5 ‘S ’ Total Quality remains incomplete unless suitable Environment for creation & sustenance of Quality is provided. Much importance not for good housekeeping . 1

2 What is 5 ‘ S ’ Many have confused 5 ‘ S ’ with cleanliness . A systematic approach leading to a Cleaner, Safer & Better workplace which is fundamental to Productivity & Quality is known as 5 ‘S ’ & pioneered by Toyota Motors in early 80’s and created super Quality of workplace 2

3 5 ‘S ’ refers to the first alphabet of five Japanese words for 5 different components JAPANESE ENGLISH SEIRI SORTING SEITON SYSTEMATISING SEISO SWEEPING SEIKETSU SANITISING SHITSUKE SELFDISCIPLINE 3

4 SHITSUKOKU STICKINGLY 5 ‘S ’ is systematic participation programme for improving the workplace environment which is base of continual improvement in the organisation 4

5 Main objectives of 5 ‘S ’ Quality Improvement Accident prevention's Pollution prevention's Productivity improvement Cost and down time reduction Creativity improvement 5

5S concept is itself not a theory but a very powerful tool when every employees from top to workers should participate It is management barometer , if you can do 5S you can do anything, The company is doing badly is doing its. 5S badly 6

1. SORTING ( SEIRI ) MEANING Distinguishing between the necessary & the unnecessary and getting rid of the unnecessary. PRINCIPLES Stratification Management ( Entailing value judgement & creating strata of importance ) 7

8 TYPICAL ACTIVITIES (SEIRI ) IN & OF Identify the unnecessary IN & OF Shelves, lockers , drawers , Racks, Passageways, Corners, Floors , Pits, Partition, storehouse ,sheds, Walls , Bulletin board, Tools, Measuring devices , Spares ,Small items, Consumables,wires,ducts, oils ,etc. 8

9 Throw out the things not needed. Through house cleaning. Deal with the causes of dirt & leaks. Treat defects & breakage. Organise the warehouse . Eliminate grime & burrs . 9

10 2.SYSTEMATISING(SEITON ) PRINCIPLES MEANING Establishing a systematic layout so you can always get just as much of what you need when you need it PRINCIPLES 10 Functional storage of all items based on 5W’s and 1H

11 TYPICAL ACTIVITIES Everything's at designated place. Thirty second storage & retrieval . Filing standards. Zoning & placement marks . First in & First out. Neat notice board. 11

12 Easy to read notices & Functional placement for Material, Parts, Carts, Tools, Equipment's , Files , Stationery items and Everything else 12

13 3. SWEEPING ( SEISO ) PRINCIPLES MEANING Eliminating trash, filth & Foreign matter for a cleaner workplace PRINCIPLES Cleaning as a form of inspection 13

TYPICAL ACTIVITIES Cleaning, inspecting & correcting minor problems. OF & FOR Cleaning, inspecting & correcting minor problems. Pneumatics,,Mechanical,Electrical, tools, Measuring devices , Stationery, Hydraulics. Cleaning even the places most people do not notice Making cleaning and inspection easier .

15 4.SANITISING ( SEIKETSU ) MEANING PRINCIPLES Making everything pollution free & supportive to healthy Environment . PRINCIPLES Making Environmental friendly noise or any vibration . 15

16 TYPICAL ACTIVITIES Dealing with leakage of toxic & explosive fumes. Dealing with any uncomfortable Chemical waste treatment. Reducing air & water pollution. Proper illumination without glare in working area . 16

17 Temperature & humidity maintenance. Effective air ducting & suction system for reducing fly content. Pure drinking water . Spotless cleanliness of workplace, floor, tables, ceiling, equipment's etc. 17

18 5.SELFDISCIPLINE(SHITSUKE ) MEANING Doing the Right thing Naturally. PRINCIPLES Good habit formation and discipline . 18

TYPICAL ACTIVITIES All together cleaning training and practice for regular cleaning. Training & insistence on wearing safety workplace glasses , shoes etc. Telephone,communication & feedback practices. Follow-up on standardization and checklists Practice for dealing with emergencies. 19

20 6.STICKINGLY ( SHITSUKOKO ) MEANING Ensuring 5 S , avoid making status is maintained or repetition of sanitizing,sorting ,systematizing &sweeping . PRINCIPLES Visual Management & 5S standardization 20

TYPICAL ACTIVITIES 21 Displays to help people operating errors. Danger alerts. Indications where things should be . PM displays. Equipment's designations,Inspection marks . Color coding,warning colours. Fire extinguishers sign. Open-shut & other directional labels 21

CLUE FOR 5 S SURVEY Lighting - Operation difficulty by insufficient light / bother by glare,reading the instrument dial , bulletin board reading Smell - Any leakage of toxic ,uncomfortable or explosive fumes. Any leakage of toxic or explosive material at workplace . 22

Any squeaking , uncomfortable noise Any action for elimination of source of uncomfortable noise Any noise source that is identifiable 16

any uncomfortable vibration felt continuously or occasionally Any vibration sources that are identifiable Temperature any low or high temp in shopfloor Heat sources which can be eliminated 24

TOXIC , VOLATILE & EXPLOSIVE MATERIAL POWDERY DUST Any uncomfortable powdery dust floating in workplace occasionally or continuously. TOXIC , VOLATILE & EXPLOSIVE MATERIAL Identify & indicate clearly as a dangerous material. Establish & disseminate emergency evacuation procedure to every one. 25

26 WORK SHOP Install all necessary safety media Have enough open space in every workshop Maintain slip free floor 26

COLOUR CODING Specify colour coding on dangerous /risky area / material Specify colour coding for eye fatigue protection for using equipment. Specify colour coding for operational limits on instruments / indicators.

HUMAN BEHAVIOUR Use of PPE such as safety shoes , helmet, masks ear plugs , goggles, etc. 28