5 S Methotology as a

source of
Maintenance quality
improvement
The slower but consistent tortoise causes less waste and is more
desirable than the speedy hare that races ahead and then stops
occasionally to doze. The Toyota Production System can be realized
only when all the workers become tortoises.
Taiichi Ohno

represented
by Olena Puhach

Where Did the 5S Methodology

Begin?
The history of 5S goes back as far as the 16th Century and
Venice shipbuilders. In an effort to streamline the
assembly process, workers used quality process
production to build ships in hours instead of days or
weeks.

Where Did the 5S Methodology

Begin?

From there, it was Sakichi Toyoda and son Kiichiro as well as Toyota
engineer Taiichi Ohno who developed the 5S methodology or what
they called the Total Production System of TPS after World War II.
The three Toyota representatives looked at both Ford Motor
Companys assembly lines and the inventory process at the
supermarket chain Piggly Wiggly. Through analysis at Ford, they did
notice waste along with workers who had to wait for one step to be
completed which resulted in layoffs and rehiring. At Piggly Wiggly
supermarkets, their inventory system of ordering only what was
needed based on demand helped them understand and implement
the JIT process into the 5S methodology.

5S Description
5S is the name of a workplace organization method that uses a
list of
five Japanese words: seiri,seiton,seiso,seiketsu, and shits
uke.Transliterated into Roman script, they all start with the
letter "S". The list describes how to organize a work space for
efficiency and effectiveness by identifying and storing the items
used, maintaining the area and items, and sustaining the new
order. The decision-making process usually comes from a
dialogue about standardization, which builds understanding
among employees of how they should do the work.
In some quarters, 5S has become 6S, the sixth element being
safety.

5S Description
Other than a specific stand-alone methodology, 5S is
frequently viewed as an element of a broader construct
known as visual control,visual workplace, or visual
factory. Under those (and similar) terminologies,
Western companies were applying underlying concepts
of 5S before publication, in English, of the formal 5S
methodology. For example, a workplace-organization
photo from Tennant Company (a Minneapolis-based
manufacturer) quite similar to the one accompanying
this article appeared in a manufacturing-management

Steps of 5S
Seiketsu - Standardise
(Conformity)
Seiri Sort (Clearing)
- clearly separating necessary from unnecessary, and remove
unnecessary

Seiton Set in order

(Configure)
- visually arrange and identify items for ease of use and retrieval

Seiso - Shine & Check

(Clean & Check)

- keep the workplace clean (not pretty) to allow problems to be identified

- continually monitor the level of clearing, organising and cleaning

Shitsuke - Sustain
(Custom & Practice,
Consensus)
-

work towards a shared set of values regarding clearing, organising

and cleaning

and the 6th one +

Safety
- improve through better clearing, organising, cleaning and visual
control

SORT
Remove unnecessary items and dispose of them properly.
Make work easier by eliminating obstacles.
Reduce chances of being disturbed with unnecessary items.
Prevent accumulation of unnecessary items.
Evaluate necessary items with regard to cost or other factors.
Remove all parts or tools that are not in use.
Segregate unwanted material from the workplace.
Need fully skilled supervisor for checking on regular basis.
Don't put unnecessary items at the workplace & define a redtagged area to keep those unnecessary items.

SET IN ORDER
Arrange all necessary items so that they can be easily
selected for use
Prevent loss and waste of time by arranging work station
in such a way that all tools / equipment is in close
proximity
Make it easy to find and pick up necessary items
Ensure first-come-first-served basis
Make workflow smooth and easy
All of the above work should be done on regular basis

SHINE
Clean your workplace completely
Use cleaning as inspection
Prevent machinery and equipment deterioration
Keep workplace safe and easy to work
Keep workplace clean and pleasing to work in
When in place, anyone not familiar to the environment
must be able to detect any problems within 50 feet in 5
secs.

STANDARDIZE
Standardize the best practices in the work area.
Maintain high standards in workplace organization at
all times.
Maintain orderliness. Maintain everything in order and
according to its standard.
Everything in its right place.
Every process has a standard.

SUSTAIN
To keep in proper working order
Also translates as "do without being told"
Perform regular audits
Training and Discipline
Training is goal oriented process. Its
resulting feedback is necessary monthly

Why add safety to make 6S?

In some industries safety is far more
important than in others.
Adding as an additional step creates:
Greater awareness
More focus
Another chance to review

5S gains
5S removes instances of the
seven wastes within your
working environment.These
are:
Transport
Inventory
Motion
Waiting
Overproduction
Over Processing

Efficiency improvements
Typically in the order of
10% to 30%
Workspace more
Ergonomic
Items located in easy
reach
No clutter to cause delays

Advantages faced on 5S
Implementation
Reduction in delays
5S will reduce delays in your
process
Visual management shows
when products and
tools are missing
Problems highlighted
Materials out of place
Leaks and other machine
problems

Reduced setups
Setup times reduced through the same
process as increasing production efficiency
Ergonomic workplace
All tools to hand
Standardized process

Advantages faced on 5S
Implementation

Morale and motivation

Less stress for operators

Safer work environment
Involvement in making own
improvements
Empowerment to make changes
A highly visual and tidy
workplace
can give a great impression to a
current or potential customer.

Abnormalities are immediately visible allowing action to be taken

Improved quality
The right tools and equipment available
Standardized processes
Improved handling so less damage
Improved reliability of equipment

Advantages faced on 5S
Implementation
Safety

No clutter to create obstacles and hazards

Ergonomic stress free workplace
No stretching or reaching
No lifting heavy objects
Standardized ways of working

5S Among the other techniques

Lean Manufacturing Software _ 5S, Kaizen, SMED, VSM, 6Sigma, TPM, DMAIC, OEE (2).mp4

for Your attention =)