5S TRAINING

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  What is 5S ?
 Why do we want to do it ?

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 WORLD WAR - 2

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 Japan Adopt Lean Manufacturing Concept
after world war
Initially, the Toyota Production System was a closely-guarded secret, but the
massive economic boom Japan experienced in the 1980s drew intense interest
from foreign corporations wondering how Toyota, the shiniest jewel in Japan's
manufacturing crown, was able to build so many products, so quickly, at such a
high quality level. As a gradual, international exchange of ideas began to take
shape, author and ULVAC Inc. executive Hiroyuki Hirano devised the five pillars
of the visual workplace, a concept that would metamorphose into the 5S
methodology as we know it today.

Atomic Bomb , 1945

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 5S Stands for ?

 Seiri – Sort (Housekeeping)

 Seiton – Systematic Arrangement
(workplace organization)
 Seiso – Shine (Cleanup)
 Seiketsu – Standardize
 Shitsuke – Sustain (Self
Discipline)

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 5S
1. Sort – “Clean - The Clever Way”
All unneeded tools, parts and supplies are
removed from the area
2. Set in Order – “A place for everything and
everything is in its place”
3. Shine – “Think Different, Think Clean”
The area is cleaned as the work is performed
4. Standardize – “A place for everything and
everything in its place, clean and ready for
use”
Cleaning and identification methods are
Work areas are safe and free of
consistently applied hazardous or dangerous conditions
5. Sustain - 5S is a habit and is continually
improved
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 Benefit for 5S

5S is a sub-part of the entire Lean philosophy :

1. 5S is simple to start and shows the value of Lean.

2. 5S is easily recognizable by both employees and
members of
higher management.
3. When a plan/vision is in place, employees know how to
be effective and are able to work towards higher levels of
efficiency.
4. 5S creates better problem-solving skills and improves
employee morale and employee engagement.
5. 5S aids in decreasing the number of workplace injuries.
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 Why Lean Management?

Lean manufacturing improves efficiency,

reduces waste, and increases productivity. The
benefits, therefore, are manifold:
1. Increased product quality:
Improved efficiency frees up employees and
resources for innovation and quality control
that would have previously been wasted.
2. Improved lead times: As
manufacturing processes are streamlined,
businesses can better respond to
fluctuations in demand
and other market variables, resulting in
fewer delays and better lead times.
3. Employee satisfaction: Workers know when 4. Increased profits: And, of course,
their daily routine is bloated or packed with more productivity with less waste and
unnecessary work, and it negatively affects better quality ultimately makes for a
morale. Lean manufacturing boosts not only more profitable company.
productivity, but employee satisfaction.
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 Some New Words

Lean Manufacturing - concepts that seek continuous improvement

by removing waste in processes
Some Japanese words one need to know:
o Kaizen-(pronounced “kai zen”) – Continual improvement
o Muda-(pronounced “moo da”) – Waste
o Gemba-(pronounced “gim ba”) – Workplace
o Kanban-(pronounced “kon bon”) - Pull type inventory control
system. Items are only produced to meet customer needs.
The request to produce more is signaled from an
upstream operation and/or customer orders.
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 ALWAYS GOOD
CONTINUAL IMPROVEMENT
CHANGE FOR THE BETTER

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 KAIZEN IS CONTINUAL IMPROVEMENT

TIME TIME

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 KAIZEN: Benefits?

Kaizen aims for improvements in productivity, effectiveness and safety. But people who
follow this approach often unlock a number of other benefits, too, including:
1. Less waste – inventory is used more efficiently, as are employee skills.
2. People are more satisfied – they have a direct impact on the way that things are done.
3. Improved commitment – team members have more of a stake in their job, and are more inclined
to contribute fully in their role.
4. Improved retention – satisfied and engaged people are more likely to stay.
5. Improved competitiveness – increases in efficiency tend to contribute to lower costs and higher-
quality products.
6. Improved consumer satisfaction – a result of creating higher-quality products with fewer faults.
7. Improved problem solving – looking at processes from a solutions perspective allows employees
to solve problems continuously.
8. Improved teams – working together to solve problems helps to build and strengthen teams.

