5S

A Simple System for

Work Place Organization

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 CURRENT BUSINESS
SCENARIO
Sunrise Academy

 Customers’ needs are changing

 New technologies are continually
being developed
 Increasing sales competition (more
sophisticated products at lower
costs)

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 WAYS TO ENSURE SURVIVAL
Sunrise Academy

 Adapting to the changing business

environment
 Move beyond old organizational
concepts and customs
 Adopt new methods appropriate to
the times

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 JAPANESE INDUSTRY
 Little comparative advantage
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 No Oil
 No Mines

 No Coal

 Scraggy forests

 Inadequate food production

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 JAPANESE INDUSTRY
 How are Japanese companies doing good?
 People know nothing comes free
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 Functional illiteracy rate – lowest in the world

 Labour relations – harmonious
 People know importance of finding better ways

of doing things

 What do they do?

 Make their jobs easier
 Make their output better
 Make their lives comfortable

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 Principles of 5 S
A neat and clean factory leads to
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 Produces fewer defects

 Higher productivity
 Meeting deadlines better
 Safer place to work

QPDS

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 DISTINCT ADVANTAGES OF 5
S
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STEP DISTINCT ADVANTAGE

 Organisation > Eliminate non usable things
 Orderliness > Eliminate searches
 Cleaning > Eliminate Waste
 Standardisation > Makes 5-S alive
 Discipline > Bad habits get replaced by
good habits.
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 Objectives of this Programme
 Understand the steps to be taken
in developing an environment that -
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 is Organized

 is Safe

 is Productive

 is capable of smooth work flow

 puts the operator in control

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 Workplace Observation
 Clearly define target area
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 Identify purpose and function of target area

 Develop area map

 Show material, people, equipment flow

 Perform scan diagnostic

 Photograph problem areas

 Develop a project display board (area)

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 Target Area Vision
Current Condition
 SAFETY
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 PRODUCT QUALITY

 EQUIPMENT

CONDITION
Desired Conditions
 WORK EFFICIENCY

 STOCK LEVELS

 INFORMATION DISPLAY
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 5 S - FOUNDATION OF
IMPROVEMENT
 Not difficult to understand
 Not difficult to do
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 Difficult to maintain
 Requirements
 Perseverance

 Determination

 Constant efforts

 Ability to see what is important

 Attention to details

 Do We have a Choice ???

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Ready to start ?

Take “Before” photographs

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 What are 5 S

First S – SEIRI - SORT

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Second S – SEITON - SYSTEMIZE

Third S – SEISO - SHINE
Fourth S – SEIKETSU - STANDARDIZE
Fifth S – SHITSUKE - SUSTAIN

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 5S PROCESS
 SORT - 1st Step
 Clearly distinguish needed items from unneeded

items & eliminate the latter

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 SYSTEMIZE - 2nd Step

 Keep needed items in the correct place to allow for

easy & immediate retrieval

 SHINE - 3rd Step

 Keep the place swept & clean

 STANDARDIZE – 4th Step

 Make the first three steps a daily affair through
records and audits

• SUSTAIN - 5th Step

• Make a habit of maintaining established procedures
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First S

SEIRI
SORT
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 FIRST ‘S’ - SORT (Seiri)
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KEEP
 Only what is needed
 Only in the amounts needed, and
 Only when it is needed.
 Leaving only the bare essentials

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 FIRST ‘S’ - SORT (Seiri)
METHODOLOGY – RED TAGGING
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 Is this item needed?

 If it is needed, is it needed in
this quantity?
 If it is needed, does it needs to
be located here?
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 FIRST ‘S’ - SORT (Seiri)
METHODOLOGY – RED TAGGING
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 Create a “Red Tag Holding Area” –

(Emotional Buffer)
 Prepare tags, and Attach red tags to
unneeded items
 Hold in Red Tag Holding Area for a period
of time to see whether they are needed
 Evaluate (disposition) red-tagged items
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 SORT – Red Tag
Search
Search Look for
Look for unneeded
Floors unneeded
furniture
Aisles Cabinets materials
Operation areas Benches, tables Raw material
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Workstations Chairs Supplies

Carts Parts
Corners, under equipment
Search these storage Work in process
Small rooms Finished goods
places
Offices Shipping
Shelves
Loading docks Racks materials
Inside cabinets Closets Look for other
Sheds unneeded items
Look for unneeded Work clothes
Search the walls
equipment Helmets
Items hung up
Machines, small tools Old bulletin boards Work shoes
Dies, jigs, bits, Signs Trash cans
Other _________ Other
Conveyance equipment
Plumbing, electrical parts
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 Red Tag Material Disposal
Category Action
Obs ole te  S e ll
 Hold for de pre ciation
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 Give away
 Throw away
De fe ctive  Re turn to s upplie r
 Throw away
Us e d about once pe r we e k  S tore in are a
Us e d le s s than once pe r month  S tore whe re acce s s ible in plant
S e ldom us e d  S tore offs ite (or in dis tant place )
 S e ll
 Give or throw away
Us e unknown  S tore until information is found

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 Red Tagged Items Log
No . o f
Da te Ne e d le ss Ite m s Re a so n fo r Ta g g ing No te s / Disp o sitio n
Ite m s
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 Conduct Daily Audits
Audit
Step Item Date
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Determine wha t is and is not needed

Unneeded equip ment, tools , etc. ...are present

Sort Unneeded items are on walls (bulletin boards etc.)

Items are present in aisle ways, stairways, corners, etc.
Unneeded inventory, supplie s, parts, materia ls are present
Safety hazards (water, oil, chemic als ) exist
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 FIRST ‘S’ - SORT (Seiri)

 Red Tagging is completed

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 Empty spaces – A sign of progress

 Change the layout of equipment
And worktables

SECOND ‘S’ >>> SYSTEMIZE (SEITON)

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 SECOND ‘S’ - SYSTEMIZE
(SEITON)

 Sorting and Systemizing go hand-in-hand

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 Systemizing can be implemented only when

the Sorting is in place
 No matter how well you arrange items
orderliness can have little impact if many
of the items are unnecessary
 If Sorting is implemented without System,
it is much less effective
 Implement them together
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 SECOND ‘S’ - SYSTEMIZE
(SEITON)
 Arranging needed items so that they
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are easy to use and labelling them so

that anyone can find them and put
them away
 Orderliness eliminates many kinds
of wastes in administrative activities.

 Step one : Deciding appropriate

locations
 Step two : Identifying location
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 Systemize – Check Sheet
Equipment Materials
Machines Raw material
Small tools Supplies
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Dies Parts
Jigs Work-in-process
Bits Finished goods
Conveyance equipment Shipping materials
Cleaning equipment Cleaning supplies
Furniture Other items
Cabinets Charts, graphs, bulletin boards
Benches, tables Pens, pencils
Chairs Work clothes
Carts Helmets
Shelves Work shoes
Racks Trash cans 26
 Systemize
- Make it obvious where things belong
 Lines
 Divider lines
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 Outlines

 Limit lines (height, minimum/maximum)

 Arrows show direction

 Labels
 Color coding
 Item location

 Signs
 Equipment related information
 Show location, type, quantity, etc.

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 Systemizing – Eliminates Waste
 Motion Waste : The person sent to get a file
could not find it
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 Searching Waste : No one can find the key to the

locked pigeon hole that contains the mail.
 Human Energy Waste : A frustrated employee
gives up on not finding an ISIR report in the part
development file.
 Excess Inventory Waste : Desk drawers are crammed
full of pencils markers and other stationary items.
 Unsafe Conditions Waste : Bundles of open wires is
potential danger
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 SECOND ‘S’ - SYSTEMIZE
(SEITON)

 ‘Systemize’ is the core of

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standardization
– Filing standardization

– Layout standardization

– Inventory standardization

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 Systemize – Visual Standards

Transparent paper trays

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–
– Functional Performance monitors
Display board
– Filing visuals
– Layout visuals
– Direction visuals

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 Conduct Daily Audits
Audit
Step Item Date
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A place for everything…

Correct places for items are not obvious
Items are not in their correct places
Systemize
Aisleways and equipment locations are not identified
Items are not put away immediately after use
Height and quantity limits are not obvious
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 Third ‘S’ – SHINE (SEISO)
 Clean everything, inside and out
 Inspect thorough cleaning
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 Prevent dirt, and contamination from

reoccurring
 Resultsin
 Fewer breakdowns

 Greater safety

 Product quality

 More satisfying work environment

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 SHINE Check Sheet
Ceilings
Aisles
Workstations
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Corners, under equipment

Loading docks
Walls
Doors
Pillars, posts
Floors
Machines
Conveyance equipment
Plumbing, sinks
Cabinets, shelves, racks
Carts, Racks
Drawers, storage bins
Fixtures, power boxes 33
 SHINE - Methodology

 Zones & responsibility

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– Allocate group responsibility for

specific areas
– Make one person a group leader

– Rotate the leadership every month

- Rotate Individual responsibilities weekly

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 Shine Cleaning Plan
Task Location Who When Materials/
tools needed
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 Conduct Daily Audits
Audit
Step Item Date
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Cleaning and looking for ways to keep it clean

Floors, surfaces, and walls are not free from dirt
Equipment is not kept free from dirt, oil, and grease
Shine
Cleaning materials are not easily accessible
Lines, labels, and signs are not clean
Other cleaning problems are present
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REACHED “THIS FAR.”

TAKE “AFTER PHOTOGRAPHS.”

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 Fourth ‘S’ – STANDARDIZE
(SEIKETSU)
 Establish guidelines for
the team 5-S conditions
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 Make the standards and

5-S guidelines visual
 Assign 3s responsibilities
and Integrate the duties
into regular work duties
 Maintain and monitor
those conditions
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 Typical Team Standards
 Sort
 Amount of inventory
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 Tools that belong in the area

 How often to remove scrap
 Straighten
 Location of aisleways
 Location of tools, equipment
 Shine
 Cleaning schedule
 Maintenance tasks
 Checklist of what to look for as
cleaning is performed

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 Fifth ‘S’ – SUSTAIN
(SHITSUKE )
Determine the methods your team
will use to maintain adherence to
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the standards

 5-S concept training

 5-S communication board
 Before and after photos
 One point lesson
 Visual standards and procedures
 Daily 5-minute 5-S activities
 Weekly 5-S application
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 SUSTAIN - Visual Management
-Slogans
-Posters
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-Photo exhibition
-Story boards
-Newsletter
-Department tours
-5s months

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 5 S - Review and Summary
 List each of the 5-S steps
 Describe the “30-second
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test”
 Why is total employee
involvement so important?
 What is management’s role?
 Briefly describe each step in
the 5-S system
 How do you intend to use
this information?
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 Date
Step Item
Determine what is and is not needed
Unneeded equipment, tools, etc. ...are present
Unneeded items are on walls (bulletin boards etc.)
Sort
Items are present in aisleways, stairways, corners, etc.
Unneeded inventory, supplies, parts, materials are present
Safety hazards (water, oil, chemicals) exist
A place for everything…
Correct places for items are not obvious
Items are not in their correct places
Systemize
Aisleways and equipment locations are not identified
Items are not put away immediately after use
Height and quantity limits are not obvious
Sunrise Academy

Cleaning and looking for ways to keep it clean

Floors, surfaces, and walls are not free from dirt
Equipment is not kept free from dirt, oil, and grease
Shine
Cleaning materials are not easily accessible
Lines, labels, and signs are not clean
Other cleaning problems are present
Maintain and monitor the first three categories
Necessary information is not visible
All standards are not known and visible
Standardize
Checklists don't exist for all cleaning and maintenance jobs
All quantities and limits are not easily recognizable
How many items can't be located in 30 seconds or less
Stick to the rules
How many workers have not had 5-S training
How many times last week was daily 5-S not performed
Sustain
Number of times that personal belongings were not stored
Number of times job aids are not available or up to date
Number of times last week 5-S inspections were not done
Total

Number of problems found+D13 Rating

None 5
1 4
2 3
3-4 2
5 or more 1
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 Workplace Scan Score Card
Five "S" Steps
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Sort
5
4
3
Sustain Systemize
2
1

Standardize Shine

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