Training of Trainers on TQM

AWARENESS
5 ‘S’

Dr. K. Narashiman,
AU – TVS Centre for Quality Management,
Anna University
knman@annauniv.edu 1
 5 ‘S’ An Awareness

CONTENTS
1. What is 5 'S‘ ?
2. Why 5 'S‘ ?
3. Who is to practice 5 'S‘ ?
4. When and Where 5 'S' can be used ?
5. How to practice 5 'S‘ ?
6. 5 'S' - A Foundation for TQM
7. 5 'S' in ISO 9001 : 2000

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 5 ‘S’ An Awareness

1. WHAT IS 5 ‘S’ ?

 5S Philosophy focuses on effective work place

organization and standardized work procedures.

 5S simplifies your work environment, reduces

waste and non-value activity while improving
quality efficiency and safety.

Contd…. 3
 5 ‘S’ An Awareness
1. WHAT IS 5 ‘S’ ? Contd….

Step 1 - SORT
Red Tag
Sort Out
Step 5 - SUSTAIN Throw Out!
Work to Standards
Monitor progress A
Continuous Improvement
Step 2 - SET IN ORDER
What goes where?
Set Limits
P Arrange close to hand

Step 4 - STANDARDISE
D
Step 3 - SHINE
Standardise activity Eliminate dirt, dust, oil & scrap
Make steps 1,2 & 3 a habit Ensure everywhere Shines!
Share Information

Contd…. 4
 5 ‘S’ An Awareness

1. 1 1st ‘S’ SEIRI - SORT

Stratification management and dealing with the causes.

1. Throw out the things you do not need.

2. Free up valuable floor space
3. Eliminate such things as broken tools, obsolete jigs
and fixtures, scrap and excess raw material.
4. Prevent the JIC job mentality (Just In Case.)
5. Number of necessary items in the workplace must be
kept to its absolute minimum.
6. Simplification of tasks, effective use of space, and
careful purchase of items follow.

Contd…. 5
 5 ‘S’ An Awareness
1. 1 1st ‘S’ SEIRI – SORT Contd….

Simple Sort Matrix

PRIORITY FREQUENCY OF USE HOW TO STORE

LOW Less than once a year Throw away

Store in distant
place

AVERAGE Once every 2 6 months Store together

Once a month Somewhere in
Once a week factory

HIGH Once a day Carry or keep at

Once an hour individual workplace

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 5 ‘S’ An Awareness

1. 2 2nd ‘S’ SEITON - ORGANIZE

 Focuses on efficient and effective storage
methods.
 What do I need to do my job?
 Where should I locate this item?
 How many of this item do I need?

 how fast you can put items away and

retrieve them in time of need

Contd…. 7
 5 ‘S’ An Awareness
1. 2 2nd ‘S’ SEITON – ORGANIZE Contd….

Functional storage and eliminating the need to look for things

1. Everything has a clearly designed place .
2. Thirty-second storage and retrieval
3. Filing standards
4. Zoning and placement marks
5. Eliminate lids and locks
6. First in, first out.
7. Neat notice boards
8. Easy-to-read notices
9. Straight lines and right angles
10. Functional placement for materials, par carts, shelves, tools, equipments,
and everything else
11. Organize the warehouse

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 5 ‘S’ An Awareness
1. 3 3rd ‘S’ SEISO - CLEAN
Cleaning as inspection and degree of cleanliness
Quick 5S drills
Individual responsibility
Make cleaning and inspection easier
Sparkling clean campaigns
Everybody is a janitor (priority 5S)
Perform cleaning inspections and correct minor problems
Clean even the places most people do not notice
Deal with the causes of dirt and leaks
Housecleaning
Inspect covers and troughs to prevent leakage and setter
Clean the grounds
Eliminate grime and burrs
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Eliminate oil pans
 5 ‘S’ An Awareness
1. 4 4th ‘S’ SEIKETSU - STANDARDISE
Visual management and 5S standardization. Both personal & environmental
cleanliness
1. Okay marks
14. Wire management
2. Danger zones marked on meters
15. Inspection marks
3. Thermal labels
16. Precision-maintenance
4. Directional markings labels
5. Belt-size labels 17. Limit labels
6. Open-and-shut directional labels 18. Color coding
7. Voltage labels 19. Transparency
8. Color-coded pipes
9. Oil labels
10. Warning colors
11. Fire extinguisher signs
12. Fool proofing
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13. Responsibility labels
 5 ‘S’ An Awareness

1. 5 5th ‘S’ SHITSUKE – SELF DISCIPLINE

 'Discipline.'
 Clear responsibility.
 Commitment to maintain orderliness.
 Practice the first 4 S as a way of life.
 Elimination of bad habits and constant practice
of good ones.
 True shitsuke - personnel voluntarily observe
cleanliness and orderliness at all times, without
having to be reminded by management.

