Poka-Yoke

5’S’
Zero Program
Defects on
Manufacturing
Work place Organization &
Standardization
 An Ancient Prayer

From the cowardice,

That Makes us,
Shrink from the Truth ;
From the laxness,
That Keeps us ,
Content with Half Truth ;
From the Arrogance,
That Makes us Believe,
That We know All truth ;
O’ My Lord,
Deliver Us.
 How Adults Learn & Retain…

• 20% of what they hear

• 30% of what they see
• 50% of what they hear and see +
• 70% of what they hear, see and say
+ +
• 90% of what they hear, see, say and do

+ + +
 Learning Recall
Type of presentation Ability to recall Ability to recall
after 3 hours after 3 days

Verbal (one-way) 25% 10-20%

lecture
Written (reading) 72% 10%

Visual and verbal 80% 65%

(illustrated lecture)
Participatory 90% 70%
(role plays, case
studies)
 But First...
Death by
Initiative

This is NOT a new initiative!

It is NOT a new way A New

of doing business! Way of

Doing
Business!

It is merely doing what we already

do, but doing it BETTER!
5 ‘S’ is Coming
Join The Run

Join the Run

What is 5’S’ ? A basic, fundamental,
systematic approach for
productivity, quality and
safety improvement in all
types of businesses.
The Five S program focuses
on having visual order,
organization, cleanliness and
standardization. The results
you can expect from a Five S
program are: improved
profitability, efficiency,
service and safety.
The precipices underlying a
Five S program at first appear
to be simple, obvious
common sense. And they are.
But until the advent of Five S
programs many businesses
ignored these basic
principles.
What is 1’S’ ? This is step 1 in a Five S
program:

"Sorting" means to sort

through everything in each
work area. Keep only what is
necessary. Materials, tools,
equipment and supplies that
are not frequently used should
be moved to a separate,
common storage area. Items
that are not used should be
discarded.
Avoid keeping things around
just because they might be
used, someday.

Sorting is the first step in

making a work area tidy. It
makes it easier to find the
things you need and frees up
additional space.
The Principle involved is Sort
In – Sort Out .
 1 ‘S’ – Sort
All Tools,pins,screws, are lying Tools placed - After Sorting
– before Sorting

Plug pins placed - After Sorting

Pins & screws placed - After Sorting

Mixed items - Before Sorting Items arranged - After Sorting

Sorting : Remove the Unneeded items, Rearrange /Regroup

the Needed Items as per Predefined Categories

Sort In - Sort Out

How is Keep the wanted things & remove the
unwanted things using Red Tag
1’S’ Procedure .
carried Red Tags Procedure :
out ? Red Tag Procedure is first step of sort
activity. All items at the work place are
Reason critically analysed for their use &
Item Name: 1.Obsolete
availability at work place. All
2.Not needed now
(once/year) unneeded items & those in excess of
Quantity:
3. Not reqd in the qty their normal use are removed to a
Reason for red tag
stored remote area marked as Red Tag
4.Not reqd in that area Holding Area. The idea of this activity
5.Defective/ scrap
6.Use not known is to keep only those items in that area
Identified by: Disposal which are relevant & required in
1.Discard relevant quantities. All items shifted to
Date: 2.Return red tag area carry a red tag which is
3.Sell filled with, quantity, reason for red tag,
4.Move to separate
storage area tagged by, date of tagging, reason for
5.Rework tagging disposal proposal & action by,
Disposal review date & status of disposal.
ActionBy:
DateReview/
Disposed
Red-tag file no.
1’S’ Each tag is allotted a unique S.
No. Also there is an action
plan updated with every
addition to red tag area to
ensure that items don’t lie
there indefinitely, but are
disposed at appropriate times.

Area Map :
Area map is the second step
TABLE
STA
RACK RACK RACK RACK RACK
VISUAL INSPECTION AREA

RACK RACK RACK RACK

F r o m W a s h in g
D e s i g n a ti o n s / S ig n s :
of Sort activity. Area map
shows location of
A rr o w li n e Fs l o w o f M a te r i a l
ND R ACK

GA N G WA Y

equipments ,racks for

Pr Panel Pr
Pr Panel
PAV3 PAV4 PAV2 Pr P a nel
PA V2 E
GANG WAY

M
P
I/P
I/P RACK I/P RACK T
Rack O /P

material storage & flow of

Y
O/P O/P
B
I
Gangway of PA AREA
N
O/P O/P O/P
I/P RACK S

materials. Different colours

I/P RACK O /P
PAV5 PAV1 PAV6
PA V6
s I/ P C u p b o ard
t Panel Pr Pr R a ck fo r s o l v e n t /
Panel Panel
d. a n d o t h e r t h in g s
P a nel Pr

