-40 CL15-20

CL20-20

BL20-50 BL20-20

BL30-20

BLH20-40 BLH20-20

BLH25-20
 Cast Materials SUPER SEITON
CL10-40 CL15-20

CL20-20

BL20-50 BL20-20
•Kanban
•Parking place
BL30-20
•Safety sign
BLH20-40 BLH20-20

Cart No. 5
BLH25-20

Cart No. 5
Safety First
 SUPER SEITON
•Max. height indication
•Placing items straight
and at right angles

Maximum piling height ： 2m

•Before 5S - unsafe
•No height control
 SEITON
SUPER

•No lifting by hands

•Sliding or rolling
 SUPER SEITON

•Indication of control limits

POTABLE
WATER
0
Kg

75 25

•Color labeling for invisible 50

substances
•Indication of flow direction
 SEITON
SUPER

COLD HOT COLD HOT

•Hanging hoses on hooks

•Color identification
•Clear ground surfaces
2 S -EXAMPLE - 5S at office

Office 5S at Alwar – An example

2 S EXAMPLE - 5S at office
 Benefits of 2S

•Searching time reduction

•Develop control through visibility
3S
 Third ‘S’

The Definition of Seiso

•Shine (SEISO)

Shine to inspect, Inspect to detect,

Detect to correct, Correct to perfect
 Shine
• Machines and equipment are kept clean and unsoiled by daily care. Work
areas are kept clean, free from contamination. Guards and shields are used to
keep chips and oils from falling on the floor . Fix a frequency & follow the
frequency of cleaning

• Areas around the shop are to be kept clean

• Walls doors and windows are to be kept clean

• All floors are clean and free of debris oil and dirt

• Clean and Paint equipment, tables and cabinets

• Cleaning schedule should be maintained

 Shine

CLEANING PROCEDURES
(a) Preparation of cleaning standard
(b) Preparation of cleaning schedule
(c) Massive cleaning day
(d) Preparation of cleaning tools

MACHINE CHECKING PROCEDURES

(a) Numbering all the check points using letter painting
(b) Foot prints on floor against each check point
(c) Marking direction arrows on floor following each check point
(d) Use colour code for frequency (Daily – Yellow, Weekly –
Blue, Monthly – Green)
 Benefits of 3S

• Breakdown time reduction

• Good looking work environment
Plant : Ennore

Line : Shop6

Work Station : Tool Crib

BEFORE: AFTER:

Teflon introduced so cleaning very easy

Cleaning difficult

5S Score = 73.8 5S Score = 73.9

 Plant : Ennore

Line : C/CASE LINE

Work Station :

BEFORE: AFTER:

Poor machine cleaning Machine cleaning improved

& painted

5S Score = 1.5 5S Score = 2

 Plant : Ennore

Line : Crank shaft

Work Station :135

AFTER:
BEFORE:
Gap between the machine
& coolant tank 300mm
Additional chute.

Coolant tank

Cemb Mass Centering Machine the gap Additional chute has been provided for
between the coolant outlet and the Regulating the coolant flow from the machine
collecting Tank is around 300 mm leading To the coolant tank.
to coolant Overflow.

Before = Equipment cleanliness.Point 12 =2 After = Equipment cleanliness = 3

4S
 Fourth ‘S’

The Definition of Seiketsu

•Standardise (SEIKETSU)

System must be controlled and maintained

and there is on improvement without
STANDARDS

1S,2S & 3S has to be standardized

 STANDARDIZE (SEIKETSU)

• Generate a maintenance system for the

first three 5S

• Develop procedures, schedules, practices

• Continue to assess the use and disposal of
items
• Regularly audit using checklists and
measures of housekeeping
• Real challenge is to keep it clean
3C’s
5S
 Fifth ‘S’

The Definition of Shitsuke

•SUSTAIN (SHITSUKE)

Maintain the standards through discipline

5S Methodology
 5S TOOL BOX
Promotion Tools Implementation Tools Evaluation Tools
5S Newsletters 5S Days (once a month) 5S Guidance Stickers
5S DAY
What is Seiton? Here is
a need for Here is
Seiton is arranging a need for
necessary items in good SEIRI Here is
order so they can easily SEITON a need for
be selected for use SEISO

5S Posters 5S Study Tours CEO’s Inspection Tours

Seiri Seiton
Shitsuke
Seiketsu Seiso

5S Banners Photographing for Improvement 5S Checklists

We all Practice 5S

5S Badges 5S Inter-Department Competition Congratulations!

SUPER Department A
Here is an

5S
Excellent Example
Department B
Department C of 5S Practice
Department D
Super 5S Contributes to Each Element of PQCDSM

A company that is implementing

Super

high5S
in successfully
Productivity is always:

consistent in Quality
 Cost-effective

accurate in Delivery
5S?

Safe for people to work in

high in Morale
 References….

A company that is implementing

Super
 5S successfully
5 Pillars is always:
of the visual workplace
---- Hiroyuki Hirano

5S?
Thank you