5S

APPROACHES
What is
5s?
5S is a system for organizing spaces so work
can be performed efficiently, effectively, and
safely. This system focuses on putting
everything where it belongs and keeping the
workplace clean, which makes it easier for
people to do their jobs without wasting time
or risking injury.
Background on 5S Activities
• The word “5S(five S)” was generalized in
1980’s in manufacturing sector in Japan,
as Toyota Production System (TPS)
became famous in the sector and “5S
activities” were set as one of the bases of
TPS ‘Taiichi Ohno’is known as Father of
‘5S’.
• Service Industry started to used “5S” in
1990’s
Details of 5S approach
 STEPS OF 5S
1 SORT
2 SET IN ORDER

3 SET IN ORDER

4 Standardize

5 SUSTAIN
 S1: Sort
• Focuses on eliminating
unnecessary items from the S1:
workplace
• Categorize Equipment, Sort
furniture, tool in your S5: S2:
Sustain Set
working place into the
following 3 categories
1. Necessary
2. Unnecessary S4: S3:
Standardize Shine
3. May not necessary
• This step will also help with the “just in case”
attitude
5S Red Tag Format
 Some
example of
1s (Sort)
in our
Plant…
CHP area before & after 1S
CHP area before & after 1S (CPP)
Sorting of oil drum and make a proper
location with Nomenclature ( FERRO)
TMT ROLLING MILL
SORTING (NECESSARY AND
UNNECESSARY ITEM)
STEPS OF 5S
1 SORT

2 SET IN ORDER
3 SHINE

4 STANDARDIZE

5 SUSTAIN
 S2: Set IN ORDER
• “Set” is based on
finding efficient S1:
Sort
and effective
storage of items
necessary S5:
• Apply “Can see, Sustain
S2:Set IN ORDER

Can take out, and

Can return”
philosophy S4: S3:

• This will save time Standardize Shine

and energy to look

for something
 S2: Setting Activities

• Needed items
• Items often use
(with current
work process)

Have consensus among Use 5S tools for Arrange them properly

co-workers on where proper Organization based on “Can see, Can
and how to organize of items such as take-out, Can return”
necessary items Philosophy
• Labeling
• Color coding
• Numbering
• Zoning etc.
• FIFO
2S-Set in Order(Seton)
 Open Storage System
 Closed Storage System
 Cannot be seen
 Open Storage System
 Visible at a glance
 SHADOW BOARD

 See at a glance any disorder

from a Distance
 Color Code
 PLACEMENT MARK

 Outline the shape and

position of equipments tools
etc

 Put names on placement even

nothing is present.
 Some
example of
2s (Set in
Order) in
our Plant…
SMS-3 SPARE PARTS MANAGEMENT
CABLE DRUM & SPARE CABLES ARE
KEPT IN ORDER IN DRI-III
ELECTRICAL TOOLS SORT & SET
IN ORDER IN PELLET PLANT
INSTRUMENT RACK BEFORE &
AFTER –CPP
EQUIPMENT DETAILING BOARD LABELLING ON
SWING CONVEYOR-PELLET PLANT
BILL CARD AVAILABLE AND FIFO
ARRANGEMENT – IN FERRO
 FERRO TAPING ZONE

9 MVA 1- TAPPING ZONE 9 MVA 2- TAPPING 9 MVA 3-TAPPING ZONE

ZONE

9 MVA 4 – TAPPING ZONE 4.5 MVA 1 TAPPING ZONE 4.5 MVA 2 TAPPING ZONE
 S3: Shine
• Cleaning up one’s
S1:
workplace daily so Sort

that there is no dust

on floors, machines or S5: S2:Set
Sustain
equipment.

• It will create S3:

S4:
ownership and build
pride in the workers
Standardize
Shine
 S3: Shining Activities

• Clean Floor, Windows and Walls.

