Training Session

on

5S
Part 1 - What is 5 S
&
Part 2 - How to
Implement 5 S
Now, we will see !
Part 1 - What is 5 S
 Impact of 5 S at the Workplace
Equipment
QUALITY En
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Material

M
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ai
ax

nt
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a
SAFETY

in
til
Jigs/Tools Up

s
k iza
ee t io
ps n
Method Imp
rove
s
EFFICIENCY Motivates
Workers
es G ood
r
Ensu
CONTROL Products Prom ot es

Timeliness

Customer Employee
Satisfaction Satisfaction
 PAN
JA

U. S. A.

INDIA

1950 1960 1970 1980

 What are the 5 S?
•Seiri - Sorting
•Seiton - Systematic Arrangement
•Seiso - Cleaning
•Seiketsu - Standardization
•Shitsuke - Training & Discipline
We Will See First ….!

What is

SEIRI
(SORTING)
Seiri - Sorting

SEIRI - SORTING /REORGANISATION

To clearly devide objects in to two groups
•Those items that are necessary.
•And Those items that are not necessary.
•To get rid of the unnecessary and to keep
the necessary.
Seiri - Sorting

WHAT IS UNNECESSARY
• Item is not needed.
•Item is needed however, quantity in stock is more
than what is needed for consumption in near future
•Contingency Parts : Critically decide the quantity
of contingency parts to be retained and criteria for
such parts.
 Seiri - Sorting Organisation
Frequency of use Storage Method
LOW•Things you have not used Throw them out
in the last one year.
•Things you have used once Store at distance OR
E

in the last 6-12 months. Keep in store

AG

•Things you have used only Store it in central

ER

once in the last 2-6 months. place in your zone.

AV

•Things used more than once Store it in the central

a month. place in your zone
•Things used once a week Store near the
workplace.
Things used daily or hourly Store near the
HIGH workplace.
Seiri - Sorting Organisation
Identifying unnecessary
1) Parts and Work in Process (WIP)
•Things fallen back behind the machine or rolled
under it.
•Broken item inside the machine
•Things under the rack/platforms.
•Extra WIP
•Stock of rejected items
•Items accumulated over period for rework
•Material awaiting disposal decision
•Material brought for some trail, still lying even after
trail
•Small qty of material no longer in use Cont…..
Seiri - Sorting Organisation
Identifying unnecessary
2) Tools, Toolings, Measuring devices
•Old jigs, tools not in use lying.
•Modified tools, tooling for trial, are lying after trail.
•Worn out items like bushes, liners, toggles etc. lying.
•Broken tolls, bits etc. may be lying.
•Measuring equipment not required for the operation being
performed, is lying.

3) Contingency parts
•Many times storage place for contingency parts become a last
refuge for broken parts, surplus items and things nobody is
likely to use. Cont…..
Seiri - Sorting Organisation
Identifying unnecessary
4) Shelves and Lockers
Shelves and lockers tends to collect things that nobody ever
uses, like surplus, broken items etc.
5) Passage and Corners :
Dust material not required seem to gather in corner.
6) Besides Pillars and under the stairs:
These place tends to collect junk, spittoon etc.
7) Walls and Bulletin Boards
Old out dated notices which have lost their relevance
Posters or bulletins on wall
Dust, remain on torn notices, cell tape pieces Cont…..
Seiri - Sorting Organisation
Identifying unnecessary
8) Floor, Pits, Partitions
Defective parts
Protection caps, covers
Packing material
Hardware items, small items
Even tools,small items
Even tools, tooloing
Items dropped on the floor are never picked

9) Computer Hard Disk

•Many unwanted, outdated, temporary files pile up
Cont…..
Seiri - Sorting Dealing with papers
How to reduce papers on your table?

1) Make a single pile of papers

2) Go through them and sort in following categories :

a) Immediate action
b) Low priority
c) Pending
d) Reading material
e)For information
Seiri - Sorting Dealing with papers
How to reduce papers on your table?
4D principle
DO...
DELEGATE….
DELAY….
DUMP….
Now,We Will the Second one ...!

