'5-S' Road map

Who ?

To do
What ?

Where?

S0 = Enablers
[Motivate
people for 5-S
implementation]
S1 = Seiri
[Sort out
what is needed
and what is not]
S2 = Seiton
[Do
systematic
arrangement for
all needed
S3 = items]
Seiso
[Ensure
spic & span
cleanliness with
inspection]
S4 = Seiketsu
[Create a
highly
standardised
workplace]
S5 = Shitsuke
[Self - discipline
at workplace]

When?

Team Leader Team Members P-D-C-A

Jul-07

Plan

S0

Actual

S0

Plan

S0

Aug-07

Sep-07

Oct-07

Nov-07

Dec-07

S1

S2

S2

S3

S1

S2

S2

S3

Gemba-1:

Gemba-2:

Actual
S0

map
Jan-08
S4

Feb-08
S4

Mar-08
S5

Remarks

Why ?

MOP

1 ] Demonstrate PQI by doing Kaizens

2 ] Remove 3 D's at Gemba

Zero
defect

SHE

1 ] Develop criteria for need/want to

release 50% place

Zero
inventory/
More
space

EFSHE

Zero
waiting

PQCD

1 ] PEEP: Place for everything &

everything in its place

S4

S4

S5

1 ] CLIA: Deploy Clean-Inspect-LubricateZero

Adjust
2 ] CPCP accidents

PQCD

1 ] SOPs Developed & Displayed

2 ] Establish SDCA

Zero
breakdown

PQCD

1 ] Through continuous education,

training, display of results & PDCA
improvement cycles

Zero setup PQCDEFSHE

ACTION PLAN FOR "S0" Enablers

Motivating people for 5S implementation (Jul - Aug 07)
Who
Freq
Status
Once

X
N/A

Weekly
X
Qtr

Qtr

Once

Requisites
Official information
5-S Billboards / Camera
Participation of all
Effective training
PQCDEFSHE objectives
1-30-300 principle
Roadmap
5-S as a part of Kaizen roadmap
Progress review
Publishing & widely communicating about the progress
Active involvement of the teams
Regular meetings
Developing suggestion schemes

Qtr
Monthly
Fortnight
Weekly

Remark

Requisites

Work Area

Classification in work areas

Audit / Visual Inspection of wants /

wastes

Scrap Disposal

Listing Wants in an Area after

eliminating waste

ACTION PLAN FOR "S1" Seiri

Sorting out what is required & dipose unwanted (Aug - Sep 07)
Who
Status

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

Remark

(S1) Waste Identification Checklist

Gemba
Work Area
TM
Usage

Condition

Repairable

Process / Equipment / Item in area

Freq. Rare Never Good Worst

Yes

No

Better
Usage
Substitute
outside area
avl
Yes

No

Yes

No

Waste

Remark

ACTION PLAN FOR "S2" Seiton

Systematic Arrangement of wanted (Oct - Nov 07)
Requisites
Who
Status
X
X
Organising wants in an area in terms of usage / value / importance to process / life cycle
X
X
X
X
Identifying amenities / infrastructure / tools
required for correct organisation (P tags)
X
X
X
Organising in compliance with PEEP &
X
Identifying missing / abnormal item or
X
structure
X

Remark

(S2) Systematic arrangement checklist

Gemba
Work Area
TM
Process / Equipment / Item in area

Usage

Value

Qty (Nos)

Critical to
process

Total
0
0
0
0
0
0
0
0
0
0
0
0

Pref. No

Scores can be 1/ 3/ 5 for low / Med / High categories repectively & Pref. no
will be in descending order of total score
Item with pref. no "1" should always be the easiest accesible and further on
In case of consumables qty. to be re-ordered when inventory level for High /
Med or Low value items reaches 25 % / 50 % levels
Arrangement to comply PEEP concept so that any missing / misplaced item
can be identified by visual inspection
List down amenities / tools / structure for correct arrangement. When identified
can be purchased or can be picked up from scrap

Requisites
External / Internal man power
arrangement for through cleaning

Thorough cleaning done & scrap

disposed safely

All Items / Process / Equipments easly

identifiable / accesible / safe

ACTION PLAN FOR "S3" Seiso

Thorough Cleaning (Nov - Dec 07)
Who

Status
X
X
X
X
X
X
X
X
X
X
X
X

Remark

Requisites
Daily Inspection / Reporting
abnormalities

Action for deviation / 5S awareness

session or training

ACTION PLAN FOR "S4" Seiketsu

Standardisation (Jan - Feb 08)
Who
Status
X
X
X
X
X
X
X
X

Remark

Requisites
Monthly / Qtrly. "5S" audit by Internal /
External accesor

Action for deviation / findings /

document learnings

5S awareness session / training for

continual improvement / Visits

Gains in terms of value, life cycle,

availability to be published

ACTION PLAN FOR "S5" Shitsuke

Sustain & Self discipline (Mar 08)
Who

Status
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

Remark

0 = Very Bad

SEIRI

1S

SEITON

2S

SEISO

3S

SEIKTSU

4S

Check Item
Materials / parts
Machines / Equipment
Papers / Plastic Mtrl
Visual Control

Check Item
Location Indicators
Item Indicators
Qty. Indicators
Walkway Demarcation

Check Item
Floor / Work station
M/c & Equipments
Cleaning Stewards

Check Item
Improvement Idea
Standard procedure
Future scope
First 3S

1 = Bad

2 = Avg

3 = Good

4 = Very Good

Description

Does the inventory or in-process inventory include unneeded mtrl / parts

Are there any unused machines or other equipment
Is there any paper / plastic scrap around
Is the waste identified
Sub Total

Description

Are shelves and other storage areas marked with addresses

Do the shelves have signboards showing which items go where
Are Max / Min Inventory levels indicated
Storage areas / Process Area / Units marked
Sub Total

Description

Description
Is any action plan in place for its deployment
Is the 5S implementation plan documented / published / communicated
Any continual improvement idea / process / recognition
Is Seiri / Seiton / Seiso maintained

0
Score
2

0
Score
2

0
Score
2

Are floors / work station shiny to spot any waste

Are they Dust free, running healthy with allowed noise / vibration
Is there a dedicated staff / do they do it voluntarily
Sub Total

Score
2

0 = Very Bad
Sub Total

SHITSUKE

5S

Check Item
Equipments / Process
Stock levels
Training
Support
5-S Billboards

1 = Bad

2 = Avg

3 = Good

Description

4 = Very Good
0

Are they easily gettable / managable

Is the inventory control adhered to
Is Training / 5S awareness in progress
Is top management active support available
Are they updated
Sub Total

Score
2

Grand Total

SEIRI
SEITON
SEISO
SEIKTSU
SHITSUKE

0
0
0
0
0

Audit Re sult

SEIRI
SHITSUKE

SEIKTSU

SEITON

SEISO

0
0

SHITSUKE

SEIKTSU

0 = Very Bad

1 = Bad

2 = Avg

SEITON

SEISO

3 = Good

4 = Very Good