1. 5S Seiri Seiton Seiso Seiketsu Shitsuke
5S is a process set down by the Japanese to maintain house-keeping. This is the DNA for any developmental program. Without implementing 5S, one cannot progress in any developmental activity. 5S helps us to keep the environment clean, helps us to identify waste, excess, non-moving that are unhealthy to an organization.
A kitchen in every household is the best example for 5S maintenance. One does not need to go for plant tours instead observe your kitchen. At the least, your spouse would be happy enough that you are paying attention to her.
5S is not one day activity or a flavor of the month. It is a continuous process and one should keep on doing it day-in and day-out.
Seiketsu
Shitsuke

2. Quality Improvements JAPAN U.S.A INDIA 1980 1950 1960 1970
This graph indicates the quality improvements do increase dramatically if 5S is followed. Basically, Indians do possess the lacuna of untidyness and we live with it. If we start implementing 5S, it will not take years for us to catch the leaders.
INDIA
1980
1950
1960
1970

3. 1. 5S Principles Every body is involved, Co-operative effort
Elimination of waste
Every body is involved, Co-operative effort
Attack root cause
Human being is not infallible
Our human body is the right example of processing the elimination of waste. Imagine a day without being making a visit to toilet. What will be our status? Similarly, any waste that is generated has to be purged or removed. This is not the duty of any single person but everyone.
However, how long one has to keep on purging the waste. Of course one gets tired of this activity. If you do not want to get bored, then find out the root cause for the waste generation and then attack it.
Infallible means “sure to succeed”. To Err is human, and to prevent him erring repeatedly, 5S is essential.

4. 2. Objectives Improve housekeeping
Make every individual responsible for housekeeping
Beautify by simple means
Productivity improvement by saving time, space etc.
It is human nature for every human being to project himself presentable or beautiful. So, why not the place we work in?
Don’t we keep our living rooms presentable? Then why cant we do the same to our workplace? In house, every family member does his part to keep it clean and here also we follow the same principle. We do not need an interior decorator to beautify the shop but simple things would do. Mind it “winners do not do different things but do things differently”.
Obviously, by keeping our house clean, we get indirect benefits in terms of time saving etc.,

5. 3. 5S’s Seiri - Sorting Seiton - Systematic arrangement
Seiso Cleaning Inspection while cleaning
Seiketsu - Standardization
Shitsuke - Self Discipline
What makes 5S?
The 5 Japanese words starting with letter S and its equivalent English Words that relate to the 5S activities.

6. 5S If we do not do 5S, we can’t do any
other work efficiently. They are features which are common to all places and are the indicators of
how well an organization is functioning.
One cannot read one’s mind but can make out an impression by seeing the appearance. Perception is more than reality. If we do not present ourselves well, we cannot sell ourselves. If we do not imbibe the discipline of cleanliness, even our spouses would leave us for good.

7. COMMON MIND SETS…
Its an additional burden. Too busy to do 5S activities. Why clean it? It will get dirty again We cannot change the existing setup. More work pressure – No time for these things
One cannot read one’s mind but can make out an impression by seeing the appearance. Perception is more than reality. If we do not present ourselves well, we cannot sell ourselves. If we do not imbibe the discipline of cleanliness, even our spouses would leave us for good.

8. SEIRI = Sorting – Just in Case to “Just-in-Time”
Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items
Activity: Establish a criteria for eliminating unwanted items. - Eliminate unwanted items either by disposing them or by relocating them.
Success Area saved or percentage of space available
Indicator

9. SEIRI = Sorting – Fight with habits

10. SEIRI = Sorting 3 Categories
√ - Item Required
X – Item Not Required
? – Undecided
Move to Red Tag Holding Area

11. What is unnecessary Seiri = Sorting 1. Item is not needed
2. Item is needed however quantity in stock is more
than what is needed for consumption in near
future
3. Item is needed but once in a blue-moon
4. Contingency Parts
Critically decide the quantity of contingency
parts to be retained and criteria for such parts

