5S

HOUSE KEEPING
HOUSE KEEPING IS A PROCESS WHEREIN EVERYONE IN THE COMPANY IS COMMITTED AND INVOLVED IN UPKEEPING OF THE WORK PLACE AND CLEANLINESS OF MACHINE, MATERIAL, ETC., SUCH THAT ONLY NEEDED MATERIAL IS KEPT AND IT¶S FASTEST ACCESSIBILITY IS ENSURED.

5 S .PRINCIPLES OF HOUSE KEEPING SEIRI SEITON SEISO SEIKETSU SEGREGATION ARRANGEMENT CLEANING MAINTANCE OF STANDARDS/ STANDARDIZATION DISCIPLINE SHITSUKE .

WHAT IS 5S ? SEIRE Sort out unnecessary items in the workplace and discard them SEITON Arrange necessary items in good order so that they can be easily picked for use  A place for everything  Everything in its place SHITSUKE Train people to follow good house keeping discipline autonomously SEISO Clean your work place completely so that there is no dust on the floor. SEIKETSU Always maintain high standard of house keeping at work place in the organization . machines and equipment.

IMPORTANCE OF 5S PRODUCTIVITY A CLEAN WORKPLACE HAS HIGH QUALITY A CLEAN WORK PLACE KEEPS COST DOWN A CLEAN WORK PLACE ENSURES DELIVERY ON TIME A CLEAN WORK PLACE IS SAFE FOR PEOPLE TO WORK A CLEAN WORK PLACE ENHANCES MORALE A CLEAN WORKPLACE IS HIGH IN .

5 S is BASICS to PRODUCTIVITY & IMPROVEMENT PRODUCTIVITY QUALITY COST DELIVERY Safety MORALE : Quality work life : No defect : No waste : No delay : No accident : Good team work .

STEPS OF HOUSE KEEPING A PICTORIAL VIEW .

b) SORT THROUGH WHAT YOU HAVE IDENTIFIED. INDICATOR OF SUCCESS AREA OR PERCENTAGE OF SPACE SAVED . WHAT YOU NEED AND DISCARD WHAT¶S UNNECESSARY.SEIRE (SEGREGATION) TAKE OUT UNNECESSARY ITEMS AND THROW THEM AWAY THIS STEP DISTUINGUISHES WANTED AND UNWANTED ITEMS AND ELIMINATES UNWANTED ITEMS ACTIVITIES: a ) SORT THROUGH AND THEN SORT OUT.

HOW TO PRACTICE SEIRE ? (SEGREGATION) DEVIDE INTO GROUPS THINK ABOUT HOUSE KEEPING IN YOUR WORKPLACE FOLLOW STEPS GIVEN BELOW TO PRACTICE SEIRE ? .

.LOOK AROUND YOU -SEPARATE OUT THINGS YOU DO NOT NEED STEP II .SET OBJECTIVES AND STANDARDS ON THE CRITERIA TO RETAIN AND THROW AWAY THING.HOW TO PRACTICE SEIRE (SEGREGATION) STEP I .ARE THERE THINGS BELONGING TO OTHER PEOPLE / COMPANY WHICH SEEMS UNNECESSARY ? .ACT ACCORDING TO REPLY STEP IV .CHECK DISPOSAL NOTICE AFTER SCHEDULE DATE .PASTE A DISPOSAL NOTICE ON THE OBJECT STEP III .

SEITON ( ARRANGEMENT ) ARRANGE REQUIRED ITEMS IN ORDER SO THAT THEY CAN BE EASILY PICKED UP FOR USE A PLACE FOR EVERY THING AND EVERYTHING IN ITS PLACE .

THAT ACCOMODATES REQUIRED ITEMS FOR EASY ACCESSIBLITY ACTIVITIES 1) SET THINGS IN ORDER BY CREATING PLACE FOR EVERYTHING 2) KEEP EVERY THING IN ITS PLACE 3) KEEP ACCESSIBILITY AS EASY AS POSSIBLE 4) USE THE PRINCIPLEE OF WIDE RANGE AND SHALLOW DEPTH FOR STORAGE SUCCESS INDICATOR 1) TIME SAVED IN SEARCHING 2) TIME SAVED IN HANDLING THE MATERIAL .SEITON (ARRANGEMENT) THESE STEPS ENABLES DETERMINATION OF THE TYPE OF STORAGE SYSTEM AND LAYOUT.

. FOLLOW THE STEPS GIVEN BELOW.SEITON (ARRANGEMENT) DEVIDE INTO GROUPS AFTER SEGREGATION. TO ARRANGE ITEMS / PRACTICE SEITON.

