5S TRAINING

BY SAMBASIVAM (M)9443405521
Do these points describe your
company work areas?
Space is crowded with parts and tools
Unneeded items are stacked between workers
Excess inventory on the floor
Excess items and machines make it difficult to
improve process flow
Equipment is dirty and a collection point for
miscellaneous materials
Needed equipment such as tools are difficult to
find

5S GOOD HOUSEKEEPING

WHAT IS 5S ?

5S is a set of TECHNIQUES
providing a standard approach
to GOOD HOUSEKEEPING
within the ORGANIZATION

About 5S

A cornerstone of 5S is that
untidy, cluttered work/study areas
are not productive.

People are happier
in a clean and tidy environment
and hence are inclined to work hard with
due care and attention.

WHY DO IT?
QUALITY EFFICIENCY
SAFETY
ELIMINATING
BREAKDOWNS
5S
EFFICIENCY
Time is wasted looking for tools, equipment and
paperwork, etc
A clean and tidy workplace leads to greater well
being and increased motivation
Team working makes unexciting work more
rewarding
ELIMINATE BREAKDOWNS
Breakdowns caused by the elimination of
dirt need never occur
Clear labelling and routine maintenance
are essential disciplines
A clean workplace highlights problems
early
SAFETY
Dirty cluttered workplaces are not safe

Safety depends on good care and
organisation

Safety should become second nature
THE 5S PRINCIPLES
SEIRI SORT
SEITON SYSTEMATIZE
SEISO SWEEP, SHINE, SCRUB
SEIKETSU STANDARDIZE
SHITSUKE SELF-DISCIPLINE
Specific Objectives-SORT

Decide what you need

Remove unnecessary clutter

All tools, gauges, materials, classified and stored

Remove items which are broken, unusable or
only occasionally used

Specific Objectives-SORT
PRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once per year
Once per year
Throw away
Store away from
the workplace
Average At least 2/6 months
Once per month
Once per week
Store together but
offline
High Once Per Day Locate at the
workplace
Before sort after sort
Before sort after sort
Specific Objectives - SYSTEMATIZE
Organise layout of tools and equipment
Designated locations
Use tapes and labels

Ensure everything is available
as it is needed and
at the point of use

A place for everything and
everything on its place."
Specific Objectives - SYSTEMATIZE
Workplace Checkpoints:-
Positions of aisles and storage places clearly
marked?
Tools classified and stored by frequency of use?
Pallets stacked correctly?
Safety equipment easily accessible?
Floors in good condition?
Lights / Reflectors clean?

Specific Objectives-
SWEEP, SHINE, SCRUB
Create a spotless workplace
Identify and eliminate causes of dirt and
grime remove the need to clean
Sweep, dust, polish and paint


Specific Objectives-
SWEEP, SHINE, SCRUB
Divide areas into zones
Define responsibilities for cleaning
Tools and equipment must be owned by
an individual
Focus on removing the need to clean

Before shine after shine
Before shine after shine
Specific Objectives
STANDARDIZE
Standardize clean-up activities by:
Sustaining five-minute daily clean up habit
Keeping a balance between personal
cleanliness and the cleanliness of the
environment / work place
Avoiding littering. Learning to pick-up tiny pieces
of waste around
Regularly audit using checklists and measures
of housekeeping


Specific Objectives
SELF-DISCIPLINE
Instilling the ability of doing things
the way they are supposed to be done
Becoming a role model by treating
your work place as your second home
Influencing others to join in keeping
a well-maintained work place.
Aiming for constant improvement

A bad example
of discipline
BENEFITS
Improvements in:-
Workforce morale
Company image
Health and Safety
Machine maintenance
Quality
Productivity
Leading to Increased Competitiveness
In this photo you can see a rack
containing the forms and flyers
common in most HR departments

Let us assume 600 employees need to
go to this rack from time to time, and
say on an average, everyone does this
about three times a year.

Each person takes 15 minutes to look
through the rack. How much is the
search-hours ?

With 5S, it came down easily to a
minute or less per visit

How much is the increase in
productivity ?
What is wrong in this picture?
BEFORE 5S AFTER 5S
Visits 1800 Visits 1800
Time Spent Each
Visit
15 Min Time Spent Each Visit 1 Min
Total Time for 600
Employees
450
Hrs.
Total Time for 600
Employees
30 Hrs

PRODUCTIVITY INCREASE (%)

93

How Does 5S Pay Off?
Preventative actions
Preventative actions
When a problem keeps occurring you need to
put into place actions to solve them. Do not
simply keep dealing with the symptoms, you
need to find the cause.
Why do tools get put back in the wrong place?
Why do items accumulate?
Why are the floors getting dirty? etc.
When you ask WHY repeatedly you will find the
problem.
5S OR 5D?
If 5S is not taken up seriously, then it leads
to 5D.
They are
Delays,
Defects,
Dissatisfied customers,
Declining profits and
Demoralized employees.
GROUP EXERCISE
5S AUDIT

SEIRI SORT
SEITON SYSTEMATIZE
SEISO SWEEP, SHINE, SCRUB