The document provides an overview of the 5S methodology aimed at improving workplace organization and efficiency, emphasizing the importance of cleanliness and order through its five pillars: Sort, Set in Order, Sweep/Shine, Standardize, and Sustain. It highlights the benefits of implementing 5S, such as increased production efficiency, reduced costs, and enhanced safety. The document also discusses common resistance to 5S implementation and offers strategies for effective integration within an organization.

1. previous next
1
Prepared By
Md Aminul Islam
Reliability Engineer
SADAF-SABIC

2. previous next
2
Workshop on
Work Environment (5 S)
Workshop Content
1. Foundation for Corporate survival , Why are the 5S necessary ?
2. Five Pillars of the 5S
3. Introducing 5S in to workplace
4. Visual Organization & Visual Orderliness
5. The Red Tag Strategy
6. The Signboard Strategy
7.Campaigning & 100% implementation in Compressor
House,Rectifier Pump House,Switchyard,Rectifiers, HT Rooms &
etc.

3. previous next
3
Why 5s ?
Factories are like People. They sweat & get dirty
with the passage of time . People deal with this
problem by bathing .
The 5S techniques help factories to wash off their
accumulated oil , Dirt & grime.
Clean,Lean,Smart & freshness are the requirement
of the competitive factories.

4. previous next
4

5. previous next
5

6. previous next
6
PROBLEMS DUE TO NOT CLEANING.......
1. Windows are so dirty that very little sunlight filters through.
this leads to poor morale & inefficient work.
2. Defects are less obvious in dark, messy factories
3. puddles of oil & water cause slipping & injuries
4. machines do not receive sufficient check-up maintenance
& tend to operate incorrectly/ break down frequently
(hazardous / late deliveries)
5. Cutting chips can get mixed to production, and assembly
processes or can blow into peoples eyes causing defects,
injuries
Why 5s ?

7. previous next
7
Why 5s ?
1. Work Effectiveness
2. More Vital Working Environment
3. Cheerful / Good Mood
4. Safety Environment
5. Higher Work Efficiency
6. Proper order for all working area
7. Take Pride
.. To Create ..
These are benefits to Employees..

8. previous next
8
Why 5s ?
1. Increase Production Efficiency
2. Reduce unnecessary Stock.
3. Lower Production Cost
4. Create more space and storage area
5. Create confidence and recognition
6. Create World Class Factories
.. To
These are benefits to Organization

9. previous next
9
(Organization) (Orderliness)
Clearly distinguish
needed items from
unneeded &
eliminate
the later
SORT SET IN ORDER
SHINESTANDARDIZE
(Standardized cleanup) (Cleanliness)
Keep needed item in
the correct place to
allow for easy &
immediate retrieval
Keep the
work shop
swept & clean
This is the
condition we support,
when we maintain
the first three pillers
SUSTAIN
Make a habit of
maintaining
established
procedures
1 2
3
4
V
I
S
U
A
L
V I S U A L
5
5 Pillars of 5 S ?

10. previous next
10
Keys to Develop a Successful
5 S Program
Attitude & mind set.
Thoroughness
Continuity
Smooth Integration with other
existing systems

11. previous next
11
Traditional Attitude
COMMON RESISTANCES TO 5S IMPLEMENTATION
1. WHAT IS SO GREAT ABOUT SORT & SET IN ORDER?
2. WHY CLEAN WHEN IT JUST GETS DIRTY AGAIN?
3. WE ALREADY IMPLEMENTED SORT & SET IN ORDER!
4. WE DID 5S YEARS AGO!
5. WE ARE TOO BUSY FOR 5S ACTIVITIES!
6. WHY DO WE NEED TO DO THAT WHEN
EVERYTHING ALRIGHT?
!
ZOC

12. previous next
12

13. previous next
13
I Pillar – Sort (Seiri)
Sort – Means Categorizing the objects, tools, things,
documents as necessary ones and unnecessary
ones so as to discard the unnecessary ones.
No unnecessary objects should be permitted
at the workplace
CATEGORISING THINGS
Things
Can be used
Cannot be used
Unlikely to be used
•Sufficient Functions
•Sufficient Period
•Sufficient Amount
•Prefer not to use
•Seem Unnecessary
•Insufficient Functions
•Insufficient Period
•Insufficient Amount

