35S
5’S history 5’S tool 5 principles of 5’S Review of 5’S performance 5’S audit checklist & analysis
Agenda
45S
History
o Developed by Toyota in 1970 o Is a part of Lean Managemento Is the reason behind core success
of Japan o In order to achieve high level of
quality, safety and productivity in working environment
o Eliminates waste and controls of inventory
o It completely relies on team work and individual commitment
55S
5S tool
“5S aims at creating the most effective work areas in which any deviation can be easily detected”
• Organize the workplace• Keep it effective• Detect any deviation
/hazard
• Bottom-up approach• Don’t confuse “5S”
with “Spring cleaning operation”
Key success factors
5S processObjectives
1. 1. SSORTORT
Identify necessary items and eliminate unnecessary ones
Make 5S strong in habit
5. 5. SSUSTAINUSTAIN
4. 4. SSTANDARDIZETANDARDIZEEstablish work standards, operating procedures to
maintain the work area clean
3. 3. SSHINEHINE
Make the workplace shine
Locate items where they are
needed
2. 2. SSET IN ET IN ORDERORDER
5S
65S
Principle’s of 5S
1. Sorting – Separating the needed from the not-needed
2. Set in order – A place for everything and everything in its place, clean and ready to use
3. Shine – Cleaning for inspection
4. Standardizing – Make up the rules, follow and enforce them
5. Sustaining – Holding the gains and improving
85S
1. Sort
Clear out, Classify and Identify :• The things you definitely need all the time• The things you definitely need occasionally• The things you might need in the future• The things you no longer need
*****Never Assume*****
Ensure that every one is in agreement
95S
Example for Sort
BEFORE AFTER
Examples of labeling
Pink :
Need All The Time
Green :
Need Occasionally
Orange :
Might Need in Future
105S
2. Set in order
Put everything in its correct place• Organize storage for all equipment
• Frequency of use, defines location relative to point of use
• If it is used frequently keep it close/low frequency store offline
• All essential such as fire extinguishers and safety equipment must be visible and easily accessible
“ A place for everything and everything in its place”
125S
3. Shine
Clean and Check• Create a clean and tidy working
environment and maintain it
• Define responsibility zones for cleaning areas and responsibilities
• Develop regular routines for maintaining a clean environment (e.g. 5 min. 5’S’ etc.)
• Cleanliness is the basis of quality. Once the workplace is clean it must be maintained
135S
It’s just a basic housekeeping of desk, computer and daily utilized belonging
Example of Shine
BEFORE AFTER
145S
4. Standardize
Conformity :• Design clear, standard labels for locations, tools, machine
conditions and locate them in standard positions
• Provide indicators where limits can be exceeded
• Draw position markers in places where items are removed and returned
Agree and set :• Standards of cleanliness.
• Procedures for maintaining standards
175S
5. Sustain
Adhere to the system rules• Develop and maintain habits through training and discipline. (At all
time)
• Use visual rather than verbal communication to train for new procedures
• Involve everyone in the development of standard documentation.(e.g. Check sheets etc.)
• Be conscious of time ( 5-10 min. 5 S)
It is important to maintain discipline• Incorrect practices must be identified
• Correct practices have to be taught and demonstrated
• Ensure everyone’s understanding and agreement
195S
Regular audit Continual improvement through regular follow up and
individual commitment Tracking of performance through each audit Review of performance through Management head
Review of 5S performance