WHAT IS 5S ?WHAT IS 5S ? 5S IS A JAPANESE CONCEPT OF 5S IS A JAPANESE CONCEPT OF

HOUSEKEEPING. HOUSEKEEPING. 5S STANDS FOR FIVE JAPANESE 5S STANDS FOR FIVE JAPANESE

WORDS .WORDS .

1. SEIRI MEANING SORT1. SEIRI MEANING SORT

2. SEITON MEANING SET IN ORDER2. SEITON MEANING SET IN ORDER

3. SEISO MEANING SHINE3. SEISO MEANING SHINE

4. SEIKETSU MEANING STANDARDISE4. SEIKETSU MEANING STANDARDISE

5. SHITSUKE MEANING SUSTAIN5. SHITSUKE MEANING SUSTAIN

5 PILLARS of 5S5 PILLARS of 5S

SORTSORT SET IN ORDERSET IN ORDER SHINESHINE STANDARDISESTANDARDISE SUSTAINSUSTAIN

What is Housekeeping?What is Housekeeping? Housekeeping is a term which implies Housekeeping is a term which implies

that everything should be in its place that everything should be in its place & there should be a place for & there should be a place for everything.everything.

Why 5S?Why 5S?

Customers needs constantly change.Customers needs constantly change. Companies compete to meet these needs.Companies compete to meet these needs. To survive, your company must stay To survive, your company must stay

competitive.competitive. To Stay competitive we have to improve in To Stay competitive we have to improve in

products & quality & lower costs.products & quality & lower costs. The five pillar system is a good starting The five pillar system is a good starting

point for all improvement programs.point for all improvement programs.

Benefits of 5S ( For employeesBenefits of 5S ( For employees))

Provides an opportunity to organise your Provides an opportunity to organise your workplace.workplace.

Makes your work place more pleasant to Makes your work place more pleasant to work in.work in.

Makes your job more satisfying.Makes your job more satisfying. Removes obstacles & frustrations in your Removes obstacles & frustrations in your

work.work. Helps you know what you are expected to Helps you know what you are expected to

do & when & where you are expected to do & when & where you are expected to do it.do it.

Makes it easier to communicate with Makes it easier to communicate with everyone you work with.everyone you work with.

Benefits of 5SBenefits of 5S ( For the Organisation)( For the Organisation)

Zero changeovers brings product Zero changeovers brings product diversification.diversification.

Zero defects bring higher quality.Zero defects bring higher quality. Zero wastes lowers costs.Zero wastes lowers costs. Zero delays provide reliable deliveries.Zero delays provide reliable deliveries. Zero injuries promotes safety.Zero injuries promotes safety. Zero breakdown brings better equipment Zero breakdown brings better equipment

availabilityavailability Zero complaints brings greater confidence Zero complaints brings greater confidence

& trust.& trust.

Definition of “SORT.”Definition of “SORT.”

Sort means that you remove all items Sort means that you remove all items from the workplace that are not from the workplace that are not needed for production.needed for production.

Why Sort is important?Why Sort is important?

Effective use of space , time ,money , Effective use of space , time ,money , energy & other resources.energy & other resources.

Reduces problems & annoyances in Reduces problems & annoyances in workflow.workflow.

communication between workers is communication between workers is improved.improved.

Product quality increases.Product quality increases. Productivity is enhanced.Productivity is enhanced.

Problems avoided by implementing Problems avoided by implementing SORT.SORT.

The factory becomes increasingly crowded & The factory becomes increasingly crowded & hard to work in.hard to work in.

Lockers, shelves & cabinets for storage of Lockers, shelves & cabinets for storage of unneeded items act as barriers of communication unneeded items act as barriers of communication between employees.between employees.

Time is wasted in searching for parts & tools.Time is wasted in searching for parts & tools. Unneeded inventory & machinery are costly to Unneeded inventory & machinery are costly to

maintain.maintain. Excess stocks in hand hides other types of stock Excess stocks in hand hides other types of stock

in production.in production. Unneeded items and equipment make it hard to Unneeded items and equipment make it hard to

improve the process.improve the process.

