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5STHE SECRET TOJAPANESE SUCCESS
 WHAT PROBLEMS DO U COMMONLYENCOUNTER AT YOUR WORKPLACE HIGH ABSENTEEISM HIGH TURNOVER DEMOTIVATED EMPLOYEES DISORDER...
 THE SOLUTION TO ALL THESEPROBLEMS IS5S
5SHOUSEKEEPING TECHNIQUEPRODUCTIVITY AND SAFETYENHANCEMENT TECHNIQUE
IDEA BEHIND 5S IN ORDER TO ACHIEVE HIGHLEVELS OF QUALITY, SAFETY,ANDPRODUCTIVITY, WORKERS MUSTHAVE A CONDUCIVE WORKINGENV...
WHAT IS 5S? Developed by the Japanese Housekeeping System Helps Create a Better WorkingEnvironment and a ConsistentlyHi...
THE 5S PRINCIPLES SEIRI – Organisation/Sort out SEITON – Orderliness/Systemize SEISO – The Cleaning/Shining SEIKETSU –...
DISCOVERY OF 5S Thirty years ago researchers startedstudying the secret of success ofJapanese manufacturing companies 5S...
DISCOVERY OF 5S Equipments were so clean and wellmaintained that any problem suchas a loose bolt or leaking oil couldbe e...
ADVANTAGES OF 5S If tools and materials are convenientlylocated in uncluttered work areas Operators spend less time look...
ADVANTAGES OF 5S A clean and tidy workplace leadsto greater well being and increasedmotivation Company image improves
ADVANTAGES OF 5S Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing
ADVANTAGES OF 5S RESULTS IN A PLACE EASIER TOMANAGE SMOOTH WORKING NOOBSTRUCTION NO DEVIATION, NO PROBLEMS B/C EVERYON...
ADVANTAGES OF 5S TIME SAVING QUICK RETRIEVAL ACCIDENTS & MISTAKESMINIMIZED INCREASES SPACE CREATES WORKPLACEOWNERSHIP
METHODOLOGYOF 5S
1. ORGANISATION(SEIRI) Decide what you need Remove unnecessary clutter All tools, gauges, materials, classifiedand then...
RED TAG TECHNIQUE GIVE STAFF RED LABELS ASK STAFF TO GO THROUGHEVERY ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THATA...
For wavering items PLACE THE SUSPECTED ITEMS INTHE RED TAG AREA FOR ONEWEEK ALLOW THE STAFF TOREEVALUATE THE NEEDED ITEM...
ORGANISATIONPRIORITY FREQUENCY OF USE HOW TO USELow Less than once peryearOnce per yearThrow awayStore awayfrom theworkpla...
2. ORDERLINESS(SEITON) ONCE YOU HAVE ELIMINATED ALLTHE UNNEEDED ITEMS NOW TURN TO THE LEFT OVERITEMS
ORDERLINESS(SEITON)Organise layout of tools andequipment–Designated locations–Use tapes and labels–Ensure everything isava...
ORDERLINESS(SEITON)Workplace Checkpoints:- Positions of aisles and storage placesclearly marked? Tools classified and st...
3. SEISO (CLEAN/SHINE) Create a spotless workplace Identify and eliminate causes ofdirt and grime – remove the needto cl...
SEISO (CLEAN/SHINE) Divide areas into zones Define responsibilities for cleaning Tools and equipment must be owned byan...
4. SEIKETSU (STANDARDISE) Generate a maintenance system for thefirst three Develop procedures, schedules,practices Cont...
5. SHITSUKE (SUSTAIN / DISCIPLINE) Means inoculate courtesy & good habits Driving force behind all 5S Make it a way of ...
LITMUS TEST FOR 5S 30 SECOND RULE ONE MUST LOCATE THE ITEM WITHIN 30 SECOND IF 5S IS PROPERLYIMPLEMENTED
WHAT U HAVE COME ACROSSAT THE END OF DAYFollowings can be harnessed form the5S1. NEAT & CLEAN WORKPLACE2. SMOOTH WORKING3....
Cont.6. QUALITY IMPROVES7. WASTAGE DECREASE8. MACHINE MAINTENANCE9. VISUAL CONTROL SYSTEM10. EMPLOYEES MOTIVATED11. WORKST...
