5S for Housekeeping and Workplace Management
5S is a participative program for improving our work, environment and total quality
It is a base for continual improving in organization and a systematic approach to good housekeeping.
2. INTRODUCTION
5S is a participative program
For improving our work, environment and total quality
It is a base for continual improving in organization
It is a systematic approach to good
housekeeping
3. WHY HOUSEKEEPING IS
REQUIRED
Workplace become clean and better organized
Shop floor and office operation become easier
and safer
Result are visible to everyone, inside and
outsiders
Visible results, enhance generation of new ideas
People are automatically disciplined
Proud of clean and organized workplace
Resultant good company image generates more
business to company
4. SIGNIFICANT BENEFITS
Happier employees with high moral
Greater people involvement
Low employee turnover
Increase number of suggestions
Better use of floor place
Less WIP- Work in progress and inventories
Better flow of work
Low machine breakdown rates
Low accident rates
High yield of materials
High product quality
5S is a people oriented and practice oriented approach
5. WHY 5S MOVEMENT?
Human being feel good if workplace is clean and well organized
Helps in reducing time
For searching things (1/3 of time people wasting in searching – Out of
16 hrs )
For handling
Helps in reducing
Waste, inconsistencies and strain
Unnecessary items and reserve stock
Space requirement
Machine downtime
Rejection / Rework
No. of accidents
5S helps people
In searching more clearly
In changing mindsets – develop a proactive attitude
6. MEANING OF 5S
• Segregation Sorting out ( SEIRI)
• Arrangement (SEITON)
• Cleaning (SEISO)
• Maintenance of
standards
(SEIKETSU)
• Discipline (SHITSUKE)
7. 1. Segregation (SEIRI)
Segregate necessary and unnecessary items and eliminate
unnecessary items
It means organizing putting things in order
Procedure for getting rid of old items
Activities
Go through what you have
Segregate / identify what you need
Categorize needed / not needed items
Discharge what is unnecessary
Establish a well defined disposal system
Success Indicators
Decrease in unnecessary items and reserve stock
Percentage of area / space saved
8. 1. Segregation (SEIRI)
Usage of items Degree of Need
(Frequency of Use)
Storage Method
HIGH Things used hourly
Things used daily
Things used weekly
Store near the work site
or carry by the person
AVERAGE Things used once in last
2 – 6 months
Things used more than
once a month
Storage in central place
in the workplace
LOW Things not used in the
past year
Things only used in last
6 -12 months
Throw them out
Store at a distance
9. 2. Arrangement/ Neatness (SEITON)
This step essentially means arranging items efficiently
for easy accessibility and using in best order
Activities
Set things in orderly creating a place for everything
Put everything in its place
Keep accessibility as easy as possible Example - Fire
extinguishers, gangways
Use the principle of wide range and shallow depths for
storage
Success Indicators
Time saved in searching
Time saved in handling material
10. Putting in
Order
Things needed
Things used
constantly
Place as close
as possible
Things used
occasionally
Place a little
further
Seldom used
but still
needed
Enclose in
separate
designate
place
Things not
needed
Potentially
useful
Consider
when useful
and move it to
designated
place
No potentially
use
Dispose after
careful
analysis
11. 3. Cleaning (SEISO)
This step eliminates dirt, dust and other foreign matter to
make workplace clean and polished
Activities
Clean equipment, tools, furniture, records, etc.
Keep the workplace spotless
Sweeping, wiping, polishing, painting etc.
Success Indicators
Reduction in machine down time
Increase life of machine parts
Reduction in number of accidents
Reduction in rejection/ rework
12. 4. Maintenance of standards (SEIKETSU)
This step is combination of segregation (seiri), arrangement
(seiton) and cleaning (seiso) as on going program to maintain
clean and well organized workplace.
Activities
Create standards and initiate steps to maintain them
Devise ways to
Expose hidden problems
Surface abnormalities
Create visual control systems
Success Indicators
No. of error / cover made transparent
No. of new problem exposed and solved
13. 4. Maintenance of standards (SEIKETSU)
What is an abnormality?
Abnormality is gap between actual performance
and the appropriate standard
Example: a. Defective good
b. Scrap
c. equipment failure
d. over production
e. lateness
f. waiting
14. What is an visual controls?
It communicates required important information
to people who need it – Example – Ladies toilet
It gets one or more of our senses in order to
Alert us to an abnormality
Help us monitor quickly
Promote adherence and prevention
15. What is an visual controls?
Visual controls
Reduce error / waste by making problem visible
Identify gap between standard and actual performance
Help in early identification of problems.
Reduce supervision
Visual factory
“It means ability to understand the status of production
area in minimum or simple observation without use of
computers or speaking to any one”
16. What is an visual controls?
Visual control system
“VCS is a series of visual and other sensory devices
integrated in order to achieve a particular outcome,
ensure conformance and prevent waste.
Example: Illustration of correct manual operation
Part contains colour coded to math parts
Red – colour above the line that goes on when help is
needed
17. What is an visual controls?
IMPORTANT POINTS FOR PREPARATION OF VISUAL CONTROLS
Easy to see from distance
Easy to understand
Ensure correct location / placement
Use colours for brightness and contrast
IMPORTANT POINTS FOR PREPARATION OF VISUAL CONTROLS
Instruction to people to avoid “Operation Errors”
Danger alerts / cautions
Directions / locations
Equipment designations
Planned programs
Preventive maintenance / calibration displays
Appeals
18. 5. Maintenance of standards (SEIKETSU)
This step is to ensure that everyone sticks to the rules
and make it a habit
Activities
Create general awareness about 4S
Training to everyone
Share success to get more enthusiasm
Success Indicators
High employee moral
Involvement of people in the movement