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 KAIZEN AT GEMBA

GEMBA: PLACE OF WORK

GEMBA is where . . .
1. Value is added
2. Actual work is done to meet customer requirement
3. Problems are solved
4. Staff is responsible for providing support, not for
giving instruction

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 5S PRINCIPLES

 Elimination of waste
 Every body is involved
 Co-operative effort
 Attack root cause
 Human being are not always effective

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 5S OBJECTIVES

 Improve housekeeping
 Make every individual responsible for
housekeeping
 Beautify by simple means
 Productivity improvement by saving time, space
etc.

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 The ‘S’ Japanese Word What is involved Objective
-Segregate necessary from
unnecessary
SEIRI Saving and recovering
1S -Remove what is not
(Sorting Out) required Space
-Decide on frequency of
sorting
SEITON -Arranging in order
2S (Systematic -Place for everything, Minimizing search time
Arrangement) Everything in its place
-Cleaning the work place/ Inspecting for problems
SEISO
3S equipment Taking corrective actions
(spic and Span) faster
-Attaining the warning
bell

SEIKETSU -Working Methodology Achieving higher

4S productivity and better
(Standardization) (Procedures) quality
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SHITSUKE -Forming the habit in form of Doing it right at First
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 SEIRI = Sorting
Japanese Meaning :
The Japanese meaning of “Seiri” is to Organize
- Get rid of waste and put it in order according to rules

Meaning Distinguish between necessary and unnecessary

items and eliminate the unnecessary 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
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 SEIRI = Sorting

1 ‘ S’
Sort for . . .
WANTED UNWANTED
 Not Needed at All
 Needed but not Now
 Needed but not here
 Needed but not so much Quantity

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 SEIRI = Sorting
Organization

Frequency of use Storage Method

• Things you have not used in the • Throw them out
past one year
LOW • Things you have used once in • Store at distance OR Keep in
the last 6-12 months store

• Things you have used only once • Store it in central place in your
in the last 2-6 months zone
AVERAGE • Things used more than once a • Store it in central place in your
month zone

• Things used once a week • Store near the workplace

HIGH • Things used daily or hourly • Store near the workplace

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 SEIRI = Sorting
Identifying unnecessary
Parts & Work in Process (WIP)
 Things fallen back behind the machine or rolled under it
 Broken items inside the machine
 Things under the racks/ platform
 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
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 SEIRI = Sorting
Identifying unnecessary
Tools, Tooling, Measuring devices
 Old jigs, tools not in use are lying
 Modified tools, tooling for trial, are lying after trial
 Worn out items like bushes, liners, toggles etc. lying
 Broken tools, bits, etc. may be lying
 Measuring equipment not required for the operation being
performed , is lying
Contingency Parts
 Many times storage place for contingency parts become a last
refuge for broken parts, surplus items and things nobody is likely to
use
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 SEIRI = Sorting
Identifying unnecessary
Shelves and Lockers : Shelves and lockers tends to collect things that
nobody ever uses , like surplus, broken items etc.
Passages and Corners
 Dust, material not required seem to gather in corner
Besides Pillars and under the stairs
 These places tends to collect junk, spittoon etc.
Walls and Bulletin Board
 Old out dated notices which have lost their relevance
 Posters or bulletins on wall
 Dust, remains of torn notices, cell tape pieces
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 SEIRI = Sorting
Identifying unnecessary
Floor, Pits, Partitions
 Defective parts
 Protection caps, covers
 Packing material
 Hardware items , small items
 Even tools, tooling
 Items dropped on the floor are never picked

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 SEIRI = Sorting
Improvement methods
Red-Tagging Unknown Items
If you find an item that you can’t identify, or that has uncertain ownership, it’s
time to use a red tag. “Red-Tagging” temporarily attaches a highly-visible tag to
the item, which notes where it was found and when. Then, red-tagged items from
all work areas are collected in a single location: a “lost and found” for tools,
materials, and equipment.