What is

SEITON
(SYSTEMATIC ARRANGEMENT)
Seiton - Systematic Arrangement

SEITON
A Place for Everything And...
Everything in its Place …!
Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

•Decide where things belong

•Decide how things should be put away
•Obey the ‘Put away’ rules
Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

• Decide where things belong
- Standardize Nomenclature
- Determine an analytical method for storage
• Decide how things should be put away
- Name & location to everything. Label both item
and location
- Store material functionally
- Prevent mistake with coding by shapes & colour
contd….
Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

• Decide how things should be put away
- Follow ‘first in first out’ rule
- If two identical items are to be located, then store
them separately, colour code them.
• Obey the rules
- Put the things back to their location after their use
Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

USE:
1) Signboard
2) Colour codes
3) Outline marking
4) Labels
Seiton - Systematic Arrangement

Functional
Storage
Seiton - Systematic Arrangement

Functional Storage
Usage * Store frequently used material
Frequency near the workplace and
less frequently at some distance
Weight & * Heavy material should be stored
Shape of at lower levels/layers
the Material Place directly on the material
handling device for case of
handling
Seiton - Systematic Arrangement

Functional Storage
Category * Same category of material may
be stored in one location.
Eg. Allen Screws, Oil Seals
Operation * All items required for an
Wise operation may be stored in one
location.
Eg. Allen key, spanner etc. hand
tools required for setting m/c
Seiton - Systematic Arrangement

Functional Storage
• Outlining and Placement Marks
-Marks boundaries of dept. aisles, Machines
-Follows straight line, right angle rule
-Nothing shall be kept outside the boundaries
• Stand and shelves
-Keep only required number of stands and
shelves
-Standardize height, size
-Provide casters where necessary so that it can
be move
Seiton - Systematic Arrangement
Functional Storage
• Wires and Ducts
- Colour code
- When there are multiple connections – bundle the wires,
label them and lake sure that they are in straight line /
right angle and firmly anchored
• Machine -tools & Tools
- Put the tools in the order you need them
- Location of the tools should be such that it can be put
away with one hand
- Try to eliminate some hand tools by permanently
attaching it to the bolt
head
Seiton - Systematic Arrangement
Functional Storage
• Blades, Dies other important consumables
- Stores them in the protected place
- Maintain these things regularly by applying
rust preventive, oiling etc.
• WIP – Work In Process
- Designate a place for each component / part
- Decide on how much quantity to be stored
- Ensure that there is no damage to good part
during transit, they do not get rusty and they
are not mislabeled.
Seiton - Systematic Arrangement
Functional Storage
• Oils
- Reduce number of oils used (Standardize)
- Colour code for oil
- Safety aspects – fire prevention, pollution,
leak, spillage

• Instrumentation & Measuring Devices

- Label them, show direction of flow
Now,We Will the Third ...!

That is

SEISO
( CLEANING )
Seiso - Cleaning

SEISO
Clean workplace completely so
that, there is no dust on the floor,
machines and equipments …!
Seiso - Cleaning

Activity - Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning
inspection
Success - Reduction in machine down time
Indicator - Reduction in no. of accidents
Seiso - Cleaning

While cleaning up and getting rid of

dirt and unclear items potential defects
such as Abrasion, Damage, Loose
Parts, Deformities, Leaks, Vibration,
Abnormal Sound etc., are revealed and
hence Seiso is inspection
Seiso - Cleaning

• Here cleaning means more than just

keeping things clean. Cleaning should
be viewed as a form of Visual
Inspection
•Preventive measures should be taken to
tackle problems of dust, grim, burrs,
leakage etc. Roots cause of the problem
should be identified and it should be
eliminate
Seiso - Cleaning

5 Minutes Every day for cleaning

•Devote 5 minutes every day for

cleaning your work area
•Participation of everyone is required
•Attack hard to clean places regularly
Seiso - Cleaning