14. previous next
14
I Pillar – Sort (Seiri)
Where did I keep my Calculator ?
Why do we have to Loose
time looking For things ?
• Because they are mixed
with other unnecessary
objects
• Stored in wrong location
• Not identified with label

15. previous next
15
100
80
60
40
20
10
1
6 MONS 1 Yr 3 Yr 5 Yr 10 Yr.
TIME
USE
FREQ.
DOC.
QTY
•6 MONTHS LATER - 10% USE FREQ
•1 YR LATER - 1 % USE FREQ.
DOCUMENT USABILITY TREND
SN COMPANY NO. OF DISCARD AMOUNT
EMPLOYEES
(TONS) KG./EMPLOYE
1. TDK 600 100 166
2. KAWASAKI STEELS 1,600 170 106
3. MITSU ENGG. 1,300 140 106
4. TAISO MARINE 1,300 210 161
DOCUMENT DISCARD RATES
I Pillar – Sort (Seiri)

16. previous next
16
I Pillar – Sort (Seiri)
Sorting Procedure
1. Inspect all material in the work area
2. Separate the utilities out of junk and / or waste
3. Get rid of the excess which is over kept / stored and
get rid of all unnecessary things.
Look for ..
• Unnecessary things cluttering your workplace
• Unnecessary cables,pipes just left as they are
• Tools materials left on the floor
• All items sorted out, classified stored and labeled ?
• All gauges and tools properly classified and stored ?
Look at ..
Cabinet , Shelf , Drawer , Storage , Floor ,
Around the table , Corner … Which have never cleaned up

17. previous next
17
RED TAG STRATEGY : IMPLEMENTING ORGANISATION BY LABELLING ALL UNNEEDED ITEMS
WITH CONSPICUOUS RED TAGS.
RED TAG TARGETS
FACTORIES
WORKSHOPS
OFFICES
INVENTORY
EQUIPMENT
SPACES
DOCUMENTS
STATIONAARY
EQUIPMENT
SUPPLIES
OTHERS
LAUNCH R.T PROJECT
IDENTIFY RED TAG TARGETS
SET RED TAG CRITERIA
MAKE THE RED TAGS
ATTACH THE RED TAGAS
EVALUATE THE RED TAGAS
MAKE SIGN BOARDS (VISUAL ORDERLINESS
ITEM
NAME
QUANTITY
DATE
REASON
RED TAG
RED TAG
STEPS IN RTS
Red Tag Strategy

18. previous next
18
I Pillar – Sort (Seiri)
Benefits by Sorting
Excess use of space is eliminated
Excess equipments / shelf / Cabinets are eliminated
All errors which might occur can be eliminated

19. previous next
19

20. previous next
20
II Pillar – Set In Order (Seiton)
Set in Order– Means Reserve necessary things always in
good order and make them readily available
Keep needed item in the correct place to
allow for easy & immediate retrieval
Steps for II S
1. Look whether main corridors, aisles and storage places
Are clearly marked ?
2. Are tools divided into Specialized use & regular use ?
3. Are pallets always stacked to the proper height ?
4. Is anything stored around fire extinguishers ?
5. Does the floor have any depression, protrusions , cracks
Or obstacles ?

21. previous next
21
Set In Order at your Workplace
Items
Necessary
Frequently
used
Some times
used
Not used at all
But must be kept
Must be placed
Near to the point
Of use
Can be placed
At a bit distance
location
To be stored
Separately with
Clear identification

22. previous next
22
Use Frequency Description Organization Method
Inventory
items
Cannot be or
unlikely to be used
Can be
used
Rarely
Used
Occasionally
Used
Often
Used
•Defective
Goods,Dead
Inventory
• Used about
Twice a year
• Used once
every one or
two months
• Used once a
week
•Used every hour
or everyday
• Discard
• Remove From
Factory &
Store elsewhere
• Store near
process
• Store near
process where
used
• Keep close at
hand all times
INVENTORY ORGANISATION SYSTEM
Sort and Set In Order