RECORD THINGS WITH LOCATIONS .HOW TO PRACTICE SEITON STEP I .DECIDE WHICH THING SHOULD BE WHERE STEP II .LOOK THE WAY THINGS ARE ARRANGED .CLOSER YOU KEEP .LEAST USED MATERIAL SHOULD ALSO HAVE A PROPER PLACE FOR EASY LOCATION STEP III .REMEMBER EVERYTHING SHOULD BE IN ITS PLACE .ASSUME YOU WILL FORGET WHERE YOU PLACED A CERTAIN OBJECT .THE MORE YOU USE .

SUCCESS INDICATOR: REDUCTION IN MACHINE DOWNTIME INCREASED LIFE OF THE MACHINE PARTS REDUCTION IN NUMBER OF ACCIDENTS REDUCTION IN REJECTION .SEISO (CLEANING) CLEAN YOUR WORKPLACE COMPLETELY SO THAT THERE IS NO DUST ANYWHERE ACTIVITIES : 1) CLEAN EQUIPMENT AND TOOLS 2) KEEP THE WORKPLACE SPOTLESS 3) SWEEPING. POLISHING. PAINTING ETC. WIPING.

DO NOT ASSUME THERE IS SOMEONE TO CLEAN UP THE MESS YOU MAKE .CLEAN / SWEEP REGULARLY .DONOT THROW / LITTER ANYTHING .HOW TO PRACTICE SEISO ? .DO NOT ALLOW THINGS & PLACE TO GET DIRTY .YOU ARE RESPONSIBLE FOR CLEANING WORKPLACE AROUND YOU .PUT ASIDE 3 MINUTES EVERY DAY FOR CLEANING .SEISO ALSO INCLUDES REGULAR CLEANING OF MACHINES & TOOLS YOU USE .

‡You wash my body & joints regularly. ‡ I Love you because: ‡You care for me.WHAT THE MACHINE SAYS WITH HIS MASTER ? My dear master. ‡ I like to work hard for you master. Your¶s faithfully Machine . ‡ You hear to my whisper.X BEGIN THE DAY WITH CLEANING THE MACHINE AND TOOLS ON WHICH YOU WORK SO THAT IT WILL FUNCTION GOOD . I can enjoy working with you . ‡ Please understand me a bit more. when I feel uncomfortable & become seriously ill. so that. Thank you for your kind consideration. before I become dirty and feel itchy. I also like to live longtime.

ACTIVITIES: 1) CREATE VISUAL CONTROL SYSTEM 2) CREATE STANDARDS AND MAINTAIN STRUCTURE FOR CONTROL OF STANDARDS 3) DEVIDE WAYS TO EXPOSE HIDDEN PROBLEMS INTO THE OPEN SUCCESS INDICATOR: NUMBER OF NEW PROBLEMS EXPOSED AND SOLVED .SEIKETSU (MAINTAINANCE OF STANDARD/ STANDARDIZATION) ALWAYS MAINTAIN A HIGH STANDARD OF HOUSE KEEPING IN THE ORGANISATION.

CONSCIOUSLY TRY TO MAINTAIN THE CLEAN ENVIRONMENT OR ELSE IT WILL BE DIRTY AGAIN .ARRANGED NECESSARY ITEMS .HOW TO PRACTICE SEIKETSU ? YOU HAVE .CLEANED YOUR WORKPLACE NEXT STEP IS TO MAINTAIN THE GOOD WORK YOU HAVE DONE .CREATE A MAINTENANCE SYSTEM FOR HOUSEKEEPING .MAY EVEN HAVE INTER .THROWN AWAY UN-NECESSARY ITEMS .DEPARTMENTAL COMPETITION .

scrap. procedures and tolerances in ways that are easy to see and follow . over production. waiting. lateness. NO SEARCHING What information can help employees work more efficiently and independently ? How can it be made easy to see and understand ? Share all the information and avoid unnecessary searching. re-order information.VISUAL CONTROL Visual control communicates improvement information to people who need it when they need it. equipment failure.g. so that they are visible at a glance . defective goods. Help us recover quickly Promote adherence and prevention Enable successful self management SHARING INFORMATION. etc. lot size. Mark items and containers with delivery dates and destination. Share routine standards. etc. It grabs one or more of our senses in order to alert us to an abnormality (A gap between actual performance and the appropriate standard) for e.

SEGREGATION SEITON SEISO SEIKETSU SHITSUKE ARRANGEMENT CLEANING MAINTENANCE OF STANDARDS/STANDARDIZATION DISCIPLINE ACTIVITIES: 1) CREATE GENERAL AWARENESS ON ³5 S´ 2) TRAINING TO EVERYONE 3) SHARE SUCCESS TO GENERATE MORE ENTHUSIASM SUCCESS INDICATOR: HIGH EMPLOYEE MORALE INVOLVEMENT OF PEOPLE IN THE MOVEMENT FOR ³ PROFIT FOR THE COMPANY ´ .SHITSUKE (DISCIPLINE) TRAIN PEOPLE TO FOLLOW GOOD HOUSEKEEPING DISCIPLINE INDEPENDENTLY SEIRE .

