What is 5 S ?5S is the name of a workplace organization method that uses a list of five Japanesewords:1. SEIRI – SORT – SEGREGATION2. SEITON – SET IN ORDER – ARRANGEMENT3. SEISO – SHINE – HOUSEKEEPING4. SEIKETSU – STANDARDIZE – MAINTAINANCE OF STANDARDS5. SHITSUKE – SUSTAIN – DISCIPLINETransliterated or translated into English, they all start with the letter "S". The listdescribes how to organize a work space for efficiency and effectiveness byidentifying and storing the items used, maintaining the area and items, andsustaining the new order. The decision-making process usually comes from adialogue about standardization, which builds understanding among employees ofhow they should do the work.
3What is 5S??5S Original Japanese Meaning in English1S SEIRI Sort out unnecessary items in the workplaceand discard them2S SEITON Arrange necessary items in good order so thatthey can be easily picked for useA place for everythingEverything in its place3S SEISO Clean your workplace thoroughly so that thereis no dust on floors,machines and equipments4S SEIKETSU Maintain high standards of workplace at alltimes5S SHITSUKE Train people to follow good housekeepingdiscipline automatically
1ST S – SEIRE (Sorting)Separating the useful from the useless: ELIMINATIONSorting out and keeping only what is necessary for the environment through:1. The elimination of the useless items2. The selection of the items required for efficiency in the workplaceObjective: the implementation of useful tools for creating an effective workenvironment without bothersome and useless influencesINDICATOR OF SUCCESS :1. Decrease in unnecessary items and reserve stock2.Percentage of area / space saved
2nd S – SEITON (Set in order)Organizing items based on their use: OrganizationPutting things in their proper place by:1. Selecting the best place for each object2. Selecting a method for the organization and identification of each objectObjective: Eliminating the need to look for objectsINDICATOR OF SUCCESS :1. Time saved in searching2. Time saved in handling material
Putting in orderThings needed Things not neededThings usedConstantlyThings usedoccasionallySeldom usedBut still neededPlace as closeas possiblePlace a littlefurtherEnclose in a sepearateDesignatedPlacePotentiallyusefullNo potentialuseConsider whereusefull and moveto designated placeDisposal aftercareful analysis
3rd S – SEISO (Housekeeping)Eliminating the sources of dirt and smudges: CLEANINGEfficient elimination of dirt by:1. Identifying the sources of dirt and smudges at the time of each cleaningprocedure2. Implementing measures to eliminate the sources of dirt and smudges and ensurecleanliness with minimal effortObjective: To keep things cleanINDICATOR OF SUCCESS :1. Reduction in machine downtime2. Increased life of the machine parts3. Reduction in number of accidents4. Reduction in rejection / rework
4th S – SEIKTSU (Standardize)Visually standardize better practices: STANDARDIZEThis Step is Combination of segregation (seiri), arrangement (seiton) and cleaning(seiso). As as,an on-going programme to maintain a clean and well – organisedworkplace.To implement effective organization by:1. Identifying better practices2. Simple procedures for these practices (visual assistance)3. Communication and training for useObjective: To observe proper practicesIndicator of success :1. Number of areas / covers made transparent2. Number of new problems exposed and solved
5th S – SHITSUKE (Sustain)To systematize compliance with better practices: SUSTAINEnsuring compliance with established standards by:1. Acquiring new habits2. Options for continued self-determination regarding compliance with establishedrules3. Information and processing of noted problemsObjective: To use the best practices and continuously improve themINDICATORS OF SUCCESS :1. High employee morale2. Involvement of people in the movement
Benefits of 5 S• Less Waste (Improved Efficiency)• Reduced Space Used For Storage• Improved Maintenance• Improved Safety• Better, More Committed Employees• Improved Quality
Less Waste Equals Improved EfficiencyA key principle of 5S is to get rid of items that are not used, and make it moreconvenient to find those items that are needed. This gets rid of clutter, unnecessarytools, scrap materials and unused supplies. It organizes, labels and places close athand those tools and materials that are needed on a regular basis. The result isthat more time is spent productively and less time is wasted finding needed toolsand materials.Less Space Used For Storage Equals Reduced CostsBy eliminating unused materials, tools and equipment, and getting rid of clutter, asurprising amount of space will be freed up. There is a cost associated withspace, not only in the rental or lease costs, but in heating/cooling, cleaning andmaintaining of that space.
Clean Equals Improved Maintenance & Less Down TimeWhen machines, equipment and tools are kept clean and free from clutter, it is easier tospot defects, part failures, and problems such as an oil leak. This allows preventativemaintenance to address the problem before it becomes a more serious problem.For example, if a machine is kept clean, an oil leak would immediately be noticed. Thesource and cause of the leak can be quickly identified and the problem fixed, before low oillevels lead to more serious damage to the machine.Improved Moral Equals Greater Commitment To JobWhen your employees see you care about them, their work area, and that you value their input,they care more about their job. 5S naturally leads to this result.5S is dependent on employee participation. 5S leads to employees being more engaged withtheir job.The clean, organized workplace that results from 5S is a more pleasant workplace that leads toimproved employee attitudes. The focus on cleanliness, organization, labor-saving efficiency,having the right tools, and using quality standards leads to an increased pride in workmanship.Add in the improved safety (lower numbers of injuries) resulting from 5S and you get aworkforce that is happier (less turn-over), more motivated, is getting more done with less effort,and is interested in further improving their workplace and your products.
Implementing 5S Equals Improved Safety• Clean means that spills get cleaned up ASAP, eliminating the potential for slips andfalls.• Clean means clutter is removed, revealing hidden electrical, chemical ormechanical hazards.• Having needed tools, materials and supplies close to where they are neededgreatly reduces travel (movement) and as a result reduces the potential for injury.• Standardization means that unsafe practices are eliminated because thosepractices are not a part of the standards.• Employees who have their eyes open for spotting ways to improve using 5Sprinciples will also be more aware of their surroundings and potential safetyhazards.
