Introduction to 5S

Contents
1. Objectives of 5S program?

2. What is 5S?

3. Planning Stage

4. Implementing Stage

5. Sustaining Stage
Objectives of a 5S Program

Developing Kaizen-minded people at
workplace(workplace standardization).

Developing managers and supervisors
for practical leadership.

Improving infrastructures for
introduction of advanced Kaizen
technologies.

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 What is 5S ?
• 5s is the beginning of a healthy, comfortable and
productive life for everyone at work.
• It is company-wide participation program involving
everyone in the organization.
• A very effective approach for motivating people, and
improving productivity and the work environment .
• 5S is an acronym for five Japanese words that are Seiri,
Seiton, Seiso, Seiketsu and Shitsuke.

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Transferability of 5S to Companies Outside of Japan


5S is a very popular productivity improvement program in Japan
today, and is becoming popular in many other countries for the
following solid reasons:

The workplace becomes clean and better organized.

Results are visible to everyone - insiders and outsiders.

Visible results enhance the generation of more, and new ideas.

People are naturally disciplined.

Operations on the shop-floor and office become easier and safer.

People become proud of their clean and organized workplace.

As a result the company’s good image generates more business.
 What is 5S ?
5S Contributes to Each Element of PQCDSM
A company that is implementing 5S
successfully is always:

high in Productivity

consistent in Quality

Cost-effective
5S?

accurate in Delivery

Safe for people to work in

high in Morale
 What is 5S ?

The Origin of The Term 5S


5S is a set of five Japanese
words. Each word starts with a
sound of “se” or “shi”.

They are Se-i-ri, Se-i-to-n, Se-i-so, 5S?
Se-i-ke-tsu, and Shi-tsu-ke.
 What is 5S ?
1. Sort Seiri

2. Set-In-Order Seiton

3. Shine Seisou

4. Standardize Seiketsu

5. Sustain Shitsuke
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 What is 5S ?
1. Sort
 Remove all items from the workplace that are
not needed for current production or administrative
operation.
“only what is needed, only in the
 Keep

amount needed, and only when it is needed”.

Red Tag Discard
No Tag
Keep it

10
 What is 5S ?
Why Sort is important?
 Space, time, money, energy
and other resources can be
managed and used most
effectively
 Problem and annoyances in
the work flow are reduced.
 Communication between
employees is improved.
 Product quality and
Productivity is enhanced.

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 What is 5S ?
2. Set-In-Order
 Arranging needed items in the way easy to use and
labeling them so that easy to find and put
away(visual management)

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 What is 5S ?
Set in order
 Arrange needed items so;
 it is easy to use.
 label them so that anyone can find them easily and put them again.
 Set-in-order is important because it eliminates;
 Time spent searching for an item
 Motion wastes
 Difficulty returning item to its original place
 Excess inventory
 Reduce damage
 safety

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 What is 5S ?

 There are two strategies correspond to set-in-order;

1. Visual Control
2. Motion Economy

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 What is 5S ?
1. Visual Control Strategy
A visual control is any communication device used in
the work environment that tells us at a glance how
work should be done.
 We can implement standardization in such a way that
all standards are identified by visual control.

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 What is 5S ?
Visual Control Techniques
 common visual control techniques;
1. Signboard strategy
2. Painting strategy
3. Color-code strategy
4. Outlining strategy
5. Visual Management Board (Kaizen
board) Strategy

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 What is 5S ?
1. Signboard strategy
signboards are used to identify what, where and how
many
There are three types of signboards
• Location indicator
• Item indicator
• Amount indicator

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 What is 5S ?
2. Painting strategy
Is a method for identifying locations on floors and walk
ways

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 What is 5S ?
3. Color-Coding strategy

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 What is 5S ?
4. Outlining strategy

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 What is 5S ?
5. Visual management board for 5S promotion

Face ① 1700mm

1100mm

Face
② （ Bac Face ①
k side)

1500mm

Refer to Refer to Attachment B

Attachment A
Format
 What is 5S ?
Face ① Face ② Photograph of the
Face 5S points
② （ Bac
k side)

Removable board

① ⑨ Photograph

② ⑲
Size:
Approx.3 ｃｍ X4 ｃｍ
 What is 5S ?
Attachment A Line No.9 Everybody understand

Image of － What Grade of 5S points

45 60 1
5S points Map － Where is it ?
60 8 5
35 43 － Improved or Not improved
Color Label 12

35 Grade A
(Major)
60 Grade B 35 Before improvement

(Middle)
8 Grade C 35 After improvement

(Minor)
Marking
Photograph No.
 What is 5S ?
2. Motion Economy Strategy
 The process of removing motion waste involves
eliminating unnecessary motion from existing
operation.
 By locating items in the best location possible, we
can minimize motion waste.
 Even more important than removing motion waste is
asking “why it occurs in the first place”.

