‘5S’

METHOD OF WORK PLACE

ORGANIZATION AND VISUAL
CONTROLS

Popularized by Hiroyuki Hirano (1990).

The origin is rooted in the works of two
American pioneers Frederick W. Taylor
and Henry Ford – Studied by Japanese
managers.
‘5S’ – Each ‘S’ means.,
• SEIRI – Sort - Clearing
• SEITON – Set - Organizing
• SEISO – Shine – Cleaning
• SEIKETSU –Standardizing
• SHITSUKE – Sustain – Self
Discipline and Training
 COMMON MIND SETS…
• Its an additional burden. Too busy to do
5S activities.

• Why clean it? It will get dirty again

• We cannot change the existing setup.

• More work pressure – No time for these

things
 COMMON MIND SETS…
• Expensive – Why to waste money?

• We are comfortable – Why to change?

• It will take time.

But the winning
companies says…
• Work efficiency enhanced due to
organized work place
• Achieve remarkable cost reduction in
production process and improved
productivity by 20%
But the winning
companies says…
• Promotes safe, healthy and beautiful
work environment
• From the bottom of the list we become
the number two profit maker
• Waste elimination, Cycle time reduction,
Space generation, Inventory reduction
and improved work ethics
But the winning
companies says…
• World class companies do
not succeed, it’s people
who do
 So,
What’s good in it?
 ‘5S’
• SEIRI – Sort - Clearing
• SEITON – Set - Organizing
• SEISO – Shine – Cleaning
• SEIKETSU –Standardizing
• SHITSUKE – Sustain – Self
Discipline and Training
1S – SORT - Clearing
“…only what is needed, in the
amounts necessary,
as they are required…”

Eliminate unwanted
items from your work
area
SORT – Fights with Habits



 SORT – Fights with Habits
• It is difficult and confusing to decide which
would be wanted in future.
• People tend to keep extras or duplicates “just in
case a need comes in future”

JUST-IN-CASE JUST-IN-TIME

• People do not realize the importance of space,

believing in unlimited space availability.
A Simple Flow chart
 What is unwanted?
1. Parts & Work in Process (WIP)
• Things fallen back behind the machine
• 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
 What is unwanted?
2. Tools, Toolings, Measuring devices
• Old jigs, tools not in use
• Broken tools, bits, etc.
• Measuring equipment not required for the operation
being performed
3. Shelves and Lockers
• Shelves and lockers tends to collect things that
nobody ever uses , like surplus, broken items etc.
4. Passages and Corners
• Dust, material not required seem to gather in corner
 What is unwanted?
5. Besides Pillars, Floors
• These places tends to collect junk.
6. Walls and Boards
• Old out dated notices which have lost their
relevance
• Dust, remains of torn notices, cello tape piece
 What is unknown?

• Simple –
• Unable to decide whether it is useful or
not.
• Good material – Not useful to you. May be
of use to somebody else.
SEIRI
SEIRI == Sorting
Sorting
Meaning
Meaning Distinguish
Distinguishbetween
betweennecessary
necessaryand
and
unnecessary
unnecessaryitems
itemsand
andeliminate
eliminatethe
the
unnecessary
unnecessaryitems
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
INTERACTIVE BIT

Give me three examples

of areas that could benefit
from sorting
 SEITON – SET -
ORGANIZING
• “A place for everything and
everything in its place”

• Identify and allocate a place for

all the materials needed for your
work.
 SEITON – SET -
ORGANIZING
• Decide where things belong.
• Decide how things should put
away
• Obey the put away rules
SEITON – EXAMPLE
SEITON
SEITON == SET-ORGANIZING
SET-ORGANIZING
Meaning
Meaning To
Todetermine
determinetype
typeof
ofstorage
storageand
andlayout
layout
that
thatwill
willensure
ensureeasy
easyaccessibility
accessibilityfor
for
everyone
everyone. .

Activity - Functional storage

- Creating place for everything and putting
everything in its place

Success - Time saved in searching

Indicator - Time saved in material handling
 INTERACTIVE BIT
• Discuss two areas where production
is frustrating
• Do the tools keep going missing, or do
you have to wait for them to become
available.
• Do operators zig-zag around the area
and/or get in each others way
• Do we have Mix Ups?
SEISO – SHINE - CLEANING

• Here cleaning means more than

just keeping things clean – Its for
your safe.

• At least 5 minutes everyday for

cleaning
SEISO-SHINE-CLEANING
SEISO-SHINE-CLEANING
Meaning
Meaning Cleaning
Cleaningtrash,
trash,filth,
filth,dust
dustand
andother
other
foreign
foreign matter.
matter.Cleaning
Cleaningas asaaform
formof
of
Inspection.
Inspection.

Activity - Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning inspection

Success - Reduction in machine down time

Indicator - Reduction in no. of accidents
INTERACTIVE BIT

What areas of the factory

are the dirtiest and/or are
depressing to work in?
 SEIKETSU -
STANDARDIZING
• Regularising 5S activities by putting
systems in place – Everyone does things
the same way
• Make it easy for everyone to identify the
state of normal or abnormal condition.
• For maintaining previous 3S, use visual
management
5S IS EASY TO DO ONCE –
CONSISTENCY IS DIFFICULT
SEIKETSU
SEIKETSU -- STANDARDIZING
STANDARDIZING
Meaning
Meaning Setting
Settingupupstandards
standards//Norms
Normsfor
foraaneat,
neat,
clean,workplace
clean,workplaceand
anddetails
detailsof
of
how
howto
to maintain
maintainthe
thenorm
norm(Procedure)
(Procedure)

Activity - Innovative visual management

- Colour coding
- Early detection of problem and early action

Success Increase in 5S indicator

Indicator
 SHITSUKE – SUSTAIN – SELF
DISCIPLINE & TRAINING
• Make ‘5S’ is a HABIT
• Without this, the time involved
in all the other S will be in
vain.
 SHITSUKE – SUSTAIN – SELF
DISCIPLINE & TRAINING
• We need Everyone to maintain
5S guidelines.
• To maintain discipline, we
need to practice and repeat
until it becomes way of life.
• Discipline is the core of 5S
 SHITSUKE – SUSTAIN –
SELF DISCIPLINE &
TRAINING
• Commitment +
Everyone’s Involvement =
Success to 5S
SHITSUKE-SUSTAIN
SHITSUKE-SUSTAIN
Meaning
Meaning Every
Everyone
onesticks
sticksto
tothe
therule
ruleand
andmakes
makesitit
aa habit
habit

Activity - Participation of everyone in developing good

habits
- Regular audits and aiming for higher level

Success High employee morale

Indicator Involvement of all people
 SOME COMPARISONS
BEFORE 5S AFTER 5S
 The rules…
• Remove fixed ideas.
• Think of ways to make it possible.
• No excuses needed.
• Go for the simple solution, not the perfect one.
• Correct mistakes right away.
• Repeat ‘Why’ 5 times.
• Ask ideas from many people.
• There is no end to improvement.
 BENEFITS
 Reduced set-up times
 Reduced cycle times
 Reduce searching time
 Increased floor space
 Lower safety incident/accident rate
 Less wasted labor
 Better equipment reliability
 Higher Quality
 Lower cost
 Reliable Delivery
 Roles and Responsibility
• Leaders must set the tone and lead by
example.
• We should commit to the initiative,
Provide time to the workforce to develop
and implement 5S changes.
• Any implementation should have a drive.
• Conduct short, focussed and frequent
communication sessions.
• Select areas that needs 5S – as pilot areas
• Share the successes
It’s a start….