155 Levels of housekeepingLEVELS :1. Horizontal surfaces/floor full of unwanted material.2. Vertical surfaces / areas near walls having clutter.3. Horizontal ,vertical surfaces clean and have no unwanteditems.However,storage areas, record rooms disorganised.4. Storage areas ,machines,offices are clean.All materials ,furtinuture,documentsproperly organised,labelled and numbered.5. Factory/office is immaculate at all times.
16Level 1 of HousekeepingWork area is in level 1 of housekeeping if, Cigarette butts/Gutkha pouches Scraps of paper Tools (Used or Unused) Packing and clamping materials Support structures Left -over raw material Obsolete documents Bulky files Unused equipment, machine etcare scattered around all over the workplace.
17Corrective action for level 1• Look at all horizontal surfaces• Examine the entire work floor. Eliminate all garbage andnon- essential items on floor,shelves,tabletops etc• Remove unnecessary papers from files• Discard old files, stationery etc• Make a definite place for all tools/documents,files and parts that are lying on thefloor tabletopsHINTS FOR IMPROVEMENT Do not put anything directly on the floor As much as possible, throw/dispose off things that have no clear foreseeable use.
18Level 2 of housekeepingWork area is in level 2 of housekeeping if there is no litter or unused material onthe floor/horizontal surface, but Clutter is found by the walls The passage ways are not clear Unused items,documents,furniture etc are leaning against the walls or columns Unused tools and equipment ,paper left beneath or beside the equipment
19Corrective action for level 2• Look at vertical surfaces• Examine walls and columns• Eliminate all garbage and non- essential items leaning against the walls/columns• Paint all walls and columns that can be reached by handHint for improvement Divide responsibilities (For area and walls)
20Level 3 of housekeepingWork area is in level 3 of housekeeping if the walkways are clear and thefactory/office is clean,but the tools,materials,papers and files are stilldisorganised in the storage areas,record rooms,drawers,filing racks etc. Tools ,parts,clamps are all mixed together Gloves,shoes etc are thrown in with tools in the toolbox Drawers,shelves are disorganised All tools are in locked storage units Drawers,shelves are locked and keys are missing Unused and worthless items found inside closed cabinets
21Corrective action for level 3• Look inside the shelves and sort the papers, material ,parts and tools• Get rid of locked cabinets• Make separate storages for tools,parts,clamps, documents etc.• Make the above area distinct and clearHINT FOR IMPROVEMENT Remove the back and sides of all the storage cabinets
22Level 4 of housekeepingAt level 4,the work area will have, Machines,equipment,furnitures spotlessly clean Storage areas clearly marked and distinguished Scrap material found in its designated scrap bin Items placed in shelves are properly labelled/ tagged Storage areas show many parallel lines and right angles for grid alignment Tools/files are colour coded and numbered
23Further improvement at Level 4 Clean ,straighten and organise automatically Storage system designed for “First In First Out” philosophy Develop other visual controlsHints for improvement Scrap and chips should fall directly into waste containers/dust bins Make a model line with super market type display of parts and tools Well defined scrap & waste collection & disposal system
24Level 5 of HousekeepingAt level 5,the work place is immaculate at all times. It witnesses, Constant and continual cleaning by all employees Origins of rubbish are removed so that dirt, clutter and garbage are eliminatedat source Tools, items and materials can be found at a glance Inventory levels can be found visually Production runs smoothly High product quality achieved
25What does 5(S) require?Consciousness revolution through :1. Perseverance, determination2. Training3. Constant effortsAbilities :1. To see / judge what is important2. Attention to detailsContinuous implementation through :1. Total participation by all employees
26Crucial points for successfulimplementation of 5SPARTICIPATION BY ALL PEOPLE :• 5S programme should be participated by all People in the organization.• 6 objectives or why’s of 5S programme should be understood by all people in theorganization :1. A clean workplace is high in PRODUCTIVITY2. A clean workplace has high QUALITY3. A clean workplace keeps COST down4. A clean workplace ensures DELIVERY on time5. A clean workplace is SAFE for people to work6. A clean workplace is high in MORALEREQUIRE FULL SUPPORT FROM ALL EMPLOYEES.
27Tangible results expected from 5SpracticeFrom People• Employees will be disciplined to be more aware of untidy workplace and motivatedto improve the level of cleanliness.• Greater team spirit and co-operation can be built up through involvement of allwithin an organisation.• Employees will be disciplined to follow safer and better ways of work,resulting inlesser risks to accidents.• Employees would be more conscious of improvement which leads to greaterefficiency and effectiveness.
28From Machines and Tools :• Machine troubles can be detected at an earlier stage to prevent a majorbreakdown, when machines are cleaned daily by people operating them.• Daily cleaning of measuring instruments will ensure accuracy and reliability.• Life of machines and tools can be extended significantly when they are handledwith care and placed in the designated locations.From Materials and Work –in –Progress :• Flow of materials and work-in-progress will become smoother.• Floor space will become organized and possible areas for improvement can beeasily identified by quick observation.• Inventory of materials and work-in-progress will become clearly visible and easilyhandled.• Material yield ratios can be improved
29From Products and Customers :• Clean workplace will ensure that final products will be free from dust.• Sales people will be eager to show customers the plant as a marketing tool.
30Housekeeping to Happiness• Housekeeping means Orderliness• Orderliness leads to Cleanliness• Cleanliness leads to Quality• Quality leads to Productivity• Productivity leads to Prosperity• Prosperity means Happiness