• Clean and Maintain office Automation Machines, Equipment
and Tools, Office Furniture
• Develop and follow regular Cleaning and Maintenance
Schedule
 STEPS OF 5S

1 SORT

2 SET IN ORDER
3 SHINE

4 STANDARDIZE

5 SUSTAIN
 S4: Standardize
• Maintain an Environment where
S1 to S3 are Implemented in the S1:
Same Sort

S5: S2:Set
Sustain

S4: S3:Shine

Standardize
 Example of “Standardize”
activities
• Work Instructions, Standard Operating Procedures (SOPs)
• Checklist Development and Regular usage for SOPs
• Standardized Common Symbols
 5S Photo Display

 Photos of before and

after
 Communicate to
everybody
 Keep display for
some time
 Some
example of
4s
(Standardize)
in our
Plant…
DISPLAY BOARD IN FERRO
IMPLEMENTATION OF JOB IN
STORE AS PER STANDARD
LOCATION WISE FIRE EXTINGUISHER
DETAILS BOARD DISPLAY-IN CPP
EMERGENCY EXIT BOARD DISPLAYED AT
DIFFERENT EXIT POINT OF TURBINE
FLOOR-CPP
LOCATION WISE FIRE EXTINGUISHER
DETAILS BOARD DISPLAYED-CPP
TRIPPING INTERLOCK OF COAL &
CHAR CIRCUIT DISPLAYED AT CHP
MCC ROOM-CPP
 STEPS OF 5S
1 SORT
2 SET IN ORDER

3 SHINE

4 Standardize

5 SUSTAIN
 S5 : SUSTAIN
• Maintain S1-S4
through discipline, S1:
Sort
commitment and
empowerment S5: S2:
• It focuses on Set

defining a new Sustain

mindset and a
standard in S4: S3:

workplace Standardize Shine

 EXAMPLE OF “SUSTAIN”
ACTIVITIES

• Regular Progress Reporting

• Refresher Training
• Periodical Evaluation of 5S activities
with proper advices for continuation
and further Improvements
• Appreciation, recognition and
awarding on good 5S Activities
• Reminder using 5S Corner, New
Letters, Good Practice Sheet
Suggestion Box etc.
WEEKLY TRAINING ON BASICS OF 5S &
IT’S IMPLEMENTATION-PELLET PLANT
ONSITE TRAINING TO THE WORKERS ON
BASICS OF 5S & IT’S IMPLEMENTATION
5S REVIEW MEETING IN FERRO
5S REVIEW MEETING IN SMS-1
BENEFITS OF 5S

 Zero changeovers leading to

product/ service diversification
 Zero defects leading to higher
quality
 Zero waste leading to lower
cost
 Zero delays leading to on time
delivery
 Zero injuries promoting safety
 Zero breakdowns bringing better
maintenance
Thank you for listening !
QUIZ TIME
1. What is the name of
5S Pillar?
1)sort,
2) set in order,
3)shine,
4)standardize,
5)sustain .
2.In which year this technology came
and by whom ?
 5S(five S)” was
generalized in 1980’s
by ‘Taiichi Ohno’
3.What are the 5s Red Tag &
when we have to used it?
The 5S red tagging system is part of the 5S
workplace organization strategy. Red tags
are used during the Sort phase of 5S to
identify items in the work area whose
immediate use or need is unclear.
4.’Shitsuke’stands for which meaning?
It’s stands for SUSTAIN
5.’Seiri’ stands for ?
It’s stands for SORT..
6. Who is the father of 5S?
Taiichi Ohno is known
as Father of 5S..
7. What is the final step of 5S implementation?
 Shitsuke ("Sustain") in 5S.
Shitsuke is the fifth and final step of
the Lean 5S method. It means
"sustain" or "sustained
discipline".
8.What is the name of ‘6s’ pillar?
6S explicitly adds Safety, an additional
pillar that provides additional focus on safety.
9.What do you mean by ‘Standardize’?
Standardize phase, is initiated
after the workspace has
been decluttered,
organized, and cleaned.
10.What do you mean by ‘Sustain’?
sustain refers to the commitment and
self-discipline to maintain the
previous four 5S steps – seiri (sort),
seiton (sort), seiso (sweep), and
seiketsu (standardized).