Before 5S
After 5S
After 5S
After 5S
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  1. 1. 5STHE SECRET TOJAPANESE SUCCESS
  2. 2.  WHAT PROBLEMS DO U COMMONLYENCOUNTER AT YOUR WORKPLACE HIGH ABSENTEEISM HIGH TURNOVER DEMOTIVATED EMPLOYEES DISORDERED/ CLUTTEREDENVIRONMENT MISTAKES/ERRORS
  3. 3.  THE SOLUTION TO ALL THESEPROBLEMS IS5S
  4. 4. 5SHOUSEKEEPING TECHNIQUEPRODUCTIVITY AND SAFETYENHANCEMENT TECHNIQUE
  5. 5. IDEA BEHIND 5S IN ORDER TO ACHIEVE HIGHLEVELS OF QUALITY, SAFETY,ANDPRODUCTIVITY, WORKERS MUSTHAVE A CONDUCIVE WORKINGENVIRONMENT
  6. 6. WHAT IS 5S? Developed by the Japanese Housekeeping System Helps Create a Better WorkingEnvironment and a ConsistentlyHigh Quality Process
  7. 7. THE 5S PRINCIPLES SEIRI – Organisation/Sort out SEITON – Orderliness/Systemize SEISO – The Cleaning/Shining SEIKETSU – STANDARDIZE SHITSUKE - Sustain/Discipline
  8. 8. DISCOVERY OF 5S Thirty years ago researchers startedstudying the secret of success ofJapanese manufacturing companies 5S turned out to be the mostimpressive "secret" The factories were so well organizedthat abnormal situations were readilyapparent
  9. 9. DISCOVERY OF 5S Equipments were so clean and wellmaintained that any problem suchas a loose bolt or leaking oil couldbe easily seen This passion of cleanliness andorderliness became a hallmark ofJapanese organizations
  10. 10. ADVANTAGES OF 5S If tools and materials are convenientlylocated in uncluttered work areas Operators spend less time looking foritems This leads to higher workstationefficiency, a fundamental goal in massproduction
  11. 11. ADVANTAGES OF 5S A clean and tidy workplace leadsto greater well being and increasedmotivation Company image improves
  12. 12. ADVANTAGES OF 5S Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing
  13. 13. ADVANTAGES OF 5S RESULTS IN A PLACE EASIER TOMANAGE SMOOTH WORKING NOOBSTRUCTION NO DEVIATION, NO PROBLEMS B/C EVERYONE KNOWS WHERE THETHINGS ARE SPPOSEDF TO BE
  14. 14. ADVANTAGES OF 5S TIME SAVING QUICK RETRIEVAL ACCIDENTS & MISTAKESMINIMIZED INCREASES SPACE CREATES WORKPLACEOWNERSHIP
  15. 15. METHODOLOGYOF 5S
  16. 16. 1. ORGANISATION(SEIRI) Decide what you need Remove unnecessary clutter All tools, gauges, materials, classifiedand then stored Remove items which are broken,unusable or only occasionally used
  17. 17. RED TAG TECHNIQUE GIVE STAFF RED LABELS ASK STAFF TO GO THROUGHEVERY ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THATARE NEEDED,IN WHAT QUANTITY NOT NEEDED RED TAG IT STORE IN THE RED TAG AREAREDTAG
  18. 18. For wavering items PLACE THE SUSPECTED ITEMS INTHE RED TAG AREA FOR ONEWEEK ALLOW THE STAFF TOREEVALUATE THE NEEDED ITEMS AT THE END OF WEEK THOSEWHO NEED ITEMS SHOULD BERETURNEDREDTAG
  19. 19. ORGANISATIONPRIORITY FREQUENCY OF USE HOW TO USELow Less than once peryearOnce per yearThrow awayStore awayfrom theworkplaceAvg. Once per monthOnce per weekStore togetherbut offlineHigh Once Per Day Locate at theworkplace
  20. 20. 2. ORDERLINESS(SEITON) ONCE YOU HAVE ELIMINATED ALLTHE UNNEEDED ITEMS NOW TURN TO THE LEFT OVERITEMS
  21. 21. ORDERLINESS(SEITON)Organise layout of tools andequipment–Designated locations–Use tapes and labels–Ensure everything isavailable as it is needed andat the “point of use”
  22. 22. ORDERLINESS(SEITON)Workplace Checkpoints:- Positions of aisles and storage placesclearly marked? Tools classified and stored by frequencyof use? Pallets stacked correctly? Safety equipment easily accessible? Floors in good condition?
  23. 23. 3. SEISO (CLEAN/SHINE) Create a spotless workplace Identify and eliminate causes ofdirt and grime – remove the needto clean Sweep, dust, polish and paint
  24. 24. SEISO (CLEAN/SHINE) Divide areas into zones Define responsibilities for cleaning Tools and equipment must be owned byan individual Focus on removing the need to clean
  25. 25. 4. SEIKETSU (STANDARDISE) Generate a maintenance system for thefirst three Develop procedures, schedules,practices Continue to assess the use and disposalof items Regularly audit using checklists andmeasures of housekeeping Real challenge is to keep it clean
  26. 26. 5. SHITSUKE (SUSTAIN / DISCIPLINE) Means inoculate courtesy & good habits Driving force behind all 5S Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits
  27. 27. LITMUS TEST FOR 5S 30 SECOND RULE ONE MUST LOCATE THE ITEM WITHIN 30 SECOND IF 5S IS PROPERLYIMPLEMENTED
  28. 28. WHAT U HAVE COME ACROSSAT THE END OF DAYFollowings can be harnessed form the5S1. NEAT & CLEAN WORKPLACE2. SMOOTH WORKING3. NO OBSTRUCTION4. SAFETY INCREASES5. PRODUCTIVITY IMPROVES
  29. 29. Cont.6. QUALITY IMPROVES7. WASTAGE DECREASE8. MACHINE MAINTENANCE9. VISUAL CONTROL SYSTEM10. EMPLOYEES MOTIVATED11. WORKSTATIONS BECOMESPACIOUS
  30. 30. Before 5S
  31. 31. After 5S
  32. 32. After 5S
  33. 33. After 5S
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