5 S + 1S HOUSEKEEPING

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5-S: HOUSEKEEPING
1. SEIRI
SORTING
2. SEITON
ARRANGING
3. SEISO
CLEANING
4. SEIKETSU MAINTAINING
5. SHITSUKE
SELF DISCIPLINE
+1. SHITTSUKOKU SUITABLE
WORKING ENVIRONMENT
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FEATURE OF 5S
5S SUPPORTS ISO 9000/TQM SYSTEM
A DIRTY FACTORY CANNOT PRODUCE
QUALITY PRODUCTS
AN ORDERLY ENVIRONMENT PROMOTES
AN ORDERLY MIND
CLUTTER HIDES PROBLEMS
A CLEAN WORK PLACE EXPOSES PROBLEM
5S
FACILITATES
CONTINUOUS
IMPROVEMENT
5-S IS NOT FACTORIES ALONG
IT IS ALSO FOR OFFICES AND HOMES
AS WELL

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OBJECTIVES
BEHIND
5S

QUALITY IMPROVEMENT
ACCIDENT\INCIDENT PREVENTION
POLLUTION PREVENTION
PRODUCTIVITY IMPROVEMENT
COST REDUCTION
ENERGY CONSERVATION
DOWNTIME PREVENTION
WORKING ATMOSPHERE
PRESERVATION OF ENVIRONMENT
MORALE BOOSTING
ENCOURAGING CREATIVITY
EMPLOYEE PARTICIPATION
DEVELOPS SELF-DISCIPLINE
BRING CHANGE-IN-ATTITUDE
FEEL ENJOY WORKING

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SUGGESTED APPROACH FOR 5S

IMPLEMENTATION
IDENTIFY THE WORK PLACE/AREA OF
IMPROVEMENT
DIAGNOSIS THE PLRESENT STATUS AS PER 5S
BRING OUT THE WEAK AREA
DETERMINE HOW TO CORRECT
ESTABLISH REMEDIAL ACTION
ESTABLISH RECURRENT PREVENTIVE
ACTION
ASSIGN INDIVIDUAL ACTIONS
RECOGNIZE OWN RESPONSIBILITIES
IMPLEMENT CORRECTIVE ACTION
VERIFY IF ACTIONS ARE EFFECTIVE
LOOK FOR OTHER BETTER IDEAS

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SUGGESTED APPROACH FOR 5 S

IMPLEMENTATION
IDENTIFY AND EXPOSE THE WEAK
AREA
HOW UNTIDY
HOW DISORDER
HOW INEFFICIENT
HOW MUCH DIRTY
HOW MUCH MESSY
HOW SMEARED
HOW RUSTED
HOW DUSTY
HOW ILL SMELLED
HOW MUCH NOISY
HOW MUCH DARK
HOW MUCH LEAKY
HOW MUCH SMOKY
HOW MUCH BUSHY
HOW MUCH JAM-PACKED

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ADVANTAGES OF 5S
IMPLEMENTATION
= WORK PLACE BECOMES CLEAN AND BETTER
WORGANISED
SHOP FLOOR AND OFFICE
OPERATION
BECOMES EASIER AND SAFER
RESULTS ARE VISIBLE TO EVERY INSIDER AND
OUTSIDER
VISIBLE RESULTS ENHANCE GENERATION OF
MORE AND NEW IDEAS

PEOPLE BECOME PROUD OF CLEAN AND

ORGANISED WORK PLAC

RESULTANT
GOOD
COMPANY
IMAGE
GENERATES MORE BUSINESS
MIND GETS FREE FLOW OF THOUGHTS

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OBJECTIVES OF
SEITON

REDUCE PREPARATION AND TOOL SETTING

REDUCE TIME SPEND WAITING FOR PARTS
MATERIALS, PAPERS AND FILES
REDUCING PROCESSING TIME AND
CYCLE TIME BY IMPROVING
THE PLANT LAYOUT OF THE WORKSHOP
TIME AND ENERGY SPENT ON LOOKING FOR
JIGS, FIXTURES,TOOLS,ETC.
HUNTING FOR PARTS IN STORES
SEARCHING FOR FILES AND INFORMATION
IN COMPUTERS

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STEPS FOR IMPLEMENTATION OF SEIRI & SEITON