23. previous next
23
Cards Exchanged
(Write down Date)
Store in B.Card
Folder
(Ready access Storage)
Organization
1.Throw out 2 years Old cards (Unconditionally)
2. Retain those with whom UR
in regular contact
3. Transfer remaining cards to (Remote storage)
Write today’s date on cards in
Remote storage box
for Stored Business cards
Organization
For Remote Storage box
Throw out all 3 yrs. old
cards Unconditionally
Transfer information.
to Add. book
ORGANIZATION FOR BUSINESS CARDS
Sort and Set In Order

24. previous next
24
Sort and Set In Order
Convenience Principle
1. Arrange suitable location with identification for all materials /
Equipment , put them back to their places after being used (tag/sign)
2. Emphasize in putting all material / equipment in proper place , where
they belong.
3. Material / Equipment frequently used must be put near and / or next
to the user.
4. Grouping the same kind of material / equipment in the same location.
Benefits
1. Reduced time for finding materials/ things.
2. Easy to inspect and recognize
3. Work effectiveness and safe area

25. previous next
25
1 2 53 4
1
2 3
4 5SD SD SD SD SD
TOOL NUMBER LABELS
EXAMPLE OF SET IN ORDER
6
6
SD
Sort and Set In Order

26. previous next
26
P
R
O
J
E
C
T
11
ORGANISATION & SET IN ORDER FOR OFFICE FILES
12 3 4 5 6 7 8 9 10 11 12
V
E
N
D
O
R
S
11 12 3 4 5 6 7 8 9 10 11 12
Sort and Set In Order
smk smk smk smk smk smk smk smk smk smk smk smk
smk smk smk smk smk smk smk smk smk smk smk smk

27. previous next
27

28. previous next
28
III Pillar – Sweep / Shine (Seiso)
Sweep : Means to Keep the work shop , offices ,Work
areas swept & clean
Areas That need to be cleaned
• Floor , Wall , Corner and Ceiling
• Office Table
• Cabinets
• Shelves
• Equipment / Materials
• Around the user

29. previous next
29
III Pillar – Sweep / Shine (Seiso)
Steps for Sweep / Clean
• Look carefully at the floor, aisles and around machines.
How much oil , dirt , dust and metal shavings can you find ?
• Are any parts of the machine dirty with oil or metal
fragments ?
• Are any supply lines or pipes oily, dirty or hard ?
• Are oil outlets clogged with dirt etc.?
• Are light bulbs , reflectors , covers dirty ?
• Eliminate all the original sources of dirt and
un cleanliness
• Cleanup even small spots.
• Use brooms / Water in cleaning process
• Paint or draw lines around fixed areas.

30. previous next
30
III Pillar – Sweep / Shine (Seiso)
Ways of Promotion (* Leader must be most active during promotion)
1. Remove stain first.
• Clean completely with the broom,mop or floor cloth.
2. Repair the defective condition which has been discovered
During the cleaning (Cleaning is Inspection! )
• Uneven floor makes it difficult to transport.It may damage the
products or cause personal injury.
• Is there any problem with the machine ?
3. Look for the source of stain and remove the root.
• Try to discover the source of dust, dirt or stain to prevent the
generation of such inconvenience and Eliminate the root cause.
• Condition of cleanliness must
improve day after day.
4. Indication
• Indicate the location of storage.
• Put the mark on item themselves.
• Indicate also on the forms or slips
• Settle fixed location
Gaskets
G1 G2 G3 G4 G5

31. previous next
31
III Pillar – Sweep / Shine (Seiso)
Benefits from Cleanliness method
1. Vital Working Atmosphere.
2. More efficient machines and equipment.
3. Extended machines and equipment lives
4. Healthy Environment
5. Cleaning is Inspection

32. previous next
32
Initial Cleaning
Eliminate dirt, dust and grime
Expose all abnormalities
Correct minor flaws & establish basic
equipment conditions
Bring equipment to its ideal state
Create workplace, free of abnormalities.
Prevent forced deterioration ( dust,fouling)
Expose latent defects and restore.
Touch & feel the equipment.
Foster eyes to detect the defects.
Learn the outline/ function of the equipment.
Know the weak points of the equipment.

