An Overview

of

‘5S’ CONCEPT
30 SECONDS RETRIEVAL
 5S What is “5S” ?
“5S” क्या है ?
5S began as part of the Toyota Production System (TPS) in Japan,
5S टोयोटा प्रोडक्शन सिस्टम (टीपीएि) के सिस्से के रूप में जापान में शुरू हुआ था।

5S is a Japanese concept for organizing workspace so that 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.

5S काययक्षेत्र को व्यवस्थथत करने के सिए एक प्रणािी िै तासक कायय कुशितापूवयक, प्रभावी ढं ग िे
और िुरसक्षत रूप िे सकया जा िके। यि प्रणािी िर उि जगि पर ध्यान केंसित करती िै , जिां वि
िोती िै और काययथथि को िाफ-िुथरा रखती िै , सजििे िोगों को िमय बबाय द सकए या चोट के
सबना अपना काम करना आिान िो जाता िै ।
 “5S” BENEFITS
“5S” करने के फायदे ?
5S

30 SECONDS RETRIEVAL
 5S What is “5S” ?
“5S” क्या है ?
5S is made of 5 Japanese Words which starts from Letter “S”
5S 5 जापानी शब्ों िे समिकर बना िै सजनकी शुरुआत “S” िे िोती िै

1s- Seiri Sort (ििी चयन/ छटाई)

2s- Seiton Straighten/Systematic Arrangement (िु-व्यवथथा)

3s- Seiso Shine/Cleanliness (िाफ़-िफाई/ चमकाना)

4s- Seiketsu Standardized (ििी मानकीकरण)

5s- Shitsuke Sustain/Self Discipline (स्वयं अनुशािन)

5S
“1S”
SEIRI- SORTING-सही चयन
 5S
“1S”
SEIRI- SORTING-सही चयन
• To take out unnecessary items either sort , red tag or dispose them

Unnecessary (गैर-ज़रूरी):
Unsafe
Necessary (जरुरी): Defective
Used for daily work Obsolete or outdated
Used periodically Unused
I am the source Extra or duplicate
 5S
“1S”
SEIRI- SORTING-सही चयन
• Red Tag and Red Tag Area: used for storage of Red Tag Material
 5S
“1S”
SEIRI- SORTING-सही चयन
• Example of Sorting
BEFORE “1S” / “1S” िे पििे AFTER “1S” / “1S” के बाद
5S
“2S”
SEITON- STRAIGHTEN- (सु-व्यवस्था)

5S Map & Checklist/Index to decide location

5S मानसचत्र और चेकसिस्ट / इं डेक्स, थथान तय करने के सिए

"Anyone should be able to easily understand proper

arrangement and abnormalities”
“सकिी को भी उसचत व्यवथथा और अिामान्यताओं को आिानी िे
िमझने में िक्षम िोना चासिए “
 “2S” EXAMPLE
I am taking one piece！
5S

मैं एक टु कडा िे रिा हं !

Can you tell which piece is taken out ? क्या आप बता िकते िैं सक कौन िा टु कडा सनकािा गया िै ? 10
5S
“2S” EXAMPLE
Seiri & Seiton are carried out
 “2S” EXAMPLE
5S
What is missing now？
２ ３ ４
１ ５

１ ２ ４ ５

Ａ Ｂ Ｃ Ｄ Ｅ

Can you tell which piece is taken out ? क्या आप बता िकते िैं सक कौन िा टु कडा सनकािा गया िै ? 12
5S
“2S” EXAMPLE

13
5S
“2S” EXAMPLE
5S
“3S”
SEISO- SHINE- साफ़-सफाई

“Regular/Daily Cleaning & Inspection of the working

area, machines, equipment etc.”
“सनयसमत / दै सनक तौर पर कायय क्षेत्र, मशीनों, उपकरणों आसद का
िफाई और सनरीक्षण करना ”
 5S
“3S” EXAMPLE & TOOLS

• Daily Machine CLIT Sheets • डे िी मशीन CLIT शीट

• Office Cleaning Check-list • कायाय िय की िफाई जााँ च-िूची

• Zone/ Area Cleaning Check-list • जोन / एररया क्लीसनंग चेक-सिस्ट

• Fans & Light Cleaning Schedule • पंखे और िाइट क्लीसनंग शेड्यूि

• Floor Cleaning Schedule • फ्लोर क्लीसनंग शेड्यूि

• Toilet Cleaning Check-List • टॉयिेट क्लीसनंग चेक-सिस्ट

5S
“3S” EXAMPLE

After Implementation of 1S, 2S & 3S

Ｂｅｆｏｒｅ（Original） Ａｆｔｅｒ（improvement）
5S
“4S”
SEIKETSU- STANDARDIZE-सही मानकीकरण

“4S means standardizing the methods

throughout the work area”
“4S का मतिब िै पूरे कायय क्षेत्र में ििी तरीकों का
मानकीकरण करना”
5S
“4S” EXAMPLES
STANDARD
SHOP FLOOR DISPLAY MANAGEMENT

FG STOCK STATUS BOARD WIP STOCK STATUS BOARD PRODUCTION PLANNING BOARD

MACHINE PM BOARD MOULD PM BOARD SAFETY BOARD

 5S
“4S” EXAMPLES
STANDARD COLOR CODES
क्र.स. सिन का रं ग सिन का इस्तेमाल
टू ल/ डाई कलर कोड सनदे श
रै क न. रं ग उदाहरण 1. ओके मटे ररयि रखने के सिए

