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5’S, Safety, Pollution, Health and Hygiene

5S Good Pollution free

House Keeping Environment

Safe
Working
Area
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 Safety
Aim : To create a congenial work place where people
work without worrying about fatigue and injury

Three “D” Evils

Dirt Danger Difficulty
Hard to do
Cause unsafe condition Cause right because they
& major accident are fatigue
equipment breakdown

Unsafe condition Unsafe act

Accidents 3
 How to maintain Hygienic & safe work place?

Unsafe act: Tripping, Slipping, Falling on floor / down the

staircase

Care :
• Avoid highly polished floors
• Avoid torn or loose carpets
• Wipe out water,soap,oil immediately fallen on the floor
• Keep the area always clean

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 How to maintain Hygienic & safe work place?
Unsafe condition: Collision and Obstructions
Care :
• Don’t scatter/over crowd material in the passage or
around the working area/files on table
• Repair damaged /corroded unsafe staircase,steps,handrails
• Provide standard slope for the stair case,proper width
and height for steps
• Repair unsafe chair,table,& rack immediately
• Correct sharp edges & projected nails on the furniture
• Close table drawer immediately after use
• Avoid trailing of telephone wires on the floor
• Avoid loose electrical wires hanging,dress them properly
• Isolate electrical equipments while repairing / cleaning
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• Provide good illumination in the office,passage,staircase
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 5’S Good House Keeping
1’S – Seiri 1S Use with Material,
Organization
2S Equipment and
3S Working area

Implementation

5S 4S Use with
5S Human beings

5S Create Management
Effectiveness
Principles of 5’S - Implementation Covering all Functions/Areas/Teams
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 Objectives of 5’S
• Creating a neat & clean
safe & healthy work place
• Developing a habit for complying
with work place rules & procedures
• Systematize day to day working
• Improving work efficiency
• Standardizing Work practice
• Improving work discipline
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 1’S - Organization
Objective :To distinguish Necessary and Unnecessary items,
and eliminate unnecessary items from work area.
Activity : - Segregate / sort items – necessary & unnecessary
- Collect, store and dispose unnecessary items,
Throw items with no value.Sell items with value
Caution : -If acceptable products mixed with reject
it is loss and waste
- If reject mixed with acceptable one
will lose brand loyalty
Benefits: Eliminates excess use of space, file, cabinet and
equipment etc.
Indicator : - % area or space saved for storage & - Revenue
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of success generated by sale of unnecessary items with value
Sale of Old Machinery / Scrap – Benefits of 1’ S

Year 98-99 99-00 00-01 01-02 02-03

Realization 27.31 23.51 56.72 68.41 21.43 12
Rs.Lacs
Do you like this storage ?

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How do you feel about this storage ?
Table draw status 15
 2’S - Neatness
Objective : “A Place for Every thing and
Every thing in it’s Right Place”
Activity : After Sorting, Arrange Necessary Things (still used
& needed) in good order such that they are easily
retrievable when required for use based on,
• FIFO system
• Point of use and Frequency of use, Self life items
(Keep accessibility as easy as possible / Frequently used
items nearer & rarely used items farther / Heavy items in
the lower compartment, lighter items in upper
• Every thing in it’s place (Specify place for every item in
the office/store/work place)
• Identify items by tags or signs 16
 2’S - Neatness
Caution : Keep things in their designated right place after use

Benefits :
• Easy accessibility
• Quick retrieval of items
• Facilitates smooth inspection
• Creates work effectiveness
• Creates safety work environment

Indicator of success :
• Time saved in searching items
• Time saved in handling materials 17
 Retrieval of Stores Items

BOLTS & NUTS

LOCATION & AREA
SECO NDS FIXED ON RACK
150 ISSUE & INVENTORY
120
SYSTEM DEVELOPED
100
100 75 TRAINING TO
ALL
45 EMPLOYEES
50
INDEXING & STOCK 30 30
LIST NEAR RACK
0 MAR DEC' MAR MAR MAR APR'
'99 99 '00 '01 '02 03
BO LTS & NUTS 120 100 75 45 30 30
MO NTH

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 Retrieval of Files

FILES

SEC O NDS
INDEXING
FOR EACH
200 LOCATION
165
OWNERSHIP
150 125 CONCEPT
100
100 65 TRAINING TO
ALL
50VISUALS MARK 30 30EMPLOYEES
ON CABINETS &
0 CUPBOARDS
MAR' MAR' MAR' MAR' MAR' APR'0
98 99 00 01 02 3
FILES 165 125 100 65 30 30
MO NTH

