5S Methodology

Cirilo G. Amigo Jr. MBA-I

Topic Reporter

Report Outline

What is 5SWhy & How to Practice 5S

Key Points in the Implementation of 5S

How to succeed & fail in 5SWalk through audit

Report Objectives:

At the end of the report, one should be able to:

• Recognize and implement 5S program in the shop floor

• Perform and assess 5S in their work area, and

• Value 5S program as a foundation of productivity

WHAT IS 5 S?

5S stands for 5 Japanese words all starting with S. But in the Philippines, someone translated these 5 Japanese words into 5 English words also starting with S.

WHAT IS 5 S?

• Therefore, it is not necessary to remember 5S in Japanese. What is important is to understand what it means and practice it rather than just memorizing the words.

What are the 5s?

Japanese English Filipino Visayan

SEIRI SORT SURIIN HAGPATUN

SEITON SYSTEMATIZE SINUPIN HAN-AYUN

SEISO SWEEP SIMUTIN GANIRUN/ SILHIGUN

SEIKETSU

SHITSUKE

STANDARDIZE

SELF-DISCIPLINE

SIGURUHIN ANG KALINISAN

SARILING KUSA

KANUNAYUN ANG PAG-LIMPYU

PAGPANTUN SA KAUGALINGUN

5 S

• 5S is not simply a list of action items. It is an integrated concept of actions, conditions and culture. The nature and implication of each needs to be understood as follows.

5 S

Japanese Brief Explanation

• 1. SEIRI Take out unnecessary items and (SORT) dispose. It is an action to

identify & eliminate all unnecessary items from the workplace.

Hagpaton / Suriin

Step - 1

Look around your workplace with your colleagues. Discover and identify items which are unnecessary to your work. Then dispose all unnecessary items.

NEVER KEEP ANYTHING WHICH ARE UNNECESSARY TO YOUR WORK.

Step - 2

If you and your colleagues cannot decide if an item is necessary or not, put Disposal Notice with the date on the item, and SET THEM ASIDE.

Step - 3

After a period, say three months, check if someone needed the item or not. If there’s none, that means the item is not needed for your work. When you cannot decide yourselves, you can make the time to make decision.

Manuals and files are not organized.

Tools and other gadgets must be stored properly and off the floor.

•Withdrawn parts/materials should be kept in proper storage area.•Assorted items above and below the desk.

Japanese Brief Explanation

2. SEITON Arrange necessary (SYSTEMATIZE) items in good order for use. It is an action to put every necessary items in good order.

Han-ayon/ Sinupin

Step - 1

Make sure that all unnecessary items are eliminated from the workplace. Then, think of what things should be put where, taking into account the flow of your work, movement of forklifts from the

point of view of safe and efficient operation.

Step - 2

Decide with your colleagues which things to put where also from the point of view of efficient operation. The principle is to put most frequently needed items close to the user so as to minimize the movement of the person. Things which are not often used could be placed slightly further away.

Step - 3

It is necessary to make sure that everyone at the workplace know what are kept where for efficient use. Make a list of things with their locations and put it on locker/cabinets. Label each drawer to show what is kept inside.

Step - 4

Apply the same principles and indicate the places where fire extinguishers are located, passages for forklifts/carts, and wherever necessary, warning signs for safety precautions, etc.

Manuals and files are not organized.

Tools and other gadgets must be stored properly and off the floor.

5 SJapanese Brief Explanation3. SEISO Clean your workplace. (SWEEP) It is an action to clean the

workplace thoroughly.

Ganiron/Silhigun

Suggestions:

• Put aside 3 minutes everyday for SEISO (sort)•You and your colleagues should be responsible for the work area around you.

•Never throw anything and make it your habit.•Clean is also checking

•Obstructing wires welding flux and metal chips on the floor.•Garbage anywhere and accumulation of dust

5 SJapanese Brief Explanation

4. SEIKETSU Maintain high standard of (STANDARDIZE) Housekeeping. It is a condition where high

standard of good housekeeping is maintained so that there is no dust or rust anywhere.

Kanunay nga taas nga sukaranan sa pag-atiman sa palibot o panimalay / Siguruhin ang Kalinisan

Suggestions:•Create a maintenance system for Housekeeping. Make a schedule for cleaning your workplace.