MAKE SPOT INSPECTION & ANALYSIS REGARDING UN-NECESSARY

& EXTRA ITEMS
GET RID OF UNNECESSARY THINGS, PROVIDE MINIMUM ADDITIONAL
STORAGE FACILITIES
DECIDE WHAT WILL BE STORED W HERE- PLACE FREQUENTLY USED
ITEMS NEARBY AND IN-FREQUENTLY USED ITEMS IN SEPARATE PLACE.
LABEL STORAGE AREAS IN ORDER TO RETURN TO DESIGNATED
LOCATION NUMBER
RECORD STORAGE PLACE IN DIRECTION CHART
REVIEW AND INSPECTION

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ADDITIONAL TECHNIQUES WHICH CAN BE USED FOR

DOING SEIRI AND SEITON
SEIRI AND SEITON
PROCESS FLOW CHART
PROBLEM SOLVING PROCESS
BRAIN STORMINGPOKE-YOKE
BENCH MARKING
CAUSE & EFFECT DIAGRAM
CASE STUDY
FROM YOUR WORK AREA SELECT A LOCATION FOR
DOING SEITON
BRIEFLY DESCRIBE THE PRESENT POSITION AND THE
LOSSES OCCURING DUE TO THIS
IDENTIFY THE CAUSES FOR THESE LOSSES
WHAT IMPROVEMENT YOU CAN SUGGEST WITH THE NEW
ARRANGEMENT

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5S - SEISO CLEANING

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DEFINITION:
REMOVAL OF GENERATED TRASH AND DIRT FROM THE
MACHINERY AND TOOLS IN ORDER TO PLUT ITEMS IN THEIR
ORIGINAL STATE.
REMOVAL OF SCRAPL, LEFT OVER MATERIALS AND OTHER
UN-NECESSARY THINGS WHICH ARE THE RESULTS OF
WORK
GET RID OF BAD AND UN-CLEAN THINGS AND PURIFYING
TO CLEAN UP EVERY THING IN THE WORK PLACE
CONCEPT:
TO CARRY OFF OR CLEAR AWAY WITH DRIVING MOVEMENT
OR
TO COLLECT, REMOVE OR CLEAR AWAY WITH A BROOM,
BRUSH,ETC.
TO ELIMINATE ANY DIRT OR DUST IN THE WORKSHOP AND
TO SUSTAIN NON-SMEARING/STAIN/DIRTNESS CONDITIONS.
TO CLEAN YOUR WOPK PLACE COMPLETELY
A CLEAN MACHINE ENSURES GOOD QUALITY, IS LESS
LIKELY TO BREAK DOWN AND WILL LAST LONGER.
REGULAR CLEANING OF EQUIPMENT AND MACHINES HELP
US TOSLOT PROBLEMS BEFORE THEY BECOME SERIOUS.

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FEATURES OF SEITON
ITEMS WHICH ARE NECESSARY ARE PLACED SO THAT
THEY CAN BE FOUND AND GOT EASILY
CONTAINER IS CREATED TO KEEP CORECT ITEM
SAFELY AND IN THEIR
PROPER ORDER
THINGS CAN BE MOVED AND TRANSPORTED AT ONE
TIME TOGETHER
PLACED IN CONTAINER THINGS ARE ARRANGED SO
THAT THEY ARE
USED EASILY IN ORDER OF USE AND ARE WITHIN
REACH
LABELS ARE ATTACHED SO THAT ITEMS CAN BE
RECOGNIZED
AT A GLANCE AND CLEAR

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SEISO
CYCLE

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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 UNNECESSARY THINGS
SEISO IS A PART OF GOOD
WORKMANSHIP
SEISO IS AN IMPORTANT PRECURSOR WITH 5S
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SEISOINSPECTION

SEISO- INSPECTION
SEISO IS NOT ONLY MAKING THINGS
LOOK CLEAN BUT LOOKING AT AND
TOUCHING EVERY PART OF THE
FACILITY DURING CLEANING
SEISO IS TO REVEAL POTENTIAL
DEFECT
SUCH
AS
ABRASION,
DAMAGE,
LOOSE
PARTS,
DEFORMALITIES,
LEAKS, TEMPERATURE, VIBRATIONS,
ABNORMAL SOUNDS, ETC. AND
HENCE SEISO IS INSPECTION

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SEISO
CAN
DETECT

LOOSE BOLT AND SCREWS

LOOSE AND BROKEN ELECTRICAL WIRE
CONNECTIONS
CRACKS AND WEAR AND TEAR IN HOSES
LEAKAGE IN PIPELINES
OIL OR AIR LEAKAGES
LOOSE HANDLES
LOOSE INSTALLATION OF LIMIT SWITCHES
RUST OR DAMAGE TO SLIDING PARTS
DISLOCATION OF SAFETY GUARDS
DIRTY AIR FILTERS
DIRTY OIL GUAGES AND INSUFFICIENT OIL
CHUTES CHOKED WITH CHIPS
CRACKS IN METER GLASS