RACK RACK RACK

TAMPO
RACK RACK RACK RACK

A L/C-1
R A C KR A C KR A C K
are used to show the
movement of different kinds
IMAGE-1
P A L/ C -1
A
D TABLE
3 TA BLE
R

of materials. From plan it can

AL/C-2 IMAGE-2 A L/C - 4
A L /C - 4

OVEN RACK RACK RACK RACK RACK

be easily seen the distances

of travel with help in
relocation for improved
layouts using principles of
flow & minimum distances.
What are benefits Creation of space is single
of 1’S’ ? biggest advantage of 1’S’
Generally if you are facing
problem of lack of space, go
for 1’S’ & space problem is
eliminated.
Sometimes one gets surprised
with the amount of space
released as a result of 1’S’
activity.
The other advantage is money
released due to sale of
unwanted items lying
unattended for long times.

When should be
1’S’ activity started 1’S’ Being the first the step of
? 5’S’ program should be
starting point.
Where is 1’S’ 1’S’ is useful in factories
useful ? work areas , offices &
homes alike.
Housewives find it
maximum useful. Even
Municipal corporations are
getting their staff trained in
steps of 5’S’ as they realize
immense benefits of it.

The space generated &

money released are the
What are the success indicators.
success indicators
of 1’S’?
 Seiri – Sorting Out
How often do you
Storage location
need them?

Always Close

Necessary items Sometimes A little far away

Seldom but can't

Separate
throw away

SEIRI Action

Immediate Throw away

throw-away quickly

Unnecessary
Resale value? Try to sell
items

Is disposal M inimize cost of

expensive? disposal
What is 2’S’ ? 2s stands for Set in order
The Principle involved is
’Place for everything &
Everything in place’

When is 2’S’ 2’S’ Activity is started

Activity started? immediately after 1’S’.
This sequence has to be
followed strictly.

How is 2’S’ activity 2’S’ activity is carried out

making use of lines ,
carried out ?
labels & signages.
Lines Standard For Floor Lines Standard color &
widths are used for
marking locations
 Type Colour Width Notes Illustration
(Inch)

Aisles (area divider) lines Yellow 3” Solid

Door Range Lines Yellow 2” Broken

Entrance/Exit Arrows Yellow 2” Solid

Direction Arrow Yellow 2” Solid

Place Marks for Dustbins Red 2” Broken

Place Markers for Material (WIP)Green 2” Solid

Place Marks for Racks, Yellow 2” Corner Line

Cupboards, Work tables 4” long

Place Marks for defective Red 3” Solid

materials

Caution Area Yellow & Black 2” Alternate solid

(STRIPES)

Place Marks For Safety Red 2” Solid

Equipment
Seiton – Set In Order
Labels Labels of standard
fonts & sizes are
used to mark
locations,
equipments,bins &
containers.

Signages Fire extinguishers,

exit ways are marked
using standard
symbols.
What is Time for
benefit of searching tools ,
2’S’ ? Before After items files etc is
eliminated to
zero.
What is 3’S’ Stands for shine.
3’S’? The principle involved is
‘cleaning with meaning’
Cleaning methods should
address questions like what is
being cleaned, where is it being
cleaned, how is it being
cleaned, who will clean & when
will it be done.
The cleaning schedule should
include walls, floor, roof etc.
Locations for cleaning material
must be marked & 2s for
cleaning material should not be
ignored.
Abnormalities like loose wires,
leakages must be tagged
promptly.
Cleanliness is also helpful to
notice damages on equipment
such as leaks, breakage and
misalignment.
 SCRAP
CARRIER
 Seiso- Shine
Is what to clean Cleaning Check list
identified?

Is the frequency set As per process req

Is the limits set?

Is the method clear

As per the area

Who is to clean? Daily/weekly

CALENDAR

Recording with
Tags/Register
meaning ?
SHINE Storage location
items

Is the items labeled? As per operation

labeled req

MATERIALS Is the area marked ? On floor or wall

Is it close at hand? In a stand

What are the 3’S provides safe,
imaculate & pleasant
benefits of 3’S’ surroundings.
activity? It is very important to
boost the morale of
working people

Clean thoroughly the

workplace inside out.
Roofs, Equipments ,
How is 3’S’ activity floor.
done? Start from the top &
come down gradually.
3’S’ Prepare the
S.No What When How Who
cleaning check-
lists & follow them.
Floor Shift Start & End Floor Mops Sweeper &
1 Cleaning Whenever there is Brooms certified by
spillage. SIC

Machine Shift Start & End Waste Cloth MC Operator

2 cleaning Whenever there is & Solvent
spillage.