Reassigning Tagged Items

Items may be left in the red tag collection space for thirty days. After that, any
supervisor may claim the item for their own work area. If nobody wants it after
another week, the item can be removed from the facility entirely. Sell it, recycle it,
or throw it away.
Note : If an item will definitely be needed by the company, but isn’t needed right
now, it might be best to store it for later. Before putting anything into storage, be
sure it will actually be needed again. Have a specific plan for getting that item out
of storage again, at a specific time. Don’t store things “just in case” without good
cause, and keep track of what’s been stored

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 Seiton : Set In Order
Japanese Meaning:
Dictionary meaning of Seiton is “to be correctly prepared” and “to prepare correctly".
In short these means :
(a) arrange correctly in accordance with the correct method of doing activities and (b)
make thorough preparations so that activities can be done even if they occur abruptly
Meaning To determine type of storage and layout that
will ensure easy accessibility for 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
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 Seiton : Set In Order
How to achieve Systematic Arrangement ?

1. Building a 5S Map
A 5S map is a diagram or floor plan that provides an overview
of a work area, process, or station. It provides a visual
reference to show where the tools, supplies, workers, and
travel paths are, and how they relate to each other. A good
map may also include a description of the work that happens in
the area shown.
Depending on your facility’s needs, you may find one approach
easier than another:
• Draw up a map, and then implement it
• Physically arrange the workplace first, and then map it out
• Map as you go, testing ideas and writing down what works
well

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 Seiton : Set In Order
Communicating the Plan

1 ) Signboards

2) Colour codes

3) Outline markings

4) Labels

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 Seiton : Set In Order
• Usage Frequency : Store frequently used material near the
workplace and less frequently at some distance

• Weight & Shape of the Material : Heavy material should be

stored at lower levels/layers place directly on the material
handling device for ease of handling

• Category : Same category of material may be stored in one

location. e.g, Allen Screws, Oil Seals

• Operation Wise : All items required for an operation may be

stored in one location. e.g, Allen key, spanner etc hand tools
required for setting m/c
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 Seiton : Set In Order
Before Sort After Sort

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 Seiton : Set In Order
Before Sort After Sort

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 Seiso : Cleaning
Japanese Meaning :
Dictionary meaning “to clean up” and “getting rid of dirt and unclean items” While
cleaning potential defects such as abrasion, damage, loose parts, deformities,
leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

Meaning Cleaning trash, filth, dust and other foreign matter.

Cleaning as a form of 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
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 Seiso : Cleaning
Here cleaning means more than just keeping things clean. Cleaning
should be viewed as a form of Visual Inspection
Preventive measures should be taken to tackle problems of dust,
grim, burrs, leakage etc. Root cause of the problem should be
identified and it should be eliminated

5 Minutes Every day for cleaning

 Devote 5 minutes everyday for cleaning your work area

 Participation of everyone is required
 Attack hard to clean places regularly
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 Seiso : Cleaning
Cleaning-Inspection points for most equipment

Cleaning : Grime, clogging, dust balls, rust, leakage etc.

Oils : No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil
lines, clogged drainage, oil spillage, worn& torn ports etc.

Tightening : Loose bolts, welding detachment, loose parts, vibration

or bumping noise, friction

Heat : Oil tanks, motors, heater, axles, control panels, washing/

cleaning water, bearing, wiring etc.

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 Seiso : Cleaning
Cleaning-Inspection points for most equipment

Breakage, Cracks : Breakage, cracks, dent on sliding parts, handle

has come off, broken switches, wire joints come off, wires are broken
or crack, crack dial of various pre. gauges, meters etc.

Pneumatics : Compressed Air lines, air valves, connections, meters,

filters, reservoirs etc.

Hydraulics : Hydraulic oil tank, oil valves, filters, pumps, hoses,

gauges, cylinders etc.

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 Seiso : Cleaning
Cleaning-Inspection points for most equipment

Mach. & Power Train : Motor fan, fan belt, couplings, Joints,
pulleys, chains, pump bearings etc.

Electrical : Control panel, lamps, light, switch, sensors, wiring,

ducts, fuses etc.

Tooling : Tools, fixtures, gauges, dies, measuring

instruments, etc.

Equipment Specific : Furnaces, rollers, chutes, CNC

machines, etc.
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 Seiso : Cleaning

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 Seiso : Cleaning
Seiso Cycle
• Before work, clean and inspect the machinery tools, jigs &
fixtures.
• Beginning of work - do trials and start up
• During operation - clean, inspect, discover and deal with
abnormalities
• After completion of work - dispose off and get rid of un-necessary
things
• Seiso is a part of good workmanship
• Seiso is an important pre-cursor with 5s
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 Seiso : Cleaning
Before Sort After Sort

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 Seiso : Cleaning
Before Sort After Sort

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 SEIKETSU = Standardization
Japanese Meaning :
Dictionary meaning “unsoiled things, purity and cleanliness "Clean manners ,Clean cloths,
clean politician. It is the proof that 3 S’s are being faithfully carried out.