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CASE STUDY

CASE STUDY

FOR ONE OF YOUR WORK AREA

PREPARE A SEISO SCHEDULE FOR
CLEANING AND INSPECTION

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LIST THE ADVANTAGES EXPECTED

OUT OF THIS SCHEDULE

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4 S - SEIKETSU /
MAINTAINING to maint. high standard of Housekeeping
CONCEPT
place organisation at all times.

and work

To think of ways to prevent work place from

becoming dirty.
Work clothes, hats, safety shoes, apron, gloves,
hair, beards, nails, mechanical
facilities, jigs, tools, materials, containers, trolleys,
conveyers, pipes, rooms, floors,
aisles, ceiling, etc.
No waiting, no breakdowns, no waiting, Minimum of
incomplete items, on schedule,
Production, no late coming/absenteeism, no
searching, no missing parts/papers, no waste of
time, no loss of revenue, etc.
to main high standard of Housekeeping and work
place organisation at all times.
CONTD..

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4 S - SEIKETSU / MAINTAINING
CONCEPT contd. From pre-page

To think of ways to prevent work place from becoming dirty.

Work clothes, hats, safety shoes, apron, gloves, hair, beards, nails,
mechanical
facilities, jigs, tools, materials, containers, trolleys, conveyers,
pipes, rooms, floors,
aisles, ceiling, etc.
No waiting, no breakdowns, no waiting, Minimum of incomplete
items, on schedule,
Production, no late coming/absenteeism, no searching, no missing
parts/papers, no waste of time, no loss of revenue, etc.

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OBJECTIVES

Achieving good housekeeping

Emphasis
on
prevention
Prevent items from
getting dirty
Check points and time
schedules
Fix accountability
Perfect implementation
of
seiri,
seiton,
seiso
continuously
Making comfortable
working environment

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CASE STUDY
Develop an Action Plan for
Maintaining the

STEPS
OF
SEIKETSU/MAINTAINING
Objects inspection
Check list/recording
Definition and degree of each
disorder
Identify tools and equipments

Setting
themes
for
improvement
Avoiding
disorders
and
breakdowns
Daily seiketsu maintenance
system

Emergency
seiketsu
maintenance system
Minor servicing

Seiri, Seiton, Seiso through

Seiketsu assigning
responsibilities suitably

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5 S - SHITSUKE/
SELF-DISCIPLINE

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CONCEPT:
To have employees habituate for correctly following
procedures specified
Morales.
Complying with work place rules and methods and maing this a
Habit.
A natural attitude to be developed for this
This attitude to act as a knitting thread to maintain the other 4S.
Vital to strictly control time and absence
Wearing helmets, safety shoes, uniforms, name plates, etc.
Keeping oneself clean, neat and disciplined.
to train people to follow good housekeeping discipline on their own
to achieve self reliance and self discipline through continuous and
daily pratics.
Rules and method for 4S
Control items are strictly obeyed
Improvements are promoted
Get rid of source of trouble and disorder
It is like a power source behind all activities of the 4S - Seiri,
Seiton, Seiso and Seiketsu
Even minor greeting at the beginnig and end of the day
Operational reports on time
There should be horizontal and vertical communication

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CASE STUDY:

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Select a theme and sub-theme

Analyse the problem
Draw cause and effect diagram for
each problem point
Develop improvement action plan
Evaluate the results

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+1S SUITABLE WORK

ENVIRONMENT

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It is required
to minimize risk to employees
to improve business performance
to establish a responsible image in
market
it is a requirement of employees
customers/clients
contractors/suppliers
community
share holders
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IT TAKES CARE OF

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Noise
Ventilation
Illumination
Hazard identification and control
Fire protection
Waste disposal
Emergency preparedness
Plan layout and area classification
Communication systems
First aid box maintenance
CASE STUDY
dentify the unsuitable working environment in one of the
selected work area
And develop an Action Plan to
bring them under control with responsibility and time schedule

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5 S GOOD
HOUSE-KEEPING AUDIT

PREPARE AN AUDIT CHECK LIST FOR THE

5S+1S
ACTION PLAN FOR IMPLEMENTATION
FORCE FIELD ANALYSIS
LIST THE FAVOURING AND RESTRAINING
FORCES
DEVELOP
AN
ACTION
PLAN
FOR
IMPLEMENTATION OF 5S IN YOUR
ORGANISATION
ALONG
WITH
RESPONSIBILITY AND TARGET DATE.

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