RACK-01 पीला रै क न. : RACK-01 , रं ग : पीला 1 नीला सिन

RACK-02 हरा 2. प्लेसटं ग िे पििे और प्लेसटं ग के
बाद मटे ररयि रखने के सिए
RACK-03 नीला

RACK-04 आसमानी (स्काई ब्लू ) 1. मशीन िे बना ररजेक्ट

मटे ररयि मशीन पर रखे िाि
RACK-05 काला सबन में डािना िै ।

RACK-06 भूरा
2 लाल सिन
2. शॉसटिं ग िे सनकिे ररजेक्ट
RACK-07 सफ़ेद मटे ररयि को शॉसटिं ग टे बि पर
रखे िाि सबन में डािना िै ।

RACK-08 ससल्वर
1. ररवकय मटे ररयि को टै ग िगा
RACK-09 लाल कर पीिे सबन में रखे।

RACK-10 सुन्हेरी (गोल्डन)

2. िोल्ड मटे ररयि को टै ग िगा
3 पीला सिन कर पीिे सबन में रखे।
इस्तेमाल के सलए कायय सनदे श :-
1. इस्तेमाि के बाद सजि रं ग का टू ि िै , उिी रं ग के टू ि रै क में रखे| 3. िस्पेक्टेड मटे ररयि को टै ग
2. प्रत्येक टू ि की जगि उि रं ग टू ि रै क में सनर्ायररत िै , टू ि को उिके सनर्ायररत थथान पर िी रखना िै | िगा कर पीिे सबन में रखे।
 5S
“4S” EXAMPLES
STANDARD WORK STATIONS

STANDARD SIZE
(SAME SIZE OF BINS) SAME SIZE OF VISUALS
FOR SAME PROCESS
TABLES

SAME TYPE, SIZE &

COLOR CODE TABLES
FOR SAME OPERATION
5S
“5S”
SHITSUKE- SUSTAIN- स्वयं अनुशासन

1S
“5S is a never
ending cyclic
process and in
the center
always is 5thS”
“5S एक कभी न
4S 5S 2S
खत्म िोने वािी
चक्रीय प्रसक्रया िै
और केंि में िमेशा
5S िोता िै ”
3S
5S
“5S” EXAMPLES & TOOLS
DIVISION OF 5S ZONE & ZONE LEADERS
 5S
“5S” EXAMPLES & TOOLS
REGULAR AUDITS & TRAININGS
5S Workplace Organization
Levels of Achievement
Needed items are routinely Needed items can be Problem sources are M ethods for housekeeping, Root causes have been
Level 5: reworked/ replaced as retrieved within 30 seconds documented with solutions labeling, inspections, and eliminated and improvement
needed to improve work area and require a minimum defined and implemented work place design are actions focus on developing
Continuously performance number of steps continually improved and preventive methods
Improve shared externally as
applicable
Needed items are routinely Needed items have been Daily inspection occurs to Agreements for labeling, Sources and frequency of
Level 4: assessed against business minimized in number/ size and assess area readiness, housekeeping, inspections, problems are documented as
needs to assure functionality are properly arranged for potential problems are and work place design are part of routine work, root
Focus on and fit retrieval and use identified and fixed consistently followed and causes are identified, and
Reliability demonstrate area corrective action plans are
performance improvement developed
A list of needed items for the Needed items have dedicated Visual controls for Work area agreements for Work team is routinely
Level 3: work area has been locations and are properly equipment, files and supplies needed item labeling and checking area to maintain 5S
documented labeled with required have been established for the visual controls are posted agreements and posting
Make it quantities work area and followed by work team results
Visual
Needed and not needed Needed items have been Key work area items to be Work area agreements are 5S level has been determined
Level 2: items have been sorted and safely stored and organized checked are indentified and identified and documented and posted on the
not needed have been according to frequency of documented for needed item organization communication board
Focus on removed from work area use and work area controls
Basics
Needed and not needed Items are placed randomly Key work area items to be No work area agreements There is no measurement of
Level 1: items are mixed throughout throughout the work place checked during a sweep are exist 5S performance
the work area not identified
Just
Beginning

Sort Straighten Shine Standardize Sustain

rev. 04-06-01
5S
“5S” EXAMPLES & TOOLS
RECORD IMPROVEMENTS: BEFORE & AFTER
5S
“5S” EXAMPLES & TOOLS

AWARD & REWARD: BEST 5S ZONE TROPHY & CARD

 “5S” IMPLEMENTATION PFD
“5S” करे कैसे ?
5S

Step 5. Create Improvement Action Plan

• Decide the Actions which needs to be done

Step-1. 5S Sensitization
• Sensitizing Organization Core Team (HODs) Step 6. 5S Implementation
Regarding 5S • Implementations as per 5S Norms

Step 2. Establish 5S Team

• 5S Zone & Zone Leaders Deciding 1S (Sorting/
• 5S Zone Layout Creation Red Tagging)
• Training to the 5S Zone Leaders

Step3. CSM
• Current State Mapping of AS-IS condition by 4S 2S (Systematic
recording video and pictures of all zones (Standardized) Arrangement)
• SPP, FPP to be used

Step.4 In-house Training

• Training to all by Zone Leaders 3S (Shining)

Step 7. 5S Evaluation & Follow Ups

• Regular Audits for Gaps
• If You Like the Video, then

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