Steps involved in implementing Steps involved in implementing “SORT” in your workplace“SORT” in your workplace

Launching a red tag project.Launching a red tag project. Identifying red tag targets.Identifying red tag targets. Setting red tag criteria.Setting red tag criteria. Making red tags.Making red tags. Attaching red tags.Attaching red tags. Evaluating red tags.Evaluating red tags. Document results of red tagging.Document results of red tagging.

1. Launching a red tag project.1. Launching a red tag project.

Red tagging is simply a method of identifying Red tagging is simply a method of identifying unneeded items , evaluating their usefulness unneeded items , evaluating their usefulness & dealing with them appropriately.& dealing with them appropriately.

Red color tags are used for red tagging as it Red color tags are used for red tagging as it catches people’s attention easily.catches people’s attention easily.

Launching a red tag team involves:Launching a red tag team involves:

1. Organising a red tag team1. Organising a red tag team

2. Organising a time & schedule for red tagging2. Organising a time & schedule for red tagging

3. Creating a local red tag holding area.3. Creating a local red tag holding area.

4. Planning for disposal of red tagged items. 4. Planning for disposal of red tagged items.

2. Identify red tag targets.2. Identify red tag targets.

This basically involves:This basically involves:

1.The specific types of items to 1.The specific types of items to evaluate. eg; In manufacturing area evaluate. eg; In manufacturing area targets can be unused raw materials, targets can be unused raw materials, finished components, finished finished components, finished products, tools , machines etc.products, tools , machines etc.

2.The physical; areas where red 2.The physical; areas where red tagging will take place.tagging will take place.

3.Set red tag criteria.3.Set red tag criteria. This is the most difficult part in the red This is the most difficult part in the red

tagging exercise is to distinguish what is tagging exercise is to distinguish what is needed from what is not.needed from what is not.

The following factors determine whether a The following factors determine whether a item is needed or not:item is needed or not:

The usefulness of the item to perform the The usefulness of the item to perform the work in hand.work in hand.

The frequency with which the item is The frequency with which the item is needed.needed.

The quantity of item needed to perform the The quantity of item needed to perform the work.work.

4. Making Red Tags.4. Making Red Tags. Red tags should be designed keeping in Red tags should be designed keeping in

mind the requirements of the organisation.mind the requirements of the organisation. Some of the information on red tags may Some of the information on red tags may

be as follows:be as follows:** Category of itemCategory of item* Item name & manufacturing number* Item name & manufacturing number* Quantity* Quantity* Reason for red tagging* Reason for red tagging* Department responsible for red tagging.* Department responsible for red tagging.* Value of red tagged item* Value of red tagged item* Date of red tagging* Date of red tagging

5. Attaching Red Tags.5. Attaching Red Tags. The best way to do red tagging is to do the The best way to do red tagging is to do the

whole target area quickly- in a day or two.whole target area quickly- in a day or two. Following are some of the unneeded items Following are some of the unneeded items

in the workplace that require red tagging:in the workplace that require red tagging: Defective & excess quantity of small parts & Defective & excess quantity of small parts &

inventory.inventory. Outdated / broken jigs & dyes.Outdated / broken jigs & dyes. Worn out bits.Worn out bits. Outdated / broken tools & inspection gears.Outdated / broken tools & inspection gears. Old rags Old rags Electrical equipment with broken cords.Electrical equipment with broken cords. Outdated signs / posters / notices & memos. Outdated signs / posters / notices & memos.

Places where unneededPlaces where unneeded items accumulateitems accumulate

Rooms & areas not designated for any Rooms & areas not designated for any particular purpose.particular purpose.

Corners next to entrances or exits.Corners next to entrances or exits. Along interior or exterior walls , next to Along interior or exterior walls , next to

partitions & behind pillars.partitions & behind pillars. Under desks & shelves & in desks & Under desks & shelves & in desks &

cabinet drawers.cabinet drawers. On unused management & production On unused management & production

schedule boards.schedule boards.

In tool boxes that are not clearly sortedIn tool boxes that are not clearly sorted..

