2. 1.T5S Activity (Overview)
Basically refers to overall 5S activities in a field. This activity is to improve
and maintain not only the existing 5S activity but also 3R and visual control
parts.
This activity shall satisfy the followings in comfortable circumstances:
① To create an exciting company atmosphere,
② To make a business easy based upon above conditions, and
③ To increase productivity and quality.
Also,
The most important points are improvement and maintenance which not
returned to the original condition.

3. 2. 5S Activity (Concept)
This refers to a basic activity for creating an exciting and
comfortable atmosphere for the production activity, and means
a breathing movement of a factory as a basic stage for an
improvement, and a movement carried out by “3 I & 3 C” principle.
Shitsuke
▣ Environmental improvement
in factory, improvement of
production and quality
1. Quality Obtainment
2. Reduction of cost
3. Improvement of
productivity
4. Increase of Innovation Mind
Seiri
Seiton
Seisoh
Seiketsu

4. 2. 5S Activity (Concept)
1. Be sure to maintain Seiri and Seiton
to allow everyone to identify easily
necessary things.
2. Propel 5S through participation in of
all Members.
3. 5S is a foundation for discovering
trouble or loss.
Be sure to unify 5S with improvement
Activity.
One of the most basic tools for living of field quality innovation
Seiri
Seiton
Seisoh
Seiketsu
Shitsuke
To dispose unnecessary things immediately by
classifying necessary and unnecessary things.
To show necessary things in designated
place for allowing that to be identified and
used easily by everyone.
To make a work field clear by removing dust,
contamination, foreign materials, etc.
To maintain and improve 3S activities of Seiri,
Seiton and Seisoh.
To make oneself familiar with an attitude to
obey learned matters and designated matters.
Improvement PointImprovement Point
Yes! This is the
first step for obeying
the basis.

5. Material
Environment/
Product Quality
Work
Method of Work
Office Division
Office
Conference table,passage,conference
room,scrubbing things,Window,wall,ceiling,
lighting, dressing room,toilet,welding room
Office Supplies
Office machine, desk, drawer, chair, telephone,
cabinet, clock, blackboard, waste basket
Document
File,drawings,regulation,standard,
various standards, various forms
Field Division
Field
Work table,passage,desk,cabinet,
lighting,Window,entrance,wall,pillar,
scrubbing things,dressing room,toilet
Equipment
Jig and Fixture
Conveyor,machinery,mold,equipment,
jig and fixture,tool box,truck,forklift
Material Parts,
Document
Material,part,product,document,drawings,
work standard,file
Etiquette,
Observance of
Regulation, Rule
Bow,costume,designation marking,
telephone response,vending machine
use,Document preparation,
factory guide for visitor
Observance of
Safety & Work
Standards
Safety rule,putting on safety device,work
Standard,work instruction observance,
smoking place observance
Punctuality
Attending and leaving the office,
conference time,break time,
time of opening and closing of office
2. 5S (Object of Activity)

6. 2. 5S (Activity Order)
Seiri
Seiton
Seisoh
Classification of necessary and
unnecessary materials
Removal of unnecessary material
Exclusion of surplus holding
material
Designation of depot for
nonconforming product
Arrangement of processing tools
(Mold included)
Arrangement of cutting tool
Arrangement of measuring
instrument and measuring jig
Arrangement of work in-process
Arrangement of raw material
and part
Arrangement of lubricant
Cleaning
Isolation of dust cause
Cleaning and Inspection of
equipment
Clean
Maintenance
Improvement
Shitsuke Settlement
5S
Object
Scope

7. 2. 5S (Requirements for Success of Activity
Total Participation
Seek control, leadership of
supervisor and total participation
bottom-up for importance of 5S.
Autonomous Performance
Attempt the complete performance
for planned things by means
of role play clarification and
formalization.
Creativity
Create the creativity of workshop
such as QC, IE, VE, etc. based on
5S.
Shitsuke
Seek settlement of 5S by making a
point of observing the regulated
things.
Responsibility
Seek an increase of workshop
control level by acting with overall
responsibility.