Cleaning - Inspection Points for most

equipment
Tightening Loose bolts, welding detachment,
loose parts, vibration or bumping noise,
friction

Heat Oil tanks, motors, heaters,

axles, control panels, washing/cleaning
water, bearing, wiring etc.
Seiso - Cleaning

Cleaning - Inspection Points for most

equipment
Breakage, Breakage, cracks dent on sliding
Cracks parts, handle has come off,
broken switches, wire joints
come off, wires are broken or
crack dial of various pre, gauge,
meters etc.
Now, Fourth ‘S’ is ...!

SEIKETSU
( STANDARDISATION )
Seiketsu - Sandardisation

SEIKETSU
Setting up Standards / Norms for a
neat & clean workplace and details
of how to maintain the
Norms(Procedure) ...
Seiketsu - Sandardisation

Maintain & Improve

The Standard of :
Seiri
Seiton
Seiso
Seiketsu - Sandardisation
•Regularizing 5S activities so that
abnormalities are revealed.
•Make it easy for everyone to identify
the state of normal or abnormal
condition
•For maintaining previous 3 S, deploy
visual management
Seiketsu - Sandardisation Visual Management

•It has been estimated by scientific study

that 60% of all human activities starts
with sight
•5S is easy to do once. It is consistency
that is difficult. That is why Visual
Management is so important, so that
evreybody will know that there is some
problem.
Seiketsu - Sandardisation Visual Management

What visual controls communicates?

It grabs one or more of our senses in order
to
Alert us to an abnormality
Help us recover quickly
Promote adherence and prevention
Enable successful self management
Seiketsu - Sandardisation Visual Management

Some method for visual communication :

Colour coding
Use of Labels
Danger Alerts
Indication where things should be put
Directional arrows/ marks
Transparent covers
Performance indicators
Seiketsu - Sandardisation Visual Management

Some method for visual communication :

Labels:
Precision management labels
Inspection Labels
Temperature Labels
Responsibility labels
Seiketsu - Sandardisation Visual Management

Points to remember in making visual control

tools :
1) Make them easy to see from distance
2) Put the display on the things
3) Everyone can tell what is right and what
is wrong
4) Anybody can follow them and make
necessary corrections easily
5) Work place should look brighter &
orderly
Seiketsu - Sandardisation Visual Management

Some everyday visual management

example :
Traffic signal
Zebra crossing
In car - Petrol indicator
- Speed Indicator
Direction arrows
Electric danger sign etc.
Seiketsu - Sandardisation Visual Management

Some visual communication signs :

And, Fifth ‘S’ is ...!

SHITSUKE
(TRAINING & DISCIPLINE)
Shitsuke - Training and Discipline

We need everyone to maintain 5S

guidelines.
To maintain DISCIPLINE, we need to
practice and repeat until it becomes a way
of life.
Discipline is the Core of 5S
Shitsuke - Training and Discipline

Discipline means making a steady

habit of properly maintaining correct
procedures.
Time and effort involved in
establishing proper arrangement and
orderliness will be in vain if we do not
have discipline to maintain it.
Shitsuke - Training and Discipline

Pledge
It shall be my constant effort to maintain
my workplace in good order by
Assign a place for everything &
keeping everything in its place
Sorting out unwanted material
periodically and discarding them
Keeping my work area neat & clean
everyday
 Part 2
How To
Implement 5S
How To Implement 5S

Step 1

Form a 5S Committee
OR
5S Coordicator
How To Implement 5S

Step 2

Divide the
Workplace
into various Zones
How To Implement 5S
5S format 1 Zone at ‘work’

Group Area Type of Audit Line/ Section Zone No.

