5S METHODOLOGY

5-STEP LEAN FRAMEWORK TO

ELIMINATE WASTEFUL ACTIVITIES

Ivan Carillo
When successfully implemented, the 5S
System can turn any dirty place into a
clean, standardized workplace.

It refers to 5 Japanese terms describing

the main steps of visual management
toward Operational Excellence:

- (1S) Seiri → Sort

- (2S) Seiton → Set In Order
- (3S) Seiso → Shine
- (4S) Seiketsu → Standardize
- (5S) Shitsuke → Sustain

Ivan Carillo
 (1S) SEIRI → SORT

Ivan Carillo
 "Sorting" means classifying everything in each
work area according to our needs.

Keep what you need. Remove what you don’t.

Anything not frequently used should be

moved to a separate, common storage area
called the Red Tag Zone.

Items that are not used should be removed or

recycled.

Do not keep anything in your workplace

because it might be useful in the future.

Ivan Carillo
 You must go through the entire area
(inside cabinets, under and behind
machines, etc.)

All obvious scrap should be put in the

Scrap Area / Bin.

All unidentified things should be in the

Red Tag / Quarantine Area.

Only items that are required should

remain.

Ivan Carillo
 BASIC STEPS

1. Clean

2. Classify

3. Assign Responsibility

4. Red Tag of unnecessary things

5. Recycle or reassign items arrived in

the Red Tag Zone

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 (2S) SEITON → SET IN ORDER

Ivan Carillo
 "A place for everything, and everything in its
place"

We can do our job in an organized workplace

more efficiently and effectively.

By arranging all necessary items, we save time

wasted in moving around.

In this step, we put things as per the frequency

of use.

Go for safe storage - heavy items at a low level,

light items at a height.

This way, If any item is missing, we can easily

find it.

Ivan Carillo
 BASIC STEPS
The items that are used so often should be kept
nearer to where they are used.

Items used very few times should be kept far

compared to frequently used things.

After completion of work, keep things in their

defined place.

If several things are used together, then store

them together.

For example, if a welding rod is used with a

welding machine, both should be kept together.

Ivan Carillo
 (3S) SEISO → SHINE

Ivan Carillo
 After Sort and Set In Order, the workplace
requires regular cleaning.

Shine is used to regularly clean the workplace,

tools, and equipment.

Cleanliness can lead to:

+ Easy detection of defects

+ Reduction of accidents
+ Improved morale in the workplace

It is not just the job of a housekeeper.

It's everyone's responsibility.

Ivan Carillo
 BASIC STEPS
Every workplace should have a person or
group assigned to clean that area.

The best approach is that those who work in a

workplace are also responsible for area
readiness.

Answer these 4 major questions.

→ Who is responsible for cleaning?

→ What needs to be cleared and where?
→ When will it be done?
→ How is it to be done, and which tools are
required?

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 (4S) SEIKETSU → STANDARDIZE

Ivan Carillo
 This is how we maintain the gains made in
Sort, Set in Order, and Shine.

Standardizing means documenting all

necessary processes or activities.

It turns Good Practices into Good Habits.

By developing standardized work, everyone

knows:

What to do
How to do
When to do
Where to do.

Ivan Carillo
 BASIC STEPS
(A) How do we Standardize?

→ Write standard operating procedures

(SOPs), process flow diagrams or flow chart

→ Standardize labeling, signage, and flow

→ Perform audits at a regular cadence

We can use labels, symbols, posters, and

banners for standardization.

Ivan Carillo
 (B) Standard Work is the best way to:

→ Document the current agreed way of

running a process
→ Provide a baseline for improvement
→ Reduce process variation
→ Mitigate the risk of injury

(C) Standardized flow and signage:

→ Common methods to show where the

work happens and ends
→ Standard methods for identifying
components and tool locations

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 (5S) SHITSUKE → SUSTAIN

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Sustain means to maintain 5S within the
work pace.

Here, record progress with evaluations,

communication, and training-related
activity.

Assign continuing responsibility.

It helps to keep watch on ongoing

training activity and maintaining the
established System.

Ivan Carillo
 BASIC STEPS

→ Create a schedule

→ Teach employees to run 5S audits

→ Adapt as necessary

Ivan Carillo
 TL;DR
(1S) Sort
↳ Classify items

(2S) Set In Order

↳ Organize everything

(3S) Shine
↳ Clean the workplace

(4S) Standardize
↳ Document the processes

(5S) Sustain
↳ Keep the momentum going
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