HOW TO PRACTICE SHITSUKE ? DECIDE IN A GROUP AND MAKE A PRESENTATION MOST DIFFICULT PART OF HOUSE KEEPING : MANAGEMENT RESPONSIBILITY TO TRAIN STAFF & EMPLOYEES TO DEVELOP A GOOD HOUSE KEEPING HABIT THE IMPRESSION YOU MAKE : TREAT YOUR WORKPLACE AS YOUR SECOND HOUSE BEWARE OF YOUR OWN ATTITUDES & HABITS .

5 LEVELS OF HOUSE KEEPINGIN IN THE COMPANY LEVEL 1: FLOOR IS FULL OF UNWANTED MATERIALS LEVEL 2: CLUTTER FOUND BY THE WALLS LEVEL 3: WORKPLACE IS CLEAN BUT TOOLS AND MATERIALS ARE DISORGANISED LEVEL 4: STORAGE AREA. MACHINE ARE CLEAN AND MATERIALS ARE ORGANISEED LEVEL 5: FACTORY IS IMMACULATE / SPOTLESS .

LEVEL 1: HOUSE KEEPING CIGARETTES /BUTTS SCRAPS OF PAPER TOOLS (UNDER USE) TOOLS (NOT IN USE) OLD DOCUMENTS Unused M/c¶ s & Equip. are scattered around all over the place CORRECTIVE ACTION Look at the horizontal surface Examine the shop floor and eliminate all garbage and non essential tools and storage Examine the floor .corner to corner and wall to wall and eliminate unwanted things Make a definite place for all tools and parts that are on the floor HINTS FOR IMPROVEMENT DO NOT PUT ANY UNWANTED MATERIAL ON THE FLOOR . Etc.

LEVEL 2: HOUSE KEEPING CORRECTIVE ACTION Clutter is found by the walls passage ways are not clear unused items are lying against the walls or pillars unused tools and equipment left beneath or beside the equipment Look at vertical surface Examine the walls and pillars eliminate all garbage and non essential tools leaning against the wall Paint the walls and pillars that can be reached by hand HINTS FOR IMPROVEMENT DIVIDE RESPONSIBILITIES FOR AREAS AND WALLS .

shoes. etc. Gloves. HINTS FOR IMPROVEMENT ROMOVE THE BACK AND SIDES OF ALL THE STORAGE CABINETS . Make separate storage for tools.clamps are all mixed together in the storage cabinet. Make the above area distinct and clear. parts. documents etc. parts. parts and tools. Unused and worthless items found inside closed cabinets Look inside the shelves and sort the materials. All tools are in locked storage units. are thrown in with the tools in the tools box..LEVEL 3: HOUSE KEEPING CORRECTIVE ACTION Tools. gauges. clamps. Get rid of locked cabinets.

. 2) Make a model line with super market type displays of parts and tools.LEVEL 4: HOUSE KEEPING CORRECTIVE ACTION Clean machine and equipment Storage area cleanly distinguished Storage area shows many parallel lines and right angles Tools are color coded Clean. strengthen. tidy and organize automatically Develop visual control HINTS FOR IMPROVEMENT 1) Scrap and chips should fall directly into waste containers.

LEVEL 5: HOUSE KEEPING AT LEVEL 5 THE WORKPLACE WILL WITNESS Constant and continual cleaning from wall to wall. parts and materials can be found at a glance Inventory levels can be found visually Production runs smoothly High product quality achieved . Work area is immaculate / spotless Tools well laid out Origins of rubbish are removed so that dirt. clutter and garbage are eliminated at the source Tools.

waste collection and disposal There would be conscious efforts to keep furniture. rework and storage areas would be cleanly marked Railings. equipment and surrounding areas clean There would be a defined place for everything & everything in its place Roads. passages. racks.HOUSE KEEPING VISION Systems would exist for housekeeping. gangways and aisles would be kept free of any material. equipment if dirty would be cleaned and painted if necessary . equipment or furniture Gangways and scrap. fences.

HOUSE KEEPING SCHEME 1) Plant is divided into different zones 2) Different zones are sub dived 3) Each sub zone has a check sheet 4) Audit is done each month or as convenient 5) Best house kept area is recognized 6) Cumulative of six months also recognized .

5 S PLEDGE IT SHALL BE MY ENDAVOUR TO DELIGHT OUR CUSTOMER BY ADHERING TO THE STANDARDS OF: PUTTING THINGS IN ORDER MAINTAINING CLEANLINESS AT OUR WORKPLACE .ACTION PLAN Where we are ? Visualize the state of housekeeping in your Division / Workplace and write down describing the status. Compare the housekeeping with 5 levels and decide the level Work in the group and conclude.