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 3’S - Cleaning
Objective : To eliminate dust, dirt and grime which are the
prime cause for the unexpected equipment
failure, unhygienic environment and accident
Activity :
• Decide cleaning points,order of cleaning and cleaning
schedule
• Arrange cleaning kits (brooms,mops,cloths,hose
pipes,brushes,vacuum cleaners et.), SOP’s and tools
• Clean perfectly in right sequence by using proper
cleaning aids
• Prepare cleaning standard / checklist and follow it
• Improve cleaning methods / tools and reduce cleaning
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time
 3’S - Cleaning
Caution :
• Follow cleaning standard, safety rules & precautions
• Develop attitude – “Cleaning is inspection”
• Identify “Hard to access area” and eliminate
• Prevent dust,dirt and grim at the source of generation
by eliminating the root causes
Benefits :
• Creates vital working atmosphere
• Enhances morale and equipment life
• Quick identification of deviations
• Enhances equipment life
Indicator of success :
• Reduction in cleaning time
• Reduction in rework 21
• Increases in equipment life
Dust & Waste Bin Locations

ELECTRICAL
WORKSHOP
PULP MILL

CANTEEN

CHIPPER
HOUSE

WATER
PLANT
RECOVERY 22
 5’S Practice

Sorting Arranging

Cleaning

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Standardizing Training
• Cleaning becomes inspection

• Inspection reveals abnormalities

• Abnormalities can be rectified

• Rectification brings positive effect

• Positive effect brings pride

to the organization
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 4’S - Standardization
Objectives :
To standardize the good house keeping activities
sorting, storage & disposal procedures, cleaning
methods, cleaning aids auditing procedures across
the unit to keep things organized, neet and clean
Activity :
• Collect sources from all work stations
• Standardize procedures for all practices – sorting,
disposal of unneeded items, Storing of needed items
in order and Cleaning.
• Prepare manuals for standard cleaning procedures
• Introduce extensive visual controls so that
abnormalities show by them selves 25
 4’S - Standardization
Caution :
• Follow cleaning standard, safety rules & precautions
• Develop attitude – “Cleaning is inspection”
• Identify “Hard to access area” and eliminate
• Prevent dust,dirt and grim at the source of
generation by eliminating the root causes
Benefits :
• Elimination of all possible errors
• Uniform standard practices by all
• Clear communication, easy monitoring
• Compliance to standard operating procedures
& practices are established across the unit
Indicator of success :
• Minimizing Non compliance to SOP’s 26
 To sustain the
performance, achievements & gains

Translate Convert
Into
the in to
Practice
Concept Culture

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Objective : 5’S - Discipline
• To develop and practice 5S good house keeping autonomously
with participation of all
• To understand and practice “First time right, Every time right”
Activity :
• Train employees to follow 5S good house keeping discipline
autonomously in their respective areas
• Practice all 4S activities religiously all the time by all employees
without asking for
• Assign individual responsibilities to all employees
• Create feed back system for abnormalities &deviations
• Develop and practice good habits (office timing, safety, rules,
uniform, following regulations etc.)
• Integrate 5’S practices in to day to day working of teams in their
area to form 5’S a part of Daily work place management
throughout the plant
• Employees follow specified procedures/checklists to ensure 28
compliance
 5’S - Discipline
Caution :
• Practice all 4S till they become habit
• Strictly follow company rules and regulations
Benefits :
• High degree of house keeping at work place(Parlor status)
• Safe and healthy work place
• Employees become self disciplined
• High morale of employees
• Organization will be proud and attract more customers
Indicator of success
• 5S score
Conduct periodic Audits company wide to assess the status and
identify area where practice needs deep rooting,
-Self audit by teams, - Internal audit by Sub committee / WCM Cell
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-External by certified assessors
 Benefits of 5’S good house keeping
For Employees
•Neat & clean work place
•Safe & healthy environment
•Vital working atmosphere
•Cheerful / good mood
•Encourage to think & analyse
•Quick location of tools,
Materials and files
For Organization
•Higher work effectiveness
•Comply work place rules, procedures
•Increased productivity
•Reduced unnecessary stocks
•Low production cost
•More space & storage area
•Enhance Confidence & recognition
•Obvious factory / Parlor status
•Pride
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Key Performance Indicators

• Savings in terms of area / space

• Monitory savings through disposal
of unwanted items
• 5’S House keeping Index
• Retrieval time
• Reduction of Accidents
• Increase in manpower productivity
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 Good Habits
• Attending duty and conducting meetings on time
• After the meeting get on to their individual job
without lapse of time
• Join the row in good order
• Smoke only at specified place / time
• Prepare job list for the day and follow
• Follow the standard operating procedures
• Use specified material / tool /machine for
specified job
• Dispose waste as per the procedure
• Switch off light/fan when not in use
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 Model Area At Plant and Office

RE CHIPPER VIBRO FEEDER FILTER WATER PUMP BLEACH REJECT PULP

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W P C PUMP ACCOUNTS MATERIALS
 3 LEVEL AUDIT
Self Audit by Level 2 Audit by Level 3 Audit by Sub Committee

Abnormalities
Audit

Audit
Feasible Study
Could Not Attend

Could Not Attend Audit

Feedback

Attended

Steering Decision Supporting

Committee System WCM
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