8. 2. 5S (Role (Manager / Supervisor)
Behavior
Instructions
Behavior
Instructions
Take the initiative and set an example for others.
If others failed to observe the rule, take corrective action to have them
observe it for them on the spot. - It is important to make them observe
the rule on the spot even though the subsequent work stops.
Expose problems by going around every corner of a work field everyday.
Determination for 5S propelling
Establishment of 5S propelling plan
Obtainment and determination of time of 5S activity
Obtainment and determination of space required to a minimum
for 5S propelling
Preparation of overall rules and check list related to 5S
Preparation and determination of classification standards for acceptable
product, not-required product, unacceptable product by going around
Carrying out 5S related training and guidance to worker
Coordination of department concerned(Role Play)
Key RolesKey Roles

9. 2. 5S Role (Worker)
Be sure to observe the regulated rule.
Understand, in connection with waste of production,
why do that should be observed.
If required, immediately report to a superior official to take
suitable actions.
Carrying out of 5S activity in a district(facility) assigned
Recommendation of practical problems improvement
Field improvement for 5S can not be achieved so easily.
Important thing is a top’s strong will of “must do it” and certain
practice ability in a field of “let’s do it in advance”.
For this, a company must propel it in a body.
Thus, improvement(team) activity is required.
Discovery of problems and improvement review for that
Improvement review and performance
Behavior
Instructions
Behavior
Instructions
Key RolesKey Roles

10. 2. 5S (Necessity of 5S and Its Effect)
eral, a factory of higher level has good conditions of arrangement, cleaning and order.
a means to make comfortable factory.
his is a technique to isolate sources generating a lot of troubles caused by unnecessary,
niform and unreasonable matters in a factory.
Trouble occurs to accuracy control.
30 minutes to find anything are not important for wait time taking several hours of the day, but
3 minutes can be fatal for production of supplied product .
It is impossible to take concurrent operating multi processes if a lot of troubles occurs to
equipment.
Surplus tenement still exists in a place where can not be seen.
Various wastes (stock, quality deterioration, efficiency deterioration, cost rising) can not be seen in
factory where does not carry out 5S activity well.
◈ Necessity of 5S
◈ Improvement in Quality
◈ Reduction of Ready Time
◈ Equipment Protection
◈ Minimization of Inventory
◈ Increase of Waste

11. 2. 5S (Necessity of 5S and Its Effect)
fect of 5S
kes much time to carry out 5S activity. It is required to take preventive actions
preventing comparatively relative large waste or loss. Various effects such as
ovement in quality and productivity, removal of waste, stock control, safety
rol, etc. can be taken by carrying out 5S activity in cases that it takes much time
nd out product or part caused that 1 minute was saved to arrange the product and
part, and product gets rusty caused that anti-corrosion process was not be taken,
so forth. Also, clean and comfortable work circumstances can give effects as
ows:
① To die down unrest caused by even small defects and minor failures,
② To ensure good feeling, low fatigue and increased efficiency by means of clean
and comfortable workshop where you spend most of the time of the day in,
③ To form high reliability between customers and job seekers, and
④ To assure company development and personnel growth.

12. 2. 5S ( What is our changed figures? )
ShitsukeShitsuke
SeiriSeiri SeitonSeiton
SeiketsuSeiketsu SeisohSeisoh
Classify clearly
necessary and
unnecessary things
and throw away
unnecessary
things.
Store the necessary
things properly to
be used and seen easily
by everyone.
Keep 3S activity of
Seiri, Seiton and
Seisoh.
Always keep work
circumstances clean.
Accustom yourself
to observe the specified
things at all times.
Development
In Quality
Reduction
Of Cost
Delivery
Date
Observance
Development
In
Safety
Batch
Production
Development
In
Operating
Rate

13. 3. 3R
This refers to a tool to ensure that Right amounts can be stored in Right container in
Right location at all times.
Right
Location
Right
Container
Right
Amounts
Allocation of
Location
Signboard
Attachment
Size Classification
by Parts
Classification by
Part Features
Box
Standardization
Packaging Form
Classification by
Container
Determination of
Max/Min
• Allocation by classification forms (part, product)
• Allocation by using interval (store,depot)
• Subsequent process information share
(Visual Stock Control)
• Presentation of Classification Move
(First-in First-out)
• Iron Basket,Plastic,Adhesive Pallet
• Large, Medium, Small parts
• Carrier Box
• Logistics moving amounts
• Worker Usability
• Box: Indication of quantity by Bundle and bag,
and total quantities of boxes
• Carrier: Indication of piece quantity
• Large Part: Quantity required