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 What is 5S ?
Implement Motion Economy
 Below are three examples of elimination motion
waste;
1. Keep frequently needed items close to you and
seldom needed items away.
2. Frequently needed items are arranged for easy
retrieval ergonomically.
3. Keep the processes close to each other and eliminate
zig-zag motion between them. 5S map can be used to
do the analysis.

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What is 5S ?

Ex: 30 Second Rule

Tool Box
 What is 5S ?
3. Shine Seisou

27
 What is 5S ?
What is Shine
 Shine means keep everything swept and clean.
 Shine is a way to keep everything in top condition so,
when someone needs to use something, it is ready to
be used.
 When Shine, we can’t avoid inspecting the item at the
same time. Therefore Shine and Inspect come
together.

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 What is 5S ?
Benefits from Shine
 Clean and comfortable workplace.
 Increase visibility to defects when it occurs.
 Helps to maintain safer workplace.
 Good working environment increase morale.
 Early detection of machinery and equipment failure.

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 What is 5S ?
4. Standardize Seiketsu

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 What is 5S ?

What is Standardize
 Standardize is the method you use to maintain the first
three pillars (Sort, Set in order and Shine)
 Make it a rule to perform given work in the given manner.
 Standardize is different from the first three pillars because
it is a method used to sustain the first three pillars rather
than housekeeping activity.

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 What is 5S ?

Benefits from Standardize

 The basic purposes are to;
1. Lead to workplace standardization
 prevent setbacks in the first three pillars
 Make implementing them a daily habit
 Ensure that all the three pillars are maintained in their fully
implemented state.
2. Lead to work standardization
 Muda elimination
 Quality improvements
 Cost improvements
 Delivery time improvements
 Process improvements

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 What is 5S ?
5. Sustain Shitsuke

Means making a habit of properly maintaining correct

procedures

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What is 5S ?
Some techniques to sustain
 5S Slogan
 5S poster
 5S newsletter and kaizen board
 5S audit
 awarding systems
 Big cleaning day
 5S month
 Benchmarking tour

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 ?
What is 5S ?
What is next

35
 2. Planning Stage
Steps for planning
1. 5S organization structure
2. Recognition of current condition
3. Deciding activity range
4. Goal setting
5. Planning stage
6. Budgeting
7. Kick-off

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 Planning Stage
1. 5S Organizational Structure

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Planning Stage
5S Promotion office duties
 Prepare over all 5S implementation plan at

company level.
 Follow up standardize 5S activities at the
company.
Perform any other 5S related activities.
Organize Training

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 Planning Stage

2. Recognition of current condition

 byusing 5S Checklist and

 Photography (Next page)

39
 Planning Stage
Photography
(1) Fixed-point Observation Type
Fix the location of the camera
and do photo shoots at the same
place both before and after
KAIZEN.

Before KAIZEN After KAIZEN

40
 Planning Stage
(2) Random Type

41
 Planning Stage
3. Decide Activity range
Limiting
Company
to Shop
-wide
Limiting to
Selecting Production
model shop Division

Limiting
to group Others

Variety of Alternatives
42
 Planning Stage
Decide 5S promotion blocks.
Sample
Block A
Block B Block C

Block D

Block E
Block F

43
 Planning
4. Goal setting Stage
1
Recognition
5S
Of current 2
Committee
condition

Evaluation
3

Setting goal 4

Post

44
 5. Planning Planning Stage
1) Overall promotion plan

Date of issue:
Issue d by 5S Promotion Office
Overall Plan for 5S Promotion
Timing Month 1 Month 2 Month 3 Month 4 Month 5 Month 6
Ite ms 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w
Preparation
Seiri
Ba sic pla n Seiton
(sta ge ) Seiso
Seiketsu
Shitsuke
Pre pa ra tion of 5S
Tools ◆ ◆ ◆ ◆
Pre pa re sta nda rd tools in a dva nce re ga rdle ss of sta ge .
Pr e par ation of
te xtbook for 5S
intr oductor y ◆ ◆ ◆ ◆
tr aining Pre pa re sta nda rd tools in a dva nce re ga rdle ss of sta ge .

5S introductory
tra ining ◆
Provide ove ra ll 5S tra ining in introductory pe riod.

5S tra ining ◆ ◆ ◆ ◆
Provide 5S tra ining prior to the sta rt of e a ch sta ge of 5S.
Ta ke photogra phs be fore /a fte r e a ch sta ge .

Photogra phy ◆ ◆ ◆ ◆ ◆
Photogr aphs on late r s tage s can be the
e valuation obje cts for 5S aw ar ding.