12. Organization LOW AVERAGE HIGH Frequency of use Storage Method
Throw them out
*Things you have not used
in the past one year
LOW
*Things you have used once
in the last 6-12 months
Store at distance OR
Keep in store
*Things you have used only
once in the last 2-6 months
Store it in central place
in your zone
AVERAGE
*Things used more than once
a month
Store it in central place
in your zone
HIGH
*Things used once a week
Store near the workplace
*Things used daily or hourly
Store near the workplace

13. Identifying unnecessary
Seiri = Sorting
Identifying unnecessary
1. Parts & Work in Process (WIP)
Things fallen back behind the machine or rolled under it
Broken / some items inside the machine
Things under the racks/ platform
Extra WIP
Stock of rejected items
Items accumulated over period for rework
Material awaiting disposal decision
Material brought for some trial, still lying even after trial
Small qty of material no longer in use
Contd..

14. Identifying unnecessary
Seiri = Sorting
Identifying unnecessary
2. Tools, Toolings, Measuring devices
Old jigs, tools not in use are lying
Modified tools, tooling for trial, are lying after trial
Worn out items like bushes, liners, toggles etc. lying
Broken tools, bits, etc. may be lying
Measuring equipment not required for the operation
being performed, is lying
3. Contingency Parts
Many times storage place for contingency parts become
a last refuge for broken parts, surplus items and things
nobody is likely to use
Contd..

15. Identifying unnecessary
Seiri = Sorting
Identifying unnecessary
4. Shelves and Lockers
Shelves and lockers tends to collect things that nobody
ever uses, like surplus, broken items, used tea-cups etc.
5. Passages and Corners
WIP material waiting for decision or dispatch
Dust, material not required seem to gather in corner
6. Besides Pillars and under the stairs
These places tends to collect junk, spittoon etc.
7. Walls and Bulletin Boards
Old out dated notices which have lost their relevance
Posters or bulletins on wall
Dust, remains of torn notices, cell tape pieces
Contd..

16. Identifying unnecessary
Seiri = Sorting
Identifying unnecessary
8.Floor, Pits, Partitions
Defective parts
Protection caps, shoe covers
Packing material, stickers, barcodes, cut-leads
Hardware items, small items, runners, plastic granules
Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
Many unwanted, outdated, temporary files pile up
Old dated mails still remaining in inbox and sent items
Deleted mails not being purged when closed
Recycle bin not emptied

17. Seiri = Sorting
TAGGING

18. Improvement methods Seiri = Sorting
1. Flow Process Chart (Procedural Analysis)
Drawing a process flow chart for the system
eg. How to make and use category wise grouping
2. Operational Analysis
Preparing the sequence of operations for system
eg. How to perform Seiri (sorting)
3. Check List
A check sheet is used to decide what sort of main system
and sub system are necessary.

20. Dealing with papers How to reduce papers on your table ?
Seiri = Sorting
Dealing with papers
How to reduce papers on
your table ?
1. Make a single pile of papers
2. Go through them and sort in
following categories
a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information

21. Dealing with papers How to reduce papers on your table ? 4 D Principle
Seiri = Sorting
Dealing with papers
How to reduce papers on
your table ?
4 D Principle DO
DELEGATE
DELAY
DUMP

22. SEITION = Systematic Arrangement
Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .
Activity - Functional storage
- Creating place for everything and putting
everything in its place
Success - Time saved in searching (30 sec to locate an item)
Indicator - Time saved in material handling

23. SEITION = Systematic Arrangement
The main target areas for Seri-Seiton improvement are :
Tool-setting and preparation operations, line balancing and process planning, parts supply to assembly line, peak time problems etc.
Improvement Methods
Kit Method / Assembly box method / Outside tool setting
Cassettisation / Parallel operations / Changes in assignment method

24. Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ?
Decide where things belong
Decide how things should be put away
Obey the Put away rules

25. Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ?
Decide where things belong
- Standardize Nomenclature
- Determine an analytical method of storage
Decide how things should be put away
- Name & locations to everything. Label both item
and location
- Store material functionally
- Prevent mistakes with coding by shapes & color
contd..

26. Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ?
Decide how things should be put away
- Follow first in first out rule
- If two identical items are to be located, then store
them separately, color code them.
Obey the rules
- Put the things back to their location after
their use

27. Seiton = Systematic Arrangement
USE :
1 ) Signboards
2) Color codes
3) Outline markings
4) Labels

28. Seiton = Systematic Arrangement
Functional
Storage

29. Seiton = Systematic Arrangement
Usage
Frequency
Store frequently used material
near the workplace and less
frequently at some distance
Weight &
Shape of the
Material
Heavy material should be stored
at lower levels/layers
Place directly on the material
handling device for ease of
handling
Functional Storage

30. Seiton = Systematic Arrangement
Same category of material may be
stored in one location.
Eg. Fasteners, Seals , resistors
Category
Operation
Wise
All items required for an
operation may be stored in one
location.
Eg. Allen key, spanner etc hand
tools required for setting m/c
Functional Storage

31. Seiton = Systematic Arrangement
Outlining and Placement Marks
- Mark boundaries of dept., aisles, Machines
- Follow straight line, right angle rule
- Nothing shall be kept outside the boundaries
Stands and shelves
- Keep only required number of stands and shelves
- Standardize height, size
- Provide casters where necessary so that it can be
moved

32. Seiton = Systematic Arrangement
Wires and Ducts
- Color code
- When there are multiple connections - bundle the
wires, label them and make sure that they are in
straight line /right angle and firmly anchored
Machine-tools & Tools
- Put the tools in the order you need them
- Location of the tool should be such that it can be
put away with one hand
- Try to eliminate some hand tools by permanently
attaching it to the bolt head

33. Seiton = Systematic Arrangement
Blades, Dies, Other important consumables
- Store them in the protected place
- Maintain these things regularly by applying rust
preventive, oiling etc.
WIP- Work In Process
- Designate a place for each component/part
- Decide on how much quantity to be stored
- Ensure that there is no damage to good part
during transit, they do not get rusty and they are
not mislabeled

34. Seiton = Systematic Arrangement
Oils & Lubricants
- Reduce number of oils used (Standardize)
- Color code for oil
- Safety aspects - fire prevention, pollution, leak,
spillage
Instrumentation & Measuring Devices
- Label them, show direction of flow

35. SEISO = Cleaning
Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection
Activity - Keep workplace spotlessly clean
- Inspection while cleaning
- Finding minor problems with cleaning inspection
Success - Reduction in machine down time
Indicator Reduction in no. of accidents

36. Here cleaning means more than just keeping
Seiso = Cleaning
Here cleaning means more than just keeping
things clean. Cleaning should be viewed as a
form of Visual Inspection
Preventive measures should be taken to tackle
problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated

37. = Trash = Dirt =Knocking = Loose parts = Leaks =Scattering
Seiso = Cleaning
Various Minor Defects
= Trash = Dirt =Knocking
= Loose parts = Leaks =Scattering
=Skips =Curvature =Abrasion
=Rust =Scratches =Eccentricity
=Lurching =Abnormal =Vibration
Movements
=Abnormal =Heat =Abnormal
Sounds smells
=Faded color =Hisses - Cracks

38. Devote 5 minutes everyday for cleaning your work area
Seiso = Cleaning
5 Minutes Every day for cleaning
Devote 5 minutes everyday for cleaning your
work area
Participation of everyone is required
Attack hard to clean places regularly

39. equipment Cleaning Oils Seiso = Cleaning
Cleaning-Inspection points for most
equipment
Grime, clogging, dust balls, rust,
leakage etc.
Cleaning
No oil, Low oil, leakage, filter clogging,
dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
etc.
Oils

40. equipment Tightening Heat Seiso = Cleaning
Cleaning-Inspection points for most
equipment
Loose bolts, welding detachment,
loose parts, vibration or bumping
noise, friction
Tightening
Oil tanks, motors, heater, axles, control
panels, washing/ cleaning water,
bearing, wiring etc.
Heat

