5S

What is 5S?

• 5S is a Japanese concept which focuses on effective

work place organization and standardized work
procedures.
• 5S is a set of techniques providing a standardized
approach to factory .
• It is a way to involve associates in the ownership of
their workspace.
• It helps create and maintain the efficiency and
effectiveness of a work area
Why 5S ?

 5S increases production
 5S improves quality
 5S reduces costs
 5S makes delivery on time
 5S improves safety
 5S makes the premises more pleasant.
 5S improves morale
 5S’s

1. SEIRI - Sorting
2. SEITON - Set in Order / Systematic arrangement
3. SEISO - Shine / Cleaning Inspection while cleaning
4. SEIKETSU - Standardize
5. SHITSUKE - Sustain / Self Discipline
SEIRI - Sorting

Identify and separate necessary items from the unnecessary by:

 Segregating useful from non-useful items.
 Disposing properly non-useful items.

Purpose:
• To make the work easy by eliminating obstacles.
• To eliminate the need to take care of unnecessary items.
• To provide no chance of being disturbed with unnecessary
items.
How to practice
STEP 1
 Look around your workplace with your colleagues.
 Discover and identify items which are unnecessary to your work.
 If required at some point in the future, move to a store location.
 Decide the maximum number of any type of item to be retained.
 Then dispose ALL unnecessary items.

STEP 2
If you and your colleagues cannot decide if an item is necessary or not, put
Disposal Notice with the date on the item, and set the item aside.

STEP 3
After a certain decided period, check if no one needs the item. If no one
needs the item, that means the item is not necessary in your work.
How to practice
Note:

 In this sorting operation, you must not forget inside all drawers,
lockers and cabinets.
 Disposal can be done in either of the ways:

 Sell to outside company.

 Move to other section where the item is needed.

 Throw it away, or dispose as garbage.

 While looking around for unnecessary items in your workplace,

look at every nook and corner
SEITON - Systematic Arrangement
Neat placement and identification of needed
items by:
 Studying the use of items and the frequency
of their use
 Considering space or location for storing the
things needed to be kept and to be disposed.
 Making safety the priority

Purpose:
• To prevent loss and waste of time.
• To be able to find out and pick up necessary items
easily.
• To ensure first come first serve basis.
 How to practice
STEP 1
› Make sure that all unnecessary items are eliminated from your workplace.
› Then think of what things should be put where, taking into account the flow of your work.

STEP 2
› Put most frequently needed items close to the user, so as to minimize the movement of
the person.
› Things which are not so often used could be placed slightly further away.
› You can make a plan with your colleagues based on these principles and locate things
accordingly.

STEP 3
› Make sure that everyone at your workplace knows what are kept where for efficient use.
› Make a list of things with their locations and put it on lockers/cabinets.
› Label each drawer/cupboard to show
› What is kept inside.
SEISO – Shine / Sweep
SWEEP
Thoroughly clean and check everything in the work area with no dust and grime anywhere

 Maintaining a clean work place

 Arranging things in order

 Placing proper labels or tagsS

Purpose:
• To create a spotless workplace.

• To turn the workplace into a clean, bright place where people

enjoy working.

• To maintain everything in the best possible condition by

constant check and care.
How to practice

 How is cleaning done?

 Start from the top
 Clean as you work
 Smell unusual odors
 Observe unusual movements
 Clean with inspection
 Choose a 5S Day.

› Learn to pick-up tiny pieces of waste around you.

› Clean as you go.
SEIKETSU - Standardize
STANDARDIZE

This means setting up standards / Norms for a neat, clean,

workplace and details of how to maintain the norms
(Procedure)
Standardize clean-up activities by:
• Sustaining five-minute daily clean up habit
• Keeping a balance between personal cleanliness and the
• cleanliness of the environment
• Avoiding littering
• Learning to pick-up tiny pieces of waste around
SHITSUKE – Self Discipline
DISCIPLINE IS THE CORE OF 5S

• This is by far the most difficult S to implement and achieve.

• Motivate, maintain and continually improve by applying 5 S in

daily work

• Discipline means making a steady habit of properly maintaining

correct procedures.

• Look back, differentiate and improve further.

• Improvement work within PDCA
• Continue to educate and re-enforce.

