1. 5S - BASIC TRAINING What is 5S and why do we want to do it?
ALOK SHARMA \06\2010

2. What is 5S ? Seiri – Sort (housekeeping)
Seiton – Systematic Arrangement
(workplace organization)
Seiso – Shine (Cleanup)
Seiketsu – Standardize
Shitsuke – Sustain (Self Discipline)

3. What is 5S ?
5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems).
These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts.
5S is one of the activities that will help ensure any company’s survival.

4. 5S
1. Sort - All unneeded tools, parts and supplies are removed from the area
2. Set in Order - A place for everything and everything is in its place
3. Shine - The area is cleaned as the work is performed
4. Standardize - Cleaning and identification methods are consistently applied
5. Sustain - 5S is a habit and is continually improved
Also - Work areas are safe and free of hazardous or dangerous conditions

5. Some New Words
Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes
Some Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvement
Muda-(pronounced “moo da”) - waste
Gemba-(pronounced “gim ba”) – workplace
Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.

6. KAIZEN: What it is? Process Improvement Observation
Use of New Paradigms
Short Time
Zero Investment
Human Development & Empowerment
Profits & Savings - Plenty

7. KAIZEN
KAI
ZEN
ALWAYS
GOOD
CONTINUAL
IMPROVEMENT
CHANGE
FOR THE BETTER

8. KAIZEN IS A JOURNEY FROM:
EVENT
RESULT
GROSS
ENFORMENT OF CHANGE
TO CAUSE
TO PROCESS
TO MICRO
TO INDUCEMENT OF CHANGE

9. CONTINUOUS CONTINUAL KAIZEN IS CONTINUAL IMPROVEMENT TIME TIME

10. KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE
OBSERVATION
INTELLIGENCE
PHYSICAL EFFORT
PARADIGM OF HIGH PRODUCTIVITY & QUALITY

11. KAIZEN AT GEMBA GEMBA: PLACE OF WORK GEMBA is where . . .
Value is added
Actual work is done to meet customer requirement
Problems are solved
Staff is responsible for providing support, not for giving instruction

12. 1. 5S Principles Elimination of waste Every body is involved,
Co-operative effort
Attack root cause
Human being is not infallible

13. 2. Objectives Improve housekeeping
Make every individual responsible for housekeeping
Beautify by simple means
Productivity improvement by saving time, space etc.

14. (Systematic Arrangement)
The ‘S’
Japanese Word
What is involved
Objective 1S
SEIRI
(Sorting Out)
Segregate necessary from unnecessary
Remove what is not required
Decide on frequency of sorting
Saving and recovering Space 2S
SEITON
(Systematic Arrangement)
Arranging in order
Place for everything, Everything in its place
Minimizing search time 3S
SEISO
(spic and Span)
Cleaning the work place/ equipment
Attaining the warning bell
Inspecting for problems
Taking corrective actions faster 4S
SEIKETSU
(Standardization)
Working Methodology
(Procedures & WI)
Achieving higher productivity and better quality 5S
SHITSUKE
(Self Discipline)
Forming the habit in form of Training and Discipline
Doing it right at First Time

16. SEIRI = Sorting
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

17. SEIRI = Sorting Japanese Meaning : The Japanese meaning of “Seiri” is
to straighten and contain.
- Get rid of waste and put it in order according to rules

18. Respiratory System 1 ‘S’ - SEIRI
1 ‘S’ – Our respiratory system sorts oxygen and other gases And exhales other gases which are unwanted for our body

19. 1S – SEIRI : SORTING 1 ‘ S’ Sort for . . . Not Needed at All
Needed but not Now
Needed but not here
Needed but not so much Quantity
1 ‘ S’
WANTED UNWANTED

20. 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. Contingency Parts
Critically decide the quantity of contingency
parts to be retained and criteria for such parts

21. 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

22. Identifying unnecessary
Seiri = Sorting
Identifying unnecessary
1. Parts & Work in Process (WIP)
Things fallen back behind the machine or rolled under it
Broken 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..

23. Identifying unnecessary
Seiri = Sorting
Identifying unnecessary
2. Tools, Tooling, 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..

24. 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 etc.
5. Passages and Corners
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..

25. Identifying unnecessary
Seiri = Sorting
Identifying unnecessary
8.Floor, Pits, Partitions
Defective parts
Protection caps, covers
Packing material
Hardware items , small items
Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
Many unwanted, outdated, temporary files pile up

26. Improvement methods Seiri = Sorting
1. Flow Process Chart (Procedural Analysis)
Drawing a process flow chart for the system
e.g. How to make and use category wise grouping
2. Operational Analysis
Preparing the sequence of operations for system
e.g. 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.