41. equipment Breakage, Cracks Seiso = Cleaning
Cleaning-Inspection points for most
equipment
Breakage, cracks, dent on sliding
parts, handle has come off, broken
switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.
Breakage,
Cracks

42. equipment Pneumatics Hydraulics Seiso = Cleaning
Function wise Cleaning check list of
equipment
Compressed Air lines, air valves,
connections, meters, filters,
reservoirs etc.
Pneumatics
Hydraulic oil tank, oil valves,
filters, pumps, hoses, gauges,
cylinders etc.
Hydraulics

43. equipment Mech & Power Train Electrical Seiso = Cleaning
Function wise Cleaning check list of
equipment
Motor fan, fan belt, couplings,
Joints, pulleys, chains, pump
bearings etc.
Mech &
Power Train
Electrical
Control panel, lamps, light, switch,
sensors, wiring, ducts, fuses etc.

44. equipment Toolings Equipment Specific Seiso = Cleaning
Function wise Cleaning check list of
equipment
Tools, fixtures, gauges, dies,
measuring instruments, etc.
Toolings
Equipment
Specific
Furnaces, rollers, chutes,
CNC machines, etc.

45. SEIKETSU = Standardization
Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure)
Activity - Innovative visual management
- Color coding
- Early detection of problem and early action
Success Increase in 5S indicator
Indicator

46. SEIKETSU = Standardization
Tools used for analysis :
MTTR
MTBF
OEE

47. Seiketsu = Standardization
Regularizing 5S activities so that
abnormalities are revealed
Make it easy for everyone to identify
the state of normal or abnormal
condition
For maintaining previous 3S, deploy
visual management

48. Seiketsu = Standardization
It has been estimated by scientific
study that 60% of all human activities
starts with sight
5S is easy to do once.It is consistency
that is difficult. That is why Visual
Management is so important, so that
everybody will know that there is
some problem.
Visual Management

49. Seiketsu = Standardization
What visual control communicates ?
It grabs one or more of our senses in
order to
Alert us to an abnormality
Help us recover quickly
Promote adherence and prevention
Enable successful self management

50. Seiketsu = Standardization
Some methods for visual communication
Color coding
Use of Labels
Danger alerts
Indication where things should be put
Directional arrows/ marks
Transparent covers
Performance indicators

51. Seiketsu = Standardization
Some methods for visual communication
Labels
Precision management labels
Inspection labels
Temperature labels
Responsibility photos

52. Seiketsu = Standardization
Points to remember in making visual c
control tools
1. Make them easy to see from distance
2. Put the display on the things
3. Everyone can tell what is right and
what is wrong
4. Anybody can follow them and make
necessary corrections easily
5. Work place should look brighter &
orderly

53. Seiketsu = Standardization
Some everyday visual management
examples
Traffic signal
Zebra crossing
In car - Petrol indicator
- Speed indicator
Direction arrows
Electric danger sign
Toilet

54. Seiketsu = Standardization
Some visual communication signs

55. SHITSUKE = Self Discipline
Meaning Every one sticks to the rule and makes it a habit
Activity - Participation of everyone in developing good
habits
- Regular audits and aiming for higher level
Success High employee morale
Indicator Involvement of all people

56. SHITSUKE = Self Discipline
Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.

57. Shitsuke = Self Discipline
We need everyone to maintain 5S
guidelines.
To maintain DISCIPLINE, we need
to practice and repeat until it
becomes a way of life.
Discipline is the Core of 5S

58. Shitsuke = Self Discipline
Discipline means making a steady
habit of properly maintaining
correct procedure.
Time and effort involved in
establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.

59. Shitsuke = Self Discipline
Pledge
It shall be my constant effort to
maintain my workplace in good
order by
Assigning a place for everything
& keeping everything in its place
Sorting out unwanted material
periodically & discarding them
Keeping my work area neat &
clean everyday

60. Machine building Bay

61. Heat Treatment Area

62. Heat Treatment Area

63. Machine Shop

64. End of the presentation & Beginning of 5S activities….