6. Evaluate Red Tagged Items.6. Evaluate Red Tagged Items. After red tagging process is over , the following criteria is After red tagging process is over , the following criteria is

used to evaluate what to do with red tagged items.used to evaluate what to do with red tagged items. Keep the item where it is.Keep the item where it is. Move the item to a new location in the work area.Move the item to a new location in the work area. Store the item away from the work area.Store the item away from the work area. Dispose the item.Dispose the item. Throw away the item.Throw away the item. Sell the item.Sell the item. Return the item to the vendor.Return the item to the vendor. Lend it out.Lend it out. Distribute the item to different department in the company.Distribute the item to different department in the company. Send it to the central red tag holding area.Send it to the central red tag holding area.

7. Document the result of red 7. Document the result of red taggingtagging

As each company has its own needs of As each company has its own needs of documenting , it needs to design its own documenting , it needs to design its own system of logging& tracking necessary system of logging& tracking necessary information as red tagging takes place.information as red tagging takes place.

Documentation of results of red tagging also Documentation of results of red tagging also helps in measuring the improvements & helps in measuring the improvements & savings produced as a result of red tagging.savings produced as a result of red tagging.

Definition of “SET IN Definition of “SET IN ORDER.”ORDER.”

This means arranging needed items This means arranging needed items so that they are easy to find , use so that they are easy to find , use and put away and anyone can find and put away and anyone can find them & put them away.them & put them away.

Why set in order is Why set in order is important ?important ?

Eliminates many kinds of wastes in Eliminates many kinds of wastes in production & clerical activities. These production & clerical activities. These include searching waste, waste due to include searching waste, waste due to difficulty in using items, Wastes due to difficulty in using items, Wastes due to difficulty in returning items.difficulty in returning items.

Problems avoided by Problems avoided by implementing “ Set in Order.”implementing “ Set in Order.”

Motion Waste.Motion Waste. Searching Waste.Searching Waste. Waste of Human Energy.Waste of Human Energy. Waste of Excess Inventory.Waste of Excess Inventory. Waste of Defective Products.Waste of Defective Products. Unsafe Working Conditions.Unsafe Working Conditions.

Definition of StandardisationDefinition of Standardisation

Standardisation means creating a Standardisation means creating a consistent way of doing tasks & consistent way of doing tasks & procedures.procedures.

Implementation of Set in Implementation of Set in orderorder

Step one: Deciding Appropriate LocationsStep one: Deciding Appropriate Locations

A 5S map is a tool to evaluate current A 5S map is a tool to evaluate current locations of parts & equipment & decide the locations of parts & equipment & decide the best locations.best locations.

Using the 5S map basically involves Using the 5S map basically involves creating 2 types of maps:creating 2 types of maps:

- A before map- A before map

- An after map.- An after map.

Implementation of Set in orderImplementation of Set in order

Step Two: Identifying Locations:Step Two: Identifying Locations: Once the locations have been decided , we need a Once the locations have been decided , we need a

way to identify these locations so that everyone way to identify these locations so that everyone will know what goes where & how much of each will know what goes where & how much of each items belongs in each location. The following items belongs in each location. The following strategies are used for deciding what where & strategies are used for deciding what where & how many.how many.

The Signboard strategyThe Signboard strategy Color coding strategyColor coding strategy Painting strategyPainting strategy Outlining StrategyOutlining Strategy

The Signboard StrategyThe Signboard Strategy

The signboard strategy uses signboard to The signboard strategy uses signboard to identify What , Where & How many?identify What , Where & How many?

The three main types of signboard are:The three main types of signboard are: Location IndicatorsLocation Indicators : These show where the : These show where the

items go.items go. Item Indicators:Item Indicators: This shows what specific This shows what specific

items go in each places.items go in each places. Amount Indicators:Amount Indicators: These show how many These show how many

of each items belongs there.of each items belongs there.

Color Coding StrategyColor Coding Strategy

Color coding can be used to show Color coding can be used to show which parts, tools , jigs, and dies are which parts, tools , jigs, and dies are to be used for which purpose.to be used for which purpose.

e.g; if certain parts are to be used for e.g; if certain parts are to be used for making a particular product they can making a particular product they can all be color coded with the same all be color coded with the same color & even stored in the same color & even stored in the same locationlocation..