33. previous next
33
 Failures
 Quality Defects
 Accelerated Deterioration
 Speed Losses
Effects Of Inadequate Cleaning

34. previous next
34
Slight Defects:
Are any nuts & bolts loose, missing?
Bolt Lengths:
Do all bolts protrude from nuts by 2-3 thread
lengths?
Washers:
Are flat washers used on long holes?
Are tapered washers used on angles, bars,
channels?
Are spring washers used where parts subjected
to vibrations?
Are identical washers used on identical parts?
Check While Cleaning

35. previous next
35
Storage:
Is lubricant storage clean & tidy in line with
5S procedures?
Is lubricant container always capped?
Lubricant Inlets:
Are grease nipples & lubrication inlets kept
clean?
Are the inlets labeled with correct type &
quantity ?
Oil Level Gauges:
Are the gauge glasses & its indicators kept
clean?
Is the correct oil level clearly marked?
Check while Cleaning Lubrication
System

36. previous next
36
Keep the vicinity of the equipment in order
and tidy.
Remove unnecessary things attached
Understand equipment structure and operating
principles.
Equipment cleaning, safety & inspection
education.
Introduce & attach abnormality tags to the
defects which can not be solved by the team.
Advancing Method
( Step 1)
CWCM-SMK AUTONOMOUS MAINTENANCE

37. previous next
37
Clean equipment regularly as part of the daily
work. Clean deeply - Remove all the layers of
grime and scale built up over many years.
Open previously ignored covers, guards and so
on, to remove every speck of dirt from every
corner & crevice.
Clean attachment & accessories, main units
(Conveying equipment, control boxes, Lubricant
tanks (Inside & outside)
Do not give up when a part gets dirty again
soon after cleaning, note how long it takes to
become dirt ? What is the source ? etc
Cleaning Tips ( Step 1)

38. previous next
38
Search for In visible/ visible defects like
Looseness, Subtle vibrations, Overheating,
Worn out pulleys, belts, dirty drive chains,
blocked suction filters .. etc
Note whether equipment is easy to clean,
Lubricate, Inspect, Operate & adjust (Identify
hindrances such as large, obstructive covers, ill
positioned lubricators etc)
Ensure that all meters operate correctly & are
clearly marked with specified values.
Hunt for corrosion inside insulating materials on
pipes, columns, tanks, blockages inside chutes &
ducts.
Investigate any leaks of product, steam, water,
Oil, compressed air
Inspection Tips ( Step 1)

39. previous next
39
Eliminate Sources of Contamination
and Inaccessible Places
DURING CLEANING
Operators use their hands and physical resources
to perform initial cleaning and detect abnormalities.
DURING INSPECTION
Operators use their brains to devise effective improvements.
Develop counter measures for all sources of
contamination, spills & leaks

40. previous next
40
PREVENT LEAKS
& SPILLS
IMPROVE
ACCESSIBILITY
Prevent leaking,spilling,
spraying or scattering of:
 Products
 Lubricants
 Hydraulic fluids
 Powders
 Vapors
 Other process material
Improve accessibility
of places that are
hard to:
 Clean, Check
 Lubricate, Tighten
 Operate, Adjust
PURPOSE
Reduce the time it takes to clean,check and lubricate
Eliminate Sources of Contamination
& Inaccessible Places

41. previous next
41
PURPOSE :-
 Maintain requirements of Cleaning,
Lubrication, Small fix i.e. Tightening
 Introduce extensive visual controls &
Standardize the gains made through
improvements.
 Set the Standards responsibilities,
subsequently reduce time for each
activity
 Eliminate forced deterioration of equipments.
Establish Cleaning
& Inspection Standards

42. previous next
42

43. previous next
43
IV Pillar – Standardize (Seiketsu)
This is the condition we support,when we maintain the
first three pillars
Standardize : Means to preserve / maintain always clean and
hygienic environment through standardization of
operating procedures.
Steps
1. Standardize procedure for everything.
2. Set tentative standards.
3. Train every one to follow
4. Monitor and promote by auditing.