Meaning Setting up standards / Norms for a neat, clean,

workplace and details of how to maintain the
norm Procedure
Activity - Innovative visual management
- Color coding
- Early detection of problem and early action

Success Increase in 5S indicator

Indicator
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 SEIKETSU = Standardization
Tools used for analysis :
MTTR : Mean Time To Repair \
Recover MTBF :Mean Time Between
Failures OEE : Overall Equipment
Efficiency
 Regularizing 5S activities so that abnormalities are
revealed
 Make it easy for everyone to identify the state of normal
or abnormal condition
 For maintaining previous 3S, deploy : Visual management
 It has been estimated by scientific study that 60% of all human activities starts with
sight
5S is easy to do once. It is consistency that is difficult. That is why
Visual Management is so important, so that everybody will
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 SEIKETSU = Standardization
What visual control communicates ?

It grabs one or more of our senses in order to :-

 Alert us to an abnormality
 Help us recover quickly
 Promote adherence and prevention
 Enable successful self management

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 SEIKETSU = Standardization
Some methods for visual communication

 Colour coding
 Use of Labels
 Danger alerts
 Indication where things should be put
 Directional arrows/ marks
 Transparent covers
 Performance indicators

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 SEIKETSU = Standardization
Points to remember in making visual control
tools

1. Make them easy to see from distance

2. Put the display on the things
3. Everyone can tell what is right and what is wrong
4.Anybody can follow them and make
necessary corrections easily
5. Work place should look brighter & orderly

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 SEIKETSU = Standardization
Some everyday visual management examples
 Traffic signal
 Zebra crossing
 In car - Petrol indicator
- Speed indicator
 Direction arrows
 Electric danger sign etc.

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 SHITSUKE = Self Discipline

Japanese Meaning :
Dictionary meaning is “learning of the manners", "having manners, dressing
neatly” OR “training children for good customs”

Meaning Every one sticks to the rule and makes it a 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

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 SHITSUKE = Self Discipline

• We need everyone to maintain 5S

guidelines.
Activities : • To maintain DISCIPLINE, we need to
 5S Committee practice and repeat until it becomes a
way of life.
 5S Training • Discipline is the Core of 5S
 5S Competition / • Discipline means making a steady habit
of properly maintaining correct
Evaluation procedure.
 5S Month • Time and effort involved in establishing
proper arrangement and orderliness will
 Posters , be in vain if we do not have discipline to
Literature etc. maintain it.

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 SHITSUKE = Self Discipline
Pledge

It shall be my constant effort to maintain my workplace

in good order by :
 Assigning a place for everything & keeping
everything in its place
 Sorting out unwanted material periodically & discarding
them
 Keeping my work area neat & clean everyday

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 SHITSUKE = Self Discipline
ORGANIZATION

 Departments into areas

 Coordinators at department level
 Coordinator at each area level
 Training for all
 Audit each area and make action check list
 Implement actions
 Audit and evaluation on continuous basis

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 Sample
Check sheet
for 5S Audit

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 Good Example

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 Good Example

Before 5S After 5S
Cleaned, organized and
drawers labeled (less time
and frustration hunting)
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 Good Example

Before After
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 Good Example

Before After
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 Good Example

Before After
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 Good Example
The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S

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 Good Example

The Good

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 5S Basic Training
Very Important – last 5S i.e. Sustain

Imagine you have applied the 5S process to your current

work area and seen improvements as you did in this
exercise

What would you have to do – or have to stop doing- to

Sustain these changes ?

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 Things to do :
Step 1: Sort
• Clearing the Work Area
• Red-Tagging Unknown Items
• Reassigning Tagged Items
• Item wise disposal plan

Step 2: Set In Order Step 3: Shine

• Building a 5S Map • Routine Cleaning Schedule
• Communicating the Plan • List of activity for
Preventative Maintenance
Step 4: Standardize Step 5: Sustain
• Display the results • Make check sheet and do
of last 3S in your audit of area
area

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 THANK YOU

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