How To Implement 5S

Step 3
Allocate Zones to
the relevant people
How To Implement 5S

Step 4
Start Implementing
Seiri
Seiton
Seiso
How To Implement 5S

Step 5

Audit the 5S
Implementation Process
How To Implement 5S
5S format 2
5S Audit Calendar For the month of :

S. No. Name Area of Audit Type of Audit Zone Dates

How To Implement 5S
5S format 3 5S AUDIT CHECKLIST – SUPPORT GROUP

5S Points Mark Range Marks

1. SEIRI (SORTING)
a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS 1-10
OK, Usable immediately
Usable (Spares)
Good, Not Required
Rework
Scrap
b) FILES AND RECORDS SORTED AND IDENTIFIED AS 1-5
Current/Follow up
Not Required (to be sent to Record Room)
c) ANY ITEM /FILES/RECORDS LYING UNSORTED 1-5
SUB-TOTAL
2. SEITON (SYSTEMATIC ARRANGEMENT)
a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged 1-5
b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5
c) Arrangement of files in Filing Rack 1-5
d) Any items /files lying haphazard 0 or 5
SUB-TOTAL
3. SEISO (Cleanliness)
a) Tables, Chairs, Machines 1-5
b) Surroundings Area free of oil, chips, cotton waste etc. 1-5
c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5
d) Measures taken to consume electricity 1-5
SUB TOTAL
TOTAL
Signature of Zone Member Sign of Auditor Date Name Dept
How To Implement 5S
5S format 4 5S AUDIT CHECKLIST – PRODUCTION GROUP

5S Points Mark Range Marks

1. SEIRI (SORTING)
a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS 1-10
OK, Usable immediately
Usable (Spares)
Good, Not Required
Rework
Scrap
b) FILES AND RECORDS SORTED AND IDENTIFIED AS 1-5
Current/Follow up
Not Required (to be sent to Record Room)
c) ANY ITEM /FILES/RECORDS LYING UNSORTED 1-5
SUB-TOTAL
2. SEITON (SYSTEMATIC ARRANGEMENT)
a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged 1-5
b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5
c) Arrangement of files in Filing Rack 1-5
d) Any items /files lying haphazard 0 or 5
SUB-TOTAL
3. SEISO (Cleanliness)
a) Tables, Chairs, Machines 1-5
b) Surroundings Area free of oil, chips, cotton waste etc. 1-5
c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5
d) Measures taken to consume electricity 1-5
SUB TOTAL
TOTAL
Signature of Zone Member Sign of Auditor Date Name Dept
How To Implement 5S
5S format 5 5S AUDIT CHECKLIST – ADMINISTRATIVE GROUP

5S Points Mark Range Marks

1. SEIRI (SORTING)
a) Records, files with clear Labeling 1-10
b) Memos / Letters Sorted out for Filling/ Action/ Follow-up 1-5
c) Any Items/Files/Records lying unsorted 0 or 5
SUB-TOTAL

2. SEITON (Systematic Arrangement)

a) Work Table, Chairs and Personal Belongings 1-5
b) Layout of office & office equipment (filling cabinet, Waste Paper Bins, Computers & Stationary 1-10
c) Any items/ Files Lying Haphazard 0 or 5
SUB TOTAL

3. SEISO (Cleanliness)
a) Tables, Chairs, Computers 1-5
b) Cupboard, Filing Cabinet 1-5
c) Floor, wall, (Including Glass panes of Windows & Ventilators) Ceiling (Tube Light, Fans & Roof) 1-5
d) Measures taken to consume electricity 1-5
SUB TOTAL
TOTAL

Signature of Zone Member Sign of Auditor Date Name Dept

How To Implement 5S
5 S NOTICE BOARD
1 AREA PROBLEMS FOR GROUP 5S ASSESMENT CHART
DATE

2 ZONE

3 LEADER TODAY TODAY LAST MONYH

AVERAGE AVERAGE

SEIRI

4 PARTICIPANT SEITON

SEISO

TOTAL
How To Implement 5S

Step 6
Give Recognition
to best 5 S Team
VP Productivity and Quality Services, Nashik

Thank You

&
Best of Luck !!!