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 5 ‘S’ An Awareness

2. Why 5 'S‘ ?
 Simple Process – No Complexity
 A tidy, disciplined environment
 Spot hidden issues easily
 Reduce time in unproductive activities
 Prevent potential disasters like missing documents
 Improve safety
 Promote a sense of pride in one’s work
 Promote ownership of one’s responsibilities
 Improve Morale of workers
 Is relatively inexpensive for the company to implement
 Promotes daily activity for continuous improvement
 Foster efficiency and productivity while improving work flow
 Encourage a proactive approach that prevents problems and waste before they occur
 Provides a practical method for dealing with the real problems that workers face
every day
 Fits with a facility's other efforts, such as total preventive maintenance, just-in-time
manufacturing, pollution prevention, safety initiatives, and lean manufacturing
efforts.
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Contd….
 5 ‘S’ An Awareness
2. WHY 5 ‘S’ ? Contd….

EXAMPLES Sort, Set in Order

See the difference?

1. Sort 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
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Contd….
 5 ‘S’ An Awareness
2. WHY 5 ‘S’ ? Contd….

EXAMPLES

After 5 ‘S’ - Cleaned,

organized and drawers
Before 5 ‘S’ labeled (less time and
frustration hunting)
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 5 ‘S’ An Awareness

3. Who is to practice 5 ‘S’ ?

 CEO should lead the practice

 Participation by everybody

 5’S’ practice should be self sustaining

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 5 ‘S’ An Awareness

4. When & Where 5 ‘S’ should be used

Application of 5S

…this can be applied anywhere,Site, Offices,Workshop,Stores?

 All the time

 Literally everywhere

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 5 ‘S’ An Awareness
5. HOW TO PRACTICE 5 'S‘ ? contd,…

1. Observe/interview/evaluate
2. Establish a quarantine area
3. Initiate the red tag process
4. Review the summary sheet with associates
5. Determine additional resource needs
6. Clean up entire project area
7. Conduct another observation
8. Evaluate area using the checklist criteria
9. Root cause analysis/establish countermeasures
10. Repeat steps 6 - 8 to improve score
11. Post evaluation on visual performance board
12. Determine review cycle
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Contd….
 5 ‘S’ An Awareness
5. HOW TO PRACTICE 5 'S‘ ? contd,…

SCORE BOARD
Dept. Owner Co-ordinator
Previous Today
Score Board ( Check List ) Date
5 ‘S’ in Office Mark
Marks
5 ‘S’ No. Checking Item Evaluation Criteria 0 1 2 3 4
CLEARING UP
ORGANIZING
CLEANING
SELF DISCIPLINE STANDARDIZING

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Contd….
 5 ‘S’ An Awareness
5. HOW TO PRACTICE 5 'S‘ ? contd,…

STATUS OF 5 ‘S’ IN OFFICE

Unit / Dept./ Section Position As On

Owner Unit Coordinator

S S S S S
1S 2S 3S 4S 5S
SEIRI SEITON SEISO SEIKETSU SHITSUKE

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 5 ‘S’ An Awareness
6. 5 ‘S’ A Foundation for TQM

 TQM is a philosophy and takes about a decade for a

traditional organization to demonstrate the destination
less journey.

 The journey starts with a clarity on why are we? where

are we? And Where do we want to go? The practice of
5’S’ in true spirit evidences the response to above
queries.

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 5 ‘S’ An Awareness

7. 5 ‘S’ & ISO 9001 : 2000

The QMS of ISO 9001:2000 is based on 8 QM Principles like
1. Customer focus
2. Involvement of people
3. System approach to management
4. Factual approach to decision making
5. Leadership
6. Process approach
7. Continual Improvement
8. Mutual beneficial Supplier relationship
To mention a few Specific relation

 4.2.3 & 4.2.4 Control of records - Seiri

 6.4 Work Environment - Seiton
 7.5.3 Identification and Traceability - Seiso
 7.5.5 Preservation of Product - Sheiketsu
 8.5.1 Continual Improvement - Shitsuke
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 5 ‘S’ An Awareness

HIROYUKI HIRANO’S MESSAGE

Let's leave the last word to Hiroyuki Hirano, author of 5 ‘S’ -
Five Pillars of the Visual Workplace:
"A company that cannot successfully implement the 5 ‘S’s
cannot expect to effectively integrate JIT, re-engineering, or
any other large-scale change. Good workplaces develop
beginning with the 5 ‘S's. Bad workplaces fall apart
beginning with the 5 ‘S’s."

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 5 ‘S’ An Awareness

Recap
1. What is 5 'S‘ ?
2. Why 5 'S‘ ?
3. Who is to practice 5 'S‘ ?
4. When and Where 5 'S' can be used ?
5. How to practice 5 'S‘ ?
6. 5 'S' - A Foundation for TQM
7. 5 'S' in ISO 9001 : 2000

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