Painting StrategyPainting Strategy

The Painting Strategy is a method for The Painting Strategy is a method for identifying locations on floors & identifying locations on floors & walkways.walkways.

eg; Painting strategy is used to create eg; Painting strategy is used to create divider line that mark off the factory’s divider line that mark off the factory’s walking area.walking area.

Outlining StrategyOutlining Strategy Outlining strategy is a good way to Outlining strategy is a good way to

show which jigs & tools are stored show which jigs & tools are stored where.where.

Outlining simply means drawing Outlining simply means drawing outlines of jigs & tools in their proper outlines of jigs & tools in their proper storage positions. When you want to storage positions. When you want to return a tool the outline simply return a tool the outline simply provides an indication of where it provides an indication of where it belongs.belongs.

Definition of “SHINE”Definition of “SHINE”

Shine means that we keep everything Shine means that we keep everything swept & clean. It lays emphasis on swept & clean. It lays emphasis on removal of dirt, grime & dust from removal of dirt, grime & dust from the workplace.the workplace.

Why Shine is Important?Why Shine is Important?

To turn the workplace into clean, bright To turn the workplace into clean, bright place where everyone will enjoy working place where everyone will enjoy working in.in.

To keep everything in top condition so To keep everything in top condition so that when someone needs to use that when someone needs to use something it is ready to be used.something it is ready to be used.

Problems avoided by implementing Problems avoided by implementing ShineShine

Defects are less obvious in dark, messy factories.Defects are less obvious in dark, messy factories. Puddles of oil & water can cause accidents.Puddles of oil & water can cause accidents. Dirty windows prevents sufficient lights into the Dirty windows prevents sufficient lights into the

workplace leading to poor morale.workplace leading to poor morale. Lack of preventive maintenance of machines Lack of preventive maintenance of machines

leads to frequent breakdowns & accidents.leads to frequent breakdowns & accidents. Cuttings / shavings can blow into peoples eyes Cuttings / shavings can blow into peoples eyes

and cause injuries.and cause injuries. Dirt / filth in the work environment can cause low Dirt / filth in the work environment can cause low

morale.morale.

Implementing Shine in your work Implementing Shine in your work place.place.

Step 1: Determine Shine targets.Step 1: Determine Shine targets. Step 2: Determine Shine assignments.Step 2: Determine Shine assignments. Step 3: Determine Shine methodsStep 3: Determine Shine methods Step 4: Prepare ToolsStep 4: Prepare Tools Step 5: Start to ShineStep 5: Start to Shine

Step 1: Determine Shine Step 1: Determine Shine Targets.Targets.

Shine targets are grouped into 3 categories.Shine targets are grouped into 3 categories. Warehouse items - These include raw materials, Warehouse items - These include raw materials,

procured sub contracted parts, parts made in-house, procured sub contracted parts, parts made in-house, assembly components, semi finished & finished assembly components, semi finished & finished products.products.

Equipment - These includes machines , tools dyes, Equipment - These includes machines , tools dyes, spare equipment, furniture etc.spare equipment, furniture etc.

Space- this refers to floors passages, pillar windows, Space- this refers to floors passages, pillar windows, rooms, lights , ceilings, shelves etc.rooms, lights , ceilings, shelves etc.

Step 2: Determine Shine Step 2: Determine Shine assignmentsassignments

Workplace cleanliness is the responsibility Workplace cleanliness is the responsibility of everyone who works there.of everyone who works there.

For determining shine targets we divide the For determining shine targets we divide the factory into shine areas and assign specific factory into shine areas and assign specific areas to individuals. The shine areas can be areas to individuals. The shine areas can be shown on a shown on a 5S map.5S map.

A A 5S schedule5S schedule showing who is responsible showing who is responsible for cleaning which areas on which days & for cleaning which areas on which days & times of the the days should also be posted times of the the days should also be posted in the workplace. in the workplace.

Step 3: Determine Shine Methods.Step 3: Determine Shine Methods.

Determining Shine methods involves the Determining Shine methods involves the following steps:following steps:

Choosing targets & tools: Define what will be Choosing targets & tools: Define what will be cleaned in each area & what supplies & cleaned in each area & what supplies & targets will be used.targets will be used.