Perform, practice and adopt 5S habits anytime and anywhere

Getting Started

 Planning – launches your 5S activity

 Evaluating – tells you what you need to do

 Preparing – gets you ready for

implementation
 Planning
 Assemble a 5S Lead team

 Define the work area 5S boundaries

 Assign work group members to their 5S areas

 Install a 5S communication board

 Determine 5S targets, activities, and schedule

 Review/finalize plans with work group and site leadership

 Evaluating Your Initial Situation

Prepare to take work area photos

Take work area photos

Evaluate current 5S Level of Achievement

“Division of factory premises in to various zones”

A Red Tag Incoming Zone 7

Area

Gallery Zone 7

Office & Tool room

Zone 7

Bar Turning &

Office & Stores Zone 6
Guard Area
Zone 1 DGBB SHOP CNC SHOP
Zone 2 Zone 3

Inspection & Packing BOF Shop

Zone 4 SCRAP YARD Zone 5

First Floor First Floor

Admin Office HM Shop
Zone9 Zone8
 “Master plan for 5S

TP Master plan For 1S & 2S implementation - MASTER PLAN

Sr# Description of 1s activity May-14
PIC Status 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Plan
1 Prepration of Factory Layout (zone wise) CII/SKF
Actual
Formation of Sub Zone leaders & steering ROBIN/ Plan
2
committee SUDHEER Actual
ROBIN/ Plan
3 Training for 1s & 2s and evaluvation SUDHEER Actual
1S Implementation
Tagging and documentation of unwanted Zone Plan
4
material leader Actual
Unwanted material shifting to Red area & Zone Plan
5
Follow disposal procedure leader Actual
Zone Plan
6 1S self Audit leader Actual
Other Z Plan
7 Cross zone Audit leader Actual
Steering Plan
8 Team Audit committee Actual
2S Implementation
List of required material in the Zone with Zone Plan
9
identification leader Actual
Systematic arrangemening of required Zone Plan
10
material with identification leader Actual
Zone Plan
11 2S self Audit leader Actual
Other Z Plan
12 2S Cross zone Audit leader Actual
Steering Plan
13 Team Audit committee Actual
 “5S AUDIT SCORE”

TP SELF AUDIT SCORE

ZONE
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9
NUMBER
Office & Inspection BOF & Scrap Bar Turning Gallery & Office first
ZONE NAME DGBB Shop CNC Shop HM shop
guard area & Packing yard & storage Incoming floor
OWNER Robin Raguveer Ajay Bhagirath Munna Sonu Somveer Govinda Sajjan

SCORE 92.40% 78.03% 98.39% 92.80% 88.63% 87.50% 92.80% 87.12% 92.04%

TP CROSS AUDIT SCORE

ZONE
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9
NUMBER
Office & Inspection BOF & Scrap Bar Turning Gallery & Office first
ZONE NAME DGBB Shop CNC Shop HM shop
guard area & Packing yard & storage Incoming floor
OWNER Robin Raguveer Ajay Bhagirath Munna Sonu Somveer Govinda Sajjan

SCORE 91.66% 84.09% 88.24% 95.49% 92.04% 90.53% 92.80% 91.66% 92.80%

TP COMMITTEE AUDIT SCORE

ZONE
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9
NUMBER
Office & Inspection BOF & Scrap Bar Turning Gallery & Office first
ZONE NAME DGBB Shop CNC Shop HM shop
guard area & Packing yard & storage Incoming floor

OWNER Robin Raguveer Ajay Bhagirath Munna Sonu Somveer Govinda Sajjan

SCORE 96.20% 90.90% 92.80% 93.93% 92.42% 92.04% 93.18% 92.04% 95.83%
Before and After photographs with Improvement Points

Zone 1 Office Area

BEFORE AFTER

Files stacked without identification and Files stacked with identification and
numbering in rack. numbering in rack.
Before and After photographs with Improvement Points

Zone 1 Office Area

BEFORE AFTER

Un used material placed in the Office Removed un used material from the
Area. Office.
Before and After photographs with Improvement Points

Zone 3 CNC Shop

BEFORE AFTER

All CNC collets and Jaws put together at Almirah made to keep Jaws and collet
one place mixed up. separately in pair.
Before and After photographs with Improvement Points

Zone 3 CNC Shop

BEFORE AFTER

All type of Nut and Bolts kept in one Wooden Box divided into parts to keep
box mixed . nut and bolts separately.
Before and After photographs with Improvement Points

Zone 3 CNC shop

BEFORE AFTER

All Spare, tools and other usable item All Items in Elmira kept properly at
kept in Elmira mixed up. designated area.
Before and After photographs with Improvement Points

Before After
THANK YOU