27. 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

28. 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

29. Arranging things in systematic way
Seiton : Systematic Arrangement
PLACE FOR EVERYTHING,
EVERYTHING IN ITS PLACE
Arranging things in systematic way

30. 2 ‘S’ – In our body there is a fixed place for every organ.
2 ‘ S’ - SEITON
2 ‘S’ – In our body there is a fixed place for every organ.

31. 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
Indicator - Time saved in material handling

32. SEITION = Systematic Arrangement
Japanese Meaning:
Dictionary meaning of Seiton is “to be correctly
prepared” and “to prepare correctly”.
In short these means :
(a) arrange correctly in accordance with the correct method of doing activities and
(b) make thorough preparations so that activities can be done even if they occur abruptly

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

34. 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 & colour
contd..

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

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

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

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

39. 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

40. Seiton = Systematic Arrangement
Wires and Ducts
- Colour 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

41. 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

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

43. Before sort after sort

44. Before sort after sort

45. 3 ‘S’ Seiso : Cleaning KIKEN KITSUI KITENOI (DANGER) (PROBLEM) (DIRT)
Clean the surroundings !

46. 3 ‘ S’ - SEISO
3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc

47. 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

48. SEISO = Cleaning Japanese Meaning :
Dictionary meaning “to clean up” and
“getting rid of dirt and unclean items”
While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

49. 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

50. 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

51. Seiso = Cleaning EXAMPLE : PREPARE CHECKLIST FOR CLEANING SL.No
TICK 1
Check Floors are clean 2
Check Work areas are clean 3
Check walls are clean 4
Check Pillars and Ceiling are clean 5
Check Windows are clean 6
Check Rooms and Electrical lights are clean

52. Seiso = Cleaning Seiso Cycle
BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES.
BEGINNING OF WORK - DO TRIALS AND START UP
DURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES
AFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGS
SEISO IS A PART OF GOOD WORKMANSHIP
SEISO IS AN IMPORTANT PRE-CURSOR
WITH 5S

53. 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

54. 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

55. 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

56. 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

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

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

59. Before shine after shine

60. Before shine after shine

61. 4 ‘S’
Seiketsu
STANDARISATION

62. 4 ‘ S’ - SEIKETSU
4 ‘S’ – In every human being the structure of fingers are same I.e. Standardised. If it is not so, then we call it is abnormal.

63. 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
- Colour coding
- Early detection of problem and early action
Success Increase in 5S indicator
Indicator

64. SEIKETSU = Standardization
Japanese Meaning :
Dictionary meaning
“unsoiled things, purity and cleanliness”
Clean manners ,
Clean cloths, clean politician
It is the proof that 3 S’s are being faithfully
carried out.

65. SEIKETSU = Standardization
Tools used for analysis :
MTTR : Mean Time To Repair \ Recover
MTBF : Mean Time Between Failures
OEE : Overall Equipment Efficiency

66. 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

67. 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

68. 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

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

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

71. Seiketsu = Standardization
Points to remember in making visual
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

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

73. Seiketsu = Standardization
Some visual communication signs

74. 5 ‘S’
Shitsuke
SELF DISCIPLINE

75. ENSURE . . .
Procedure & Work Instruction are correct.
Standard are expressed in specific.
Visual Aids are used.
Train at all levels.
Work ethics for effective management.
Transparent & Discipline work culture.

76. 5 ‘S’ – Every human body has its standard process which they maintain.
5 ‘ S’ - SHITSUKE
5 ‘S’ – Every human body has its standard process which they maintain.

77. 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

78. SHITSUKE = Self Discipline
Japanese Meaning :
Dictionary meaning is
“learning of the manners”
“having manners, dressing neatly” OR
“training children for good customs”

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

80. 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

81. 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.

82. 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

83. ORGANIZATION Organization Departments into areas
Coordinators at department level
Coordinator at each area level
Training for all
Audit each area and make action check list
Implement actions
Audit and evaluation on continuous basis
Organization

85. Some 5S Examples
After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
Before 5S

86. 5S Pictures Before After ERAANHA 2004-11-01
1/2882-FCS Uen Rev D

87. 5S Pictures Before: Repair After ERAANHA 2004-11-01
1/2882-FCS Uen Rev D

88. 5S Pictures Before After ERAANHA 2004-11-01
1/2882-FCS Uen Rev D

89. The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S

90. The Good

93. THANK YOU