45
Planning Stage
Sort Activity Plan Sheet (Sample)
Planning Stage

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 Planning Stage
2) Setup of activity time
In case of 5S activity on Sustaining Stage (e.g. Cleaning)

Type of cleaning Time Frequency (timing)

Minor operation before/after working

Daily cleaning 5 – 10 min.
hour at each shop

Weekly cleaning 15 – 30 min. Weekend

Monthly cleaning 30 – 60 min. End of month

Big cleaning days 2 – 4 hrs. Before national holidays

In case of necessity for assistance

Location which is not easy to clean 1 – 2 days
request to other division

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 Planning Stage
3) Training plan
5S Committee

49
 Planning Stage
6. Budgeting
It is necessary to prepare a budget for 5S activity because it costs
money.

50
 Planning Stage
7. Kick-off (Declaration of 5S activity)
Inform all Assemble all
employees employees
of kick-off

Kick-off
Explain
Declare
the activity
the policy

51
 Planning Stage
Promotion declaration of 5S activity

52
 Implementation Stage

Implementing
Sort Activity

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 Implementation Stage
Procedure For Sort Activity

Preparation

Necessary items Unnecessary items

Making a Shop Stock List Red Tag Strategy

Quantification Evaluation of unnecessary items

Set-in-order activities Disposal of unnecessary items

Shine Activity In parallel

Set-In-Order activity
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 Implementation Stage

Implementing Set-
In-Order Activity

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 Implementation Stage
Procedure For Set- in- order Activity
Set targets for Set-In-Order Activity

Decision of location, Storage, Indication method

Preparation of tools for Set-In-Order Activity

Decision of schedule and work allocation

Implementation of Set-In-Order

56
 Implementation Stage

Implementing
Shine Activity

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Implementation Stage
Determine shine target area

Determine shine assignments

Determine shine methods

Preparing proper tools for shine

Start to shine

58
Implementation Stage

Implementing
Standardize
Activity

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 Implementation Stage
 Standardize means to set up rules for Sort, Set-
in-order and Shine Activities

It is all about
“Make up the rules and follow them!”
 Implementation Stage
Standards for Sort
 Red Tag Rules
• When to Red Tag
• How to Red Tag
• What’s go on the Red Tag
• more…
 Rules for the Red Tag Holding Area
• When to clear out
• How to dispose of items
• more…
Implementation Stage
Standards for Set-in-order
• Which items
• Where
• How many
• Who replenishes
• Return all items…
• What to do when items are missing
• Visual standards – signs, lines, labels and
color coding
more…
 Implementation Stage
Standards for Shine
 Clean and Inspect (C&I)
 Show the task, person responsible, items
needed, frequency, desired workplace
 Where to keep cleaning supplies,
how to replenish when finished
more…
 Implementation Stage

Implementing
Sustain Activity

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 Let’s sustain the gains !

The Questions Is
“How to Sustain ?

65
 Let’s sustain the gains !
1. Patrolling
a. Top management Patrol
Must
 Check Up the activities Comprehensively
 Give emphasis on sustaining of the activity
 consider committees feedback

66
 Let’s sustain the gains !

Making a round tour

of workplace

67
 Let’s sustain the gains !

b. 5S Committee members and Promotion

office Patrol
Must
 Evaluate “5S Check List”
 Record problems on”5S check
findings”
 Take picture of 5S problems

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 Let’s sustain the gains !
c. Mutual patrol
 Check mutually among 5S groups
d. Self patrol
 5S leader and members check the results of
activity by themselves.
e. Checklist patrol
 Point out the problems by themselves at site as
well as evaluate the results and encourage members to
urge KAIZEN.
f. Camera patrol
 Visibly highlight the problems and progress of the activity
using photographs.

69
2. Use Slogan and Poster of 5S Activity
• It encourage all the participants.

＜ Samples of slogan ＞
“Refresh yourself and workplaces by 5S activity.”

“Let's maintain current 5S activity and KAIZEN for tomorrow”

“We polish “Our Minds” as well us our factories”

＜ Sample of poster ＞
 Auditing and Guiding 5S Activities
The purpose of this audit is to outline an approach of making 5S a
success in industrial as well as in our working areas.
CRITERIA FOR 5S AUDIT RATING:
Evaluation Scale 5S Practice 5S Theory Data/Fact
1 Nothing at all and no sense No knowledge and cannot No data.
(0 - 30 %) of commitment. explain. No improvement effort.
Not doing 5S at all.

2 Doing some but not There is a knowledge but There is data but superficial.
(31 – 50 %) sufficient. people do not know how
Doing before auditors arrival. to practice.

3 Doing what is supposed to Understand and have Sufficient data but not in order.
(51 – 70 %) do but need to put more overall knowledge.
effort.

4 Almost ok, but not fully Almost ok, but in some Sufficient data and in order.
(71 – 90 %) completed yet or insufficient. are need further improve. Able to explain.

5 There is a proper evidence of Completely YES Orderly stratified data.

(91 – 100 %) 5S. Can show and answer
5S culture can be seen. immediately
Visual Control is functional.
 Let’s sustain the gains !
3. Awarding System
Promotion results must be shared by all the members, and
awarding for 5S promotion results according to evaluation
is recommended.

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 Conclusion
Objectives of 5S
Create a safe workplace
Create a comfortable workplace
Create an efficient workplace

Subject of 5S
5S of place
5S of material
5S of information
5S of mind
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The end!
Thank you for
your attention!

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