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5s Explanation Operation
5s Explanation Operation
5s Explanation Operation
A 5S implementation helps to define the first rules to eliminate waste and maintain an
efficient, safe, and clean work environment. It was first popularized by Taiichi Ohno, who
designed the Toyota Production System and Shigeo Shingo, who also put forward the
concept of poka-yoke. 5S is a system for organizing spaces so work can be performed
efficiently, effectively, and safely. This system focuses on putting everything where it
belongs and keeping the workplace clean, which makes it easier for people to do their jobs
without wasting time or risking injury. Implementing 5S in a workplace makes it easier for
people to navigate, find what they need, and keep things organized. 5S involves assessing
everything present in a space, removing what's unnecessary, organizing things logically,
performing housekeeping tasks, and keeping this cycle going. Organize, clean, repeat.
A workspace might be better off without unnecessary items or items used infrequently.
These things can get in the way or take up space.
The five S methodology helps a workplace remove items that are no longer needed (sort),
organize the items to optimize efficiency and flow (straighten), clean the area in order to more easily
identify problems (shine), implement color coding and labels to stay consistent with other areas
(standardize) and develop behaviors that keep the workplace organized over the long term (sustain).
1. Sort (seiri) –Sort, involves going through all the tools, furniture, materials, equipment, etc.
in a work area to determine what needs to be present and what can be
removed. Distinguishing between necessary and unnecessary things, and getting rid of
what you do not need.
Remove items not used in area – outdated materials, broken equipment, redundant
equipment, files on the computer, measurements which you no longer use
Ask staff to tag all items which they don’t think are needed – this improves
understanding about need and use
Classify all equipment and materials by frequency of use to help decide if it should be
removed – place ‘Red Tag’ on items to be removed
Establish a ‘holding area’ for items that are difficult to classify – hold item for allotted
period to enable others not on 5S team to review.
When a group has determined that some items aren't necessary, consider the
following options:
Identify and allocate a place for all the materials needed for your work
Assign fixed places and fixed quantity
Make it compact
Place heavy objects at a height where they are easy to pick from
Decide how things should be put away, and obey those rules
3. Shine (seiso) – Create a clean worksite without garbage, dirt and dust, so problems can be
more easily identified (leaks, spills, excess, damage, etc) The Shine stage of 5S focuses on
cleaning up the work area, which means sweeping, mopping, dusting, wiping down surfaces,
putting tools and materials away, etc. Shine also involves performing regular maintenance
on equipment and machinery. Planning for maintenance ahead of time means businesses
can catch problems and prevent breakdowns. That means less wasted time and no loss of
profits related to work stoppages.
Sustain refers to the process of keeping 5S running smoothly, but also of keeping
everyone in the organization involved. Managers need to participate, as do employees
out on the manufacturing floor, in the warehouse, or in the office. Sustain is about
making 5S a long-term program, not just an event or short-term project. Ideally, 5S
becomes a part of an organization's culture. And when 5S is sustained over time, that's
when businesses will start to notice continuous positive results.
The Safety step involves focusing on what can be done to eliminate risks in work
processes by arranging things in certain ways.
This might involve setting up workstations so they're more ergonomic, marking intersections
—such as the places where forklifts and pedestrians’ cross paths—with signs, and labeling
the storage cabinet for cleaning chemicals so people are aware of potential hazards. If the
layout of the workplace or the tasks people perform are dangerous, those dangers should
be reduced as much as possible. That's what the sixth S focuses on.
Sort:
Separate required tools, materials, and instructions from those that are not needed.
Remove everything that is not necessary from the work area.
Store:
Sort and organize all tools, equipment, files, data, material, and resources for quick, easy
location, and use. Label all storage locations, tools, and equipment.
Shine:
Set new standards for cleanliness. Clean and remove all trash, grease, and dirt. Everything
must be clean, tidy, and neatly put in its appropriate place. Cleanliness provides a safe
workplace—and makes potential problems noticeable, e.g., equipment leaks, loose parts,
missing guards, loose paperwork, or materials.
Standardize:
Engage the workforce to systematically perform steps 1, 2, and 3 above daily, to maintain
the workplace in perfect condition as a standard process. Establish schedules and set
expectations for adherence.
Sustain:
Make 5S part of your culture, and incorporate it into the corporate philosophy. Build
organizational commitment so that 5S becomes one of your organizational values so that
everyone develops 5S as a habit. Integrate the 5S methodology into the performance
management system.
Deal with causes of filth and grime. Red tag grime areas and prioritize conditions for correction
Perform management reviews
Have a place for everything and everything it its place to assure neatness
Analyze the existing conditions (status quo) for tooling, equipment, machinery, inventory,
supplies, wiring, dashboards etc. including retrieval and storage does
Decide where things go, reduce inventories, create name and location for everything
Decide how things should be put away, including the exact location. Use labels, tool outlines
and color codes
Obey the rules. Determine everyday controls and out of stock conditions
Use aisle markings for forklifts, boxes etc. and establish pallet zones for work in
progress(WIP)
This is more than keeping things clean, it includes ways to keep things clean
Establish a philosophy and commitment to be responsible for all aspects of working
conditions
Clean everything in the workplace, including equipment and correct root causes (identified in
step 1)
Perform RCA and remedy machinery and equipment problems
Complete training on basics of equipment maintenance
Divide each area into zones and assign individual responsibilities for each zone
Rotate difficult and unpleasant jobs
Implement 3-min, 5-min and 10-min 5S activities
Use inspection checklists and perform white rag inspections
4. Standardize : Make cleaning and checking routine.
5S, sometimes referred to as 5s or Five S, refers to five Japanese terms used to describe
the steps of the 5S system of visual management. Each term starts with an S. In Japanese, the
five S's are Seiri, Seiton, Seiso, Seiketsu, and Shitsuke. In English, the five S's are translated as
Sort, Set in Order, Shine, Standardize, and Sustain.
There are five key practices involved in 5S. They are as follows:
Japanese American
Definition
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