Performing the five minutes shine: Cleaning Performing the five minutes shine: Cleaning should be practiced daily & should not take a should be practiced daily & should not take a lot of time.lot of time.

Creating standards for shine procedures:Creating standards for shine procedures: People ought to know effective procedures of People ought to know effective procedures of

shine so that their time is used efficiently.shine so that their time is used efficiently.

Step 4: Prepare ToolsStep 4: Prepare Tools

Here we apply “Set in Order “ to our Here we apply “Set in Order “ to our cleaning tools storing them in places cleaning tools storing them in places where they are easy to find , use & where they are easy to find , use & return.return.

Step 5 : Start to Shine.Step 5 : Start to Shine.

Suggestions about implementing Shine Suggestions about implementing Shine procedures:procedures:

Ensure that dirt from floor cracks , wall Ensure that dirt from floor cracks , wall corners & around pillars are removed.corners & around pillars are removed.

Wipe off dirt from walls windows & doors.Wipe off dirt from walls windows & doors. Be through in cleaning dirt, scrap, shavings, Be through in cleaning dirt, scrap, shavings,

oil, dust , rust, & other foreign matters from all oil, dust , rust, & other foreign matters from all surfaces.surfaces.

Ensure use of cleansing agents when Ensure use of cleansing agents when sweeping is not sufficient to remove dirt.sweeping is not sufficient to remove dirt.

Cleanliness / InspectionCleanliness / Inspection.. It is important to do certain amount of cleanliness It is important to do certain amount of cleanliness

inspection while implementing shine activities.Once inspection while implementing shine activities.Once daily cleaning becomes a habit we should start daily cleaning becomes a habit we should start incorporating systematic inspection procedures into incorporating systematic inspection procedures into our shine procedures.our shine procedures.

The cleaning inspection steps are as follows:The cleaning inspection steps are as follows: Determine cleaning / Inspection targetsDetermine cleaning / Inspection targets.. These are the targets related to shine and includes- These are the targets related to shine and includes-

machines, equipment, jigs, dies, cutting tools & machines, equipment, jigs, dies, cutting tools & measuring instruments.measuring instruments.

Assign cleanliness / Inspection jobs:Assign cleanliness / Inspection jobs: Once it has Once it has been determined who will do cleanliness/ inspection been determined who will do cleanliness/ inspection jobs it should be displayed for the concerned jobs it should be displayed for the concerned people to see. people to see. .............. ..............

Determine cleanliness / inspection methods:Determine cleanliness / inspection methods: List all inspection items & combine them to make a List all inspection items & combine them to make a

inspection checklist.inspection checklist. Implement cleaning / inspection:Implement cleaning / inspection: While While

implementing one should use all the senses to implementing one should use all the senses to detect abnormalities. Some tips for diagnosing detect abnormalities. Some tips for diagnosing abnormalities are given below.abnormalities are given below.

i) Look closely at how the machine works & watch i) Look closely at how the machine works & watch for slight defects ( e.g; oil leakage, debris for slight defects ( e.g; oil leakage, debris scattering, deformations etc.)scattering, deformations etc.)

ii) Listen closely for changes in sound the machine ii) Listen closely for changes in sound the machine

iii) Use your nose to detect burning smelliii) Use your nose to detect burning smelliv) Touch the machine only where it is safe during iv) Touch the machine only where it is safe during

operation & during downtime. operation & during downtime. Correct equipment problem:Correct equipment problem: All equipment problems should be fixed or All equipment problems should be fixed or

improved.improved.

Definition of “STANDARDISE”Definition of “STANDARDISE”

Standardise is the result that exists Standardise is the result that exists when the first three pillars- Sort, Set when the first three pillars- Sort, Set in Order, & shine are properly in Order, & shine are properly implemented.implemented.

Why Standardise is Why Standardise is important?important?

To prevent setbacks in first three To prevent setbacks in first three pillars.pillars.

To make implementing them a daily To make implementing them a daily habit & to make sure that all the three habit & to make sure that all the three pillars are maintained in their fully pillars are maintained in their fully implemented state.implemented state.

Problems avoided by Problems avoided by implementing implementing Standardise Standardise

activities.activities. Conditions go back to their old undesirable Conditions go back to their old undesirable

state even after a company wide 5S state even after a company wide 5S implementation programme.implementation programme.