Wall Cleaning 1st Day of Month Brooms with Sweeper &

3 from Dust & extended certified by
Cobwebs handles SIC

Work Tables Shift Start & End Waste Cloth M/C Operator
4 Whenever there is & Solvent
spillage.
What is 4’S’? 4’S’ stands for standardization of 1’S’, 2’S’ &
3’S’.
The Principle involved is standardisation of
above 3s i.e. defining clearly what is required
level to be achieved.
The workplace must have display of required
standards. Area map. Audit sheets, work
instructions,Do’s & Don’ts in that
workplace.history cards for equipments, COT
checklists, Safety check lists, production
performance graphs, Quality performance
graphs, planned maintenance records, OEE
graphs, improvement tracking graphs.

When is 4’S’ 4’S’ is carried out after completing 3’S’

activity.
carried out?
It is important to follow the sequence as
bypassing the steps can lead to no benefit of
any step.
The idea is workplace should speak itself
giving an idea about state of affairs in the
shop.
 Seiketsu - Standardise
Prepare a list of all standards that needs to be located in
the work area
this will include, area map, 5 S audit sheet

PICTORIAL WORK INSTRUCTIONS FOR-OPERATION & DO'S and DONT'S

SMED, AM-COT, SAFETY POINTS
HISTORY CARD
PLANNED MAINTENANCE-RECORD AND PLANS
CURRENT PERFORMANCE GRAPHS/TRENDS-
PRODUCTION INFORMATION AS OF CURRENT
OUTPUT PERFORMANCE
QUALITY PERFORMANCE
OEE
IMPROVEMENT'S TRACKING GRAPHS/CHARTS
SKILL LEVEL
ANY OTHER INFO THAT MAY BE REQUIRED FROM TIME TO TIME
Audit both the area and equipment for all the above work
instructions and usage- no ncr's
 4‘S’ – Standardize
Workplace Organization Checklist for: ______________________________ Score 5: Nonon-conformances Sc ore 5: No non-conforma nce s Re cord of

Score given by 5-
Score 3: Upto2 non-conformances Sc ore 3: Upto 2 non-conforma nce s s coring
Process Owner:______________________________ Score 1: More than2 non-conformances Sc ore 1: More than 2 non-conform anc es

Self-score
Score given:
Category Particulars to be checked

S team
5 3 1 Non-conform anc es observed:
Seiri>Sort Distinguishbetweenwhat is neededandnot needed Date
Organisation Have all unnecessaryitems been removed?
Are all remaining items neatlyarranged?
Are walkways / aisles and work areas clearlyoutlined?
Does a procedure exist for removing unneeded items?
Seiton> Set In order Aplace for everythingandeverythinginplace
Orderliness Is there a place for everything?
Is everything in its place? (Search free, count &climb free, FIFO)
Is it easyto find out where to keep items?
Are things put awayafter use?
Is the standard quantityfor each item established?
Seiso>Shine Cleaningandlookingfor ways tokeepit cleanandorganized
Cleanliness Are work areas clean and hygenic?
Is equipment kept clean?
Are cleaning materials easilyaccessible?
Are all items kept in the demarcated places?
Are cleaning guidelines and schedules easilyvisible?
Are Seiri (sort) and Seiton (stabilize) complete?
Seiketsu>Standardise Maintainandmonitor the first 3 categories
Adherence Is all necessaryinformation (locations, machine names etc.) visible?
Are all standards (e.g. colour code, label etc.) known and visible?
Is there a checklist in the area?
Are standards and limits (of storage) easilyrecognizable?
Shitsuke>Sustain Stick tothe rules
Self-Discipline Does everyone observe the standard procedure?
Are red tags procedures followed?
Are personal items and belongings stored neatly?
Are job aids up to date and effective?
Miscellaneous

Total for eachscore

Ave ra ge
Over all total
Percentage score (divide by115)

Prepare Audit sheets and conduct audits

What is 5’S’ 5’S’ stab\nds for sustain.
activity ? Sustain activity is carried out
using following steps :
Train all operators in
observing SOPs & Red
Tag Procedures.
Place of neat storage of
personal items.
Process owners carry out
Daily Audit & 5’S’
Teams meet once a week.
Recognition for Best Area as
a rolling trophy.

How is 5’S’ Sustaining is done

activity through Audits &
done ? Training
 5 ‘S’ Sustain
Action Plan

S.No. Action Who Target Date

Act on Audit Nonconformities