4 SEISO SEIKETSU SHITSUKE SHITSUKE: maintain achieved standard of 5'S' all times T A R G E T S No dust on floor Creation of clean Good habit to A C T I O N S Separate passages for people from vehicles .3 SEITON SEISO SEIKETSU SEIKETSU: and organised workplace STEP .STANDARD FOR GOOD 5S PRACTICE P E T S STEP -1 SEIRI SEITON SEIRI: Only needed items SEITON: A place for everything and everything in its place Dispose items not needed Nothing directly Assign a place placed on floor for everything Use space more No searching effectively Extensive Start daily cleaning by Effect 'FIFO' retrieval stocks everybody Implement KAIZEN activities cleaning Remove causes of problems Standardise good practices Observe various standards fully STEP .2 SEIRI SEITON SEISO SEISO: machines and equipment STEP .

Y Setting Visual Dispalys Specifications Loose electrical cables. Fencing/ boundary File storage. wall clocks on time Symmetry in everything sign / identity boards with standardization .Checklist for House Keeping Check points Safety Shop floor Common areas Gate / Security / Horticulture Scrap yard Administration / office X . etc.. pantry front office/ reception / canteen Marked parking spaces for cars/ scooters/ visitors entry. lubricant spillage's. noise pollution. Toilet upkeep. etc. exposed switches. materials on the floor. massive greenery.. oil leakage's . etc . New look .

nuts. components and work in process are labelled for easy retrieval 3 Dies.) 7 Problems for spots difficult to clean are solved from time to time 8 Tools or documents can be retrieved in les than one minute without searching 9 Rules for 5 S practice are implenented and observed autonomously 10 5S patrol is regularly conducted by supervisors for continued improvement Continued« . jigs. machine failures etc.EVALUATION STANDARD FOR GOOD PRACTICE OF 5 S Sr. CHECK POINTS RATING 1 5S Activity bulletin board is well organised and data is updated 2 Locations for material. components and other materials are not found on floor 5 Passges and operations areas are clearly separated by distinct lines and indications 6 Failures found are immediately fixed (uneven floor. No. fixtures and tools are located conviniently for use without searching 4 Bolts. projections.

tools and documents are labelled and easy to retrive Rules are strictly observed ( punctual in time. cleaning.EVALUATION STANDARD FOR GOOD PRACTICE OF 5 S Sr. Not-tackled-1 . quality and cost and achieving good results Voilators of rules are warned each other among colleagues Components. No. etc) 5S is well maintained and upgraded by creative activities RATING 16 17 18 19 20 Rating:Satisfactory-5. Tackled-3. 11 12 13 14 15 CHECK POINTS Inspections at starting and closing time are practised and recorded Jigs and tools are easy to return to designated locations Dirt and stain on machines are removed on the spot immedietly Causes for dirt and stain are removed for perfect solution Pnuematic devices are regularly cleaned and inspected and failures are repaired immedietly People are active in implementing KAIZEN on safety.

K. L BEVINAHALLI SBU PARAMETER HOUSE KEEPING ( 5 S EVALUATION ) DEPARTMENT / SECTION CRITERIA MARKS MARKS ALLOTTED ACTUAL 5 PAGE 2 OF 2 MONTH : WEEK OBSERVATIONS Are the areas free of trash & dust ? Has the floor been cleaned ? Are clean up responsibilities assigned ? Are trash cans empty ? Marks Obtained Are apparels as per guidelines / regulations ? Are private belonging kept away ? Does everyone retain from eating & drinking from the work place ? Does everyone avoid private conversations during work time ? Marks Obtained TOTAL MARKS 5 5 5 20 5 5 5 5 20 100 TEAM LEADER 5 S HOUSE KEEPING COMMITTEE Date : . I.F.

instruments kept clean ? Marks Obtained 5 5 5 5 20 P.I. Fixtures.T.L BEVINAHALLI SBU HOUSE KEEPING ( 5 S EVALUATION ) DEPARTMENT / SECTION PAGE 1 OF 2 MONTH : WEEK PARAMETER CRITERIA Have unwanted things been removed ? Is the reason for presence of unauthorised items known ? Are gangways and work areas clearly marked ? Are the things properly arranged ? Marks Obtained Does each item have an earmarked place ? Is each item in its place when not in use ? Are things kept away after use ? Are work areas uncluttered ? Are shelves & tables kept in orderly fashion ? Marks Obtained MARKS ALLOTTED MARKS ACTUAL OBSERVATIONS 5 5 5 5 20 4 4 4 4 4 20 Are apparels neat & clean ? Is ventilation adequate ? Are work areas clean ? Are equipments including machines including Jigs.O .K.F .

TQM -IMPLEMENTATION HOUSE KEEPING AND VISUAL CONTROLS ARE THE FIRST STEPS FOR TOTAL QUALITY MANAGENENT IMPLEMENTATION .