At the end of the day piles of unneeded At the end of the day piles of unneeded items lie scattered around.items lie scattered around.

Tool storage tanks become disorganised & Tool storage tanks become disorganised & must be put back in order.must be put back in order.

Cutting , shavings fall on the floor & are not Cutting , shavings fall on the floor & are not swept.swept.

Implementation of StandardiseImplementation of Standardise Assign 3S responsibilitiesAssign 3S responsibilities:: Unless 3S clear Unless 3S clear

instructions are given Sort, Set in Order & shine instructions are given Sort, Set in Order & shine will have little meaning. 3S instructions should be will have little meaning. 3S instructions should be given to people who deliver goods from suppliers, given to people who deliver goods from suppliers, delivery sites should be clearly marked. A delivery sites should be clearly marked. A 5S job 5S job cycle chartcycle chart listing 5S jobs to be done alongwith listing 5S jobs to be done alongwith their frequency should be displayed in each area. their frequency should be displayed in each area.

Integrate 3S duties into regular work duties:Integrate 3S duties into regular work duties: If people carry out 3S duties only when they find If people carry out 3S duties only when they find

things slipping. then 5S implementation has not things slipping. then 5S implementation has not taken root. Maintenance must become everyone’s taken root. Maintenance must become everyone’s regular work.regular work.

Check 3S maintenance level:Check 3S maintenance level: A regular check A regular check should be their to ensure how effective the 3S jobs should be their to ensure how effective the 3S jobs are being maintained.are being maintained.

Definition of “SUSTAIN”Definition of “SUSTAIN”

Sustain means to make a habit of Sustain means to make a habit of properly maintaining correct properly maintaining correct procedures.procedures.

Why Sustain is important?Why Sustain is important?

Unless we commit ourselves to sustain Unless we commit ourselves to sustain the benefits of 5S activities, the benefits of 5S activities, implementation of the first four pillars implementation of the first four pillars quickly falls apart.quickly falls apart.

Problems avoided byProblems avoided by Implementing Sustain.Implementing Sustain.

Unneeded items begin piling up as soon as Unneeded items begin piling up as soon as sorting is completed.sorting is completed.

Tools & jigs are not returned to their original Tools & jigs are not returned to their original place.place.

No matter how dirty equipment becomes little or No matter how dirty equipment becomes little or nothing is done to clean it.nothing is done to clean it.

Dirty machines start to malfunction & produce Dirty machines start to malfunction & produce defective goods.defective goods.

Dark , dirty disorganised workplace lowers Dark , dirty disorganised workplace lowers workers morale.workers morale.

Management’s role in Management’s role in

Implementation of SustainImplementation of Sustain.. Educating all in the factory about 5S Educating all in the factory about 5S

concepts tools & techniques.concepts tools & techniques. Creating terms for implementation.Creating terms for implementation. Allowing times for implementation & Allowing times for implementation &

creating schedules for work.creating schedules for work. Providing resource for 5S implementation.Providing resource for 5S implementation. Acknowledging & supporting 5S activities.Acknowledging & supporting 5S activities. Promoting ongoing 5S efforts.Promoting ongoing 5S efforts. Improving the quality & efficiency of work.Improving the quality & efficiency of work.

Employees role in Employees role in Implementation of 5S.Implementation of 5S.

Continuing to learn more about 5S.Continuing to learn more about 5S. Helping to educate others about 5S.Helping to educate others about 5S. Being enthusiastic about 5S Being enthusiastic about 5S

implementation.implementation. Helping to promote 5S implementation Helping to promote 5S implementation

efforts efforts Taking initiative to figure out ways to Taking initiative to figure out ways to

implement 5S in your work.implement 5S in your work. Asking your supervisor / manager for Asking your supervisor / manager for

support you need to implement 5S.support you need to implement 5S.

Tools that helps Tools that helps sustain 5S efforts.sustain 5S efforts.

5S Posters5S Posters 5S Slogans5S Slogans 5S Newsletter5S Newsletter 5S Pocket Manuals5S Pocket Manuals 5S Months / weeks.5S Months / weeks.