44. previous next
44
IV Pillar – Standardize (Seiketsu)
How to Standardize Cleaning
Daily
Weekly
Monthly
Yearly
Table,Machine tool ,
Working Area, Floor
Sort all unnecessary
Items in the area
Windows, Door, Wall
Ceiling, Shelves,
Cabinets and special
Cleaning for floor
Everything !
Big cleaning day
Broom , Mop, Rag,
Brush,Vacuum Cleaner
Long Broom,Rag,
Brush , Sponge
Chemical cleaning
All Kinds !
None !
CLEANING

45. previous next
45

46. previous next
46
Prepare SOP of all your Equipment
Cleaning Standards
Cooling Capacity : 4500 Kcal/hr. Equipment :Split Air Conditioner
Current : 0.3 amps. Model :Tempest
Power Consumption :650 W Make :Shriram
Sl.
No
Cleaning Area Identification
Cleaning
Standard
Cleaning Tool
Cleaning
Method
Cleaning
Time (min)
Cleaning Cycle Resp.
1
Plastic Cabinet No dust/dirt
1
Nagle
2
Remote Control No dust/dirt
0.45
3
Filter No dust/dirt
1.5
4
Thermostat No dust/dirt
1
5 Motor
No abnormal
noise , No
dust/oil spills
1.5
6
Capacitor No dust
1
7
Coil Set
No dust/dirt and
leaks.
1
8
Blower No dust
1
9
Cord Wire No dust/dirt
1
10
Water Tray
No
accumulation
2
Suresh
11
Drainage Pipe No leaks
1
SureshD
WT
CW
cs
B
C
M
T
F
R
P
Daily Weekly
Nagle
Nagle
Nagle
Nagle
Nagle
Nagle
Nagle
Nagle

47. previous next
47
Cleaning / Inspection Standards
1
2
3
4
5
6
7
Operator
Operator
Operator
Operator
Operator
Operator
Operator

48. previous next
48
Cleaning / Inspection Standards

49. previous next
49
ORDERLINESS :
•ARRANGING NEEDED ITEMS SO THAT THEYARE EASY TO USE
•LABELLING THEM TO MAKE THEIR STORAGE SITES EASILY
UNDERSTOOD BY ANYONE
•SIMPLIFICATION BY STANDARDIZATION
FACTORY & OFFICE
STANDARDIZATION
MACHINARY
STANDARDIZATION
OPERATION
STANDARDIZATION
DRAWING
STANDARDIZATION
CLERICAL
PROCESS
STANDARDIZATION
VOUCHER
STANDARDIZATION
STANDARDIZATION OF
WHERE THINGS ARE KEPT
IV Pillar – Standardize (Seiketsu)

50. previous next
50

51. previous next
51
V Pillar – Sustain discipline (Shitsuke)
Sustain : Means to Establish a system to honour operation
standardization faithfully.
• Make a habit of maintaining established procedures
• Be present 5 mins. Before morning meeting.
• Put the protective devices as specified by standards.
• Be decent at the dining room (Wash hands, Maintain row etc.)
• Start the job in the afternoon in high spirit.
• Take recess at the specified time and place.
• Smoke only at the specified time and location. Etc.
Some Tips

52. previous next
52
Role of Each group in 5S
•COO
Sr.Vice President STEERING COMMITTEE
• Dept. heads Engineers / Supervisor
PROMOTION COMMITTEE
FACILITATOR
5S GROUPS
Prepare the ground properly

53. previous next
53
Role of Each group in 5S
Steering committee
• Issue annual 5S Policy
• Join the monthly 5S audit / Review
• Provide direction & support to the activities.
Promotion committee
• Be the member of 5S committee
• participate in 5S activity
• Provide energy & momentum to activities
• Be the checker & observer / follow up.
Facilitator
• Be the member of 5S committee
• Participate in 5S activity
• Be the observer & support members in 5S activities.
• Be the checker & observer / follow up.
• Arrange training / Update 5S information on boards

54. previous next
54
Benefits of 5S
• 5S is the software for safety.
• Space full , bright and unobstructed workshop will show
the flow of things at a glance.
• Regulations are duly honoured.
• Traffic regulations are observed faithfully.
• Clothes and protectors are worn as specified by operation
standards
• A heavy sense of improvement dominates.
• A lovely workshop is created by the positive attitude of
everybody

55. previous next
55
A Clean Workplace is High in Productivity
A Clean Workplace has High Quality
A Clean Workplace keeps Cost Down
A Clean Workplace Ensures Delivery on Time
A Clean Workplace is Safe for People to Work
A Clean Workplace is High in Morale
Benefits of 5S

56. previous next
56
CWCM-SMK AUTONOMOUS MAINTENANCECWCM-SMK AUTONOMOUS MAINTENANCE
The End