•Interdepartmental competition is a very efficient means of sustaining and enhancing people’s interest on 5 S.

Obsolete items and empty drums not regularly disposed or turn over to proper locations for safekeeping.

5 SJapanese Brief Explanation

5. SHITSUKE Do things spontaneously (SELF-DISCIPLINE) without being told or

ordered. It is a condition where all members practice the above 4S’s spontaneously and willingly as a way of life. Accordingly, it is a CULTURE

Pagpanton sa kaugalingon/ Sariling Kusa

Suggestions:•Treat your workplace as your (own) second home.You are spending more of your WAKING TIME at your workplace than at home.

WHY 5 S?Benefits of 5 S:5S gives vitality to people.

The process of 5S requires people to think, consult and agree with others, and cooperate with each other. At the same time, practicing 5S gives people satisfaction of being creative, friendly with others and seeing changes for the better.

WHY 5 S5S improves CREATIVITY of people.5S improves COMMUNICATION among people.5S improves HUMAN RELATIONS among people5S improves TEAMWORK among people5S improves COMRADESHIP among people5S gives VITALITY to people.

VITALITY of the people is the locomotive to move the company forward.

WHY 5 S?Benefits of 5 S:5S Rationalizes Operations of the Company

As shown in the following figure, 5S is located in the center of various productivity improvement approaches. Therefore, practice of 5S satisfies various technical requirements for rationalized factory operations.

Ultimate Goal

Intermediate Goal

Approach,Strategy,Method

Ground

Better Tomorrow for EveryoneBetter Tomorrow for Everyone

Effective use of Resources

Efficiency Improvement

Economic Operations

J

I

T

T

P

M

T

Q

C

5

S

5 S

Quality Work Place

Total Customer Satisfaction

Elimination of Loss & Waste

Total Participatio

n

Physical Improvement of Working Condition

Self-Disciplined Workforce

Elimination of loss and waste

TotalParticipation

5 STherefore, practice of 5S satisfies various technical requirements for rationalized factory operation. It reduced cycle time, increased floor space, reduced lead times, reduced training cycles, lowered accident rate, enhanced communication, and reduced inventory.

JIT

QCC

TQC TPM

IE

5S

Key Points in the Implementation of 5 S

Start small and easy, proceed slowly but steadily.

o If you make haste, it is easy to fail.o For big organizations, start with pilot

areao Trial practice at model area and

model machine

Start with the most suitable “S”o For messy workplace, start from 1st S-

SEIRE (Sort)o For trouble some machine, first conduct

SEISO (Sweep) then - Inspect the machine but it requires specialists.

o Everyone can participate in “SEISO” but they need to be familiar with machines, proper cleaning procedures and tools

Key Points in the Implementation of 5 S

Key Points in the Implementation of 5 SOnly 1 or 2 3S’s are enough for

initial practice not all 5 S.o First 3S’s (SEIRI, SEISO, SEITON) are

action wordso 4th S - SEIKETSU is a CONDITIONo 5th S - SHITSUKE is according to

CULTUREEveryone’s participation is importantoTwo heads are better than one. Four eyes see more than two.oEncourage participation first by EDUCATION than by DEMONSTRATION, later through ACTUAL practice, and of course RECOGNITION.oSet aside a day for launching (e.g. Big Clean Up Day)

•Standardize and create manuals detailing office procedures.•Provide mechanism to evaluate what is happening at anytime.•Maintain cleanliness and orderliness.

Key Points in the Implementation of 5 S

Factors Leading to Success of 5S

Strong sponsorship and leadership of CEO

Active promoter/5S committeeGood launching activityRegular auditsGood documentationVisits external consultantsCompetition

Factors Which Hinder Success of 5S

Project sponsor is not the decision maker

Organizational politicsLack of experience in undertaking

cross-functional activitiesLack of top management supportImplementation carried out through

orders from the topImplementation done by task forces5S treated as a projectEmphasis on immediate results

How do we sustain 5S?

Integrate as part of the company strategic plan

Consistent and regular auditIntegrate as part of the system5S Road RaceMonthly recognition of 5S winnersCEO’s Inspection TourExchange VisitsPeriodic Review

How do we evaluate 5S?

5S Evaluation SheetFixed Point Photography ControlRegular 5S Audit Interdepartmental Competition

THANK YOU