5s Key to work place improvement Lead By: Jayanth Murthy KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

5s AIMS at achieving this state Putting 5s to Work Who does not like a Clean Orderly Disciplined Environment ? At home & At work !!! 5s AIMS at achieving this state

Mess ?!

Clean & Organized – Puts A Smile On Your Face !

One Way to Do It !!

The 5s Way To Do It !!

One to Keep Files !

The 5s Way To Do It !!

The 5s Way To Do It !!

The 5s Way To Do It !!

The 5s Way To Do It !!

5-S Seiri - sort out Seiton -systematic arrangement Seiso - Scrub clean, Spic & Span Seiketsu – Standardize - State the rules Shitsuke - Self-discipline (Follow rules) KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

SEIRI 1st Step of 5s Red Tagging & Red Tag Areas (set Rules first) Step Zero - of 5s Identify strategic Spots & take Photos / Video – To Capture Current Status 1st Step of 5s SEIRI Sorting of all items Segregate Necessary from Unnecessary Take action on Unnecessary Red Tagging & Red Tag Areas (set Rules first) Heaps to Come out – 10 trucks (in a factory)

When In Doubt, Throw It Out ! Red Tag To, Stock Facilities Locations / Space Documents Computer Files Machines Stationary Not People !! When In Doubt, Throw It Out !

Seiri Classify into: wanted, ? and unwanted Discard unwanted Create red tag area for ? items Move ? Items to red tag area Put red tag on unmovable ? items Wanted but not here Wanted but not in this Qty Wanted but not now Not Wanted at all KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Before Seiri

Before Seiri

Before Seiri

After Seiri

SEITON 2nd Step of 5s This Leads To Standardizing Of Storage. Systematic Arrangement A Place For Every Thing & Every Thing In Its Place Arrange Necessary Items Systematically Easy to identify, find, take & put back Everything to have a place & label This Leads To Standardizing Of Storage. Any Body Can : See Things (floor lines, door opening lines, labels etc) Can Take out it fast (less than 30 sec) Can Return It Where, What, How Many ? (Define & label)

Seiton Make Place for all wanted items Target: Max searching time: 30 seconds Sign boarding/labeling Outlining Color Coding Visual Controls KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Does It Ring A Bell ?

Before

Before

Before

After Seiton

After Seiton

Before

After Seiton

After Seiton

After Seiton

After Seiton

The 5s Way To Do It !!

After Seiton

After Seiton

After Seiton

After Seiton

Before Seiton

After Seiton

After Seiton

After Seiton

After Seiton

SEISO Spic and Span – Collective Cleaning Autonomous Cleaning 3rd Step of 5s SEISO Spic and Span – Collective Cleaning Autonomous Cleaning Cleaning is Inspection Cleaning with meaning Seiso Boards (tools) Seiso calendar & responsibility charts Decide What, When, Who and How to clean

COT Cleaning with meaning Seiso calendar/map Seiso Cleaning is inspection COT Cleaning with meaning Seiso calendar/map KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Cleaning using your own hands

Cleaning using your own hands

After Seiton

Before

After Seiton

After Seiton

Before

After Seiton

Seiso Board

Seiso Board

4th Step of 5s SEIKETSU Standardization (so that first 3 ‘S’ is maintained AND… No – Unnecessary items pile up No – Mess / out of place items No - Dirt Make the rules & Follow them SDCA 5 min / 10 min 5s Setting Standards

Seiketsu Setting up of Rules: Place token when tool (or file) is taken Make schedule to restore basic conditions Establish measures to track adherence to rules answer the 5w1h as regards first 3 S KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Token System For Tracing Tools

Token System For Tracing Tools

First Aid Point, Emergency Tel No & the Telephone next to it !! Standardize First Aid Point, Emergency Tel No & the Telephone next to it !!

SHITSUKE 5th Step of 5s Self Discipline Training & People Involvement Follow the rules set (if not use ..Retraining / Disciplinary Measures !) Photo Gallery Slogans Audit Radar Charts

Shitsuke Self Discipline of adhering to Rules: Adhere to rules yourself Post adherence on visual displays Spread rules and adherence by teaching others and tracking everybody’s performance on visual displays KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Audit Format For Office Environment 5s Audit For Production / Factory Environment 5s Audit Casting a Radar Chart & Keeping it Updated

Some More Cases On 5s

Seiton

Seiton

Seiton

Seiton

Seiton

Seiri

Seiton

Seiso

Seiton

Seiton

What is 5s ? Seiri – Sorting of all items Segregate Necessary from Unnecessary Take action on Unnecessary Seiton – Systematic Arrangement Arrange Necessary Items Systematically Easy to identify, find, take & put back Everything to have a place & label Seiso – Spin & Span Everything to be clean Use cleaning as inspection Seiketsu – Setting Standards Set standards & rules 5 min / 10 min 5s Audit Shitsuke – Self Discipline Training & People Involvement

5s Requires Team Work

1 Top management Commitment 2 Top management Commitment Three More Things 1 Top management Commitment 2 Top management Commitment 3 Top management Commitment

KAIZEN INSTITUTE OF AMERICA KAIZEN INSTITUTE OF EUROPE KAIZEN INSTITUTE: AFRICA-ASIA-PACIFIC KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

S.Gondhalekar, Mumbai Jayanth Murthy, Africa Founder: Masaaki Imai Head (Bus. Dev): Bud H. Cox Africa-Asia-Pacific: S.Gondhalekar, Mumbai Jayanth Murthy, Africa S.Durairajan, Chennai ,V.K.Grover, Pune Kristianto Jahja , Jakarta Over 160 consultants worldwide. KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Consulting Clients in Africa-Asia Pacific: Bidco, Nairobi Spinners and Spinners, Kenya Superfoam Ltd, Kenya Taj group of hotels Milton Plastics Bombay Oil Industries Rallis, India & Hitech Gears (supplier to Honda) Latest additions (from March 2000): Spencon - Uganda / Zambia / Kenya Comcraft Group Of Companies Power techniques . KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Unique Features of Consultancy: Hands-on consultants Implementation in shortest time Cash-stingy solutions Energizing people Release of latent capabilities Human development Learning organization KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN