1. Safety, Health & Environment
Overview of 5S
WELCOME
Prashant Rane
Safety, Health & Environment
26 May 2010

3. 5S Principles Elimination of all types of waste
Every body is involved,
Team work
Attack root cause
Continual improvement is possible
Mind set change, culture building

4. What are 5S ? 5S are five Japanese words beginning with S
Involvement programme
Participation programme
Culture building path
System for continual improvement of mind set of employees

5. 5S is foundation for visual factory

6. What are the 5 S´s ? SEIRI Sorting / Organise SEITON Neatness
SEISO Cleaning
SEIKETSU Standardisation
SHITSUKE Self Discipline
SEIRI
SEITON
SEISO
SEIKETSU
SHITSUKE
Development
Time

7. Objectives 1S: Release the space
2S: Minimize searching and access time
3S: Zero Leakage
: Zero Spillage
: Make easy to clean and inspect
: Zero Accident
: Zero Breakdown
: Zero Abnormality.

8. Objectives continued.. 4S : Zero rework : Zero internal rejection
: Zero external rejection
: Zero customer complaints
: Zero variance on all
targets and commitments

9. Objectives continued.. 5S : Zero violations of rules
procedures and policies
: Zero reminders

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

11. 1S : 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 released as a percentage of space
Indicator available

12. 2S : 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 and access
Indicator - Time saved in material handling

13. SEITION = Systematic Arrangement
Easy to identify
Easy to Locate
Easy to Pickup and access
Easy to keep it back
Easy to Inspect
Easy to read
Easy to instruct

14. 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

15. 3S: 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 spillage, leakages, down time
Indicator Reduction in no. of accidents

16. SEISO = Cleaning Organise major initial cleaning
Identify the Leakages and put tags
Identify the spots difficult to clean
Implement Projects to make cleaning easy
Team involvement in projects

17. SEISO = Cleaning
Develop cleaning checklist
Train for doing root cause analysis

18. Seiso = Cleaning and Inspection
5-10 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

19. Seiso = Cleaning and Inspection
Create a checklist for initial cleaning
Where ?
How ? (Equipment, Material, ...)
How often ? (daily, weekly, ...)

20. SEIKETSU = Standardization
Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure and standards)
Activity - Innovative visual management
- Colour coding
- Early detection of problem and early action
Success Improvement in 1S, 2S and 3S level
Indicator Zero Rejections, Variance on targets

21. SEIKETSU = Standardization
Seiketsu is result of first 3S implementation
Systematic training on problem solving is must to all team members

22. 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
Growth of the organisation

23. SHITSUKE = Self Discipline
Develop the rules, procedures, practices, standards
Train all the employees to understand and use
No follow up is required
No. chasing is required
No Reminding is required
No violations of norms or discipline
Employee is proud of his role and activity

24. SHITSUKE = Self Discipline
Activities :
5S Training
5S Month, exhibitions
Posters , Literature etc.
Periodic audits of the level of the 5S
Worst photo contest
Presentations by each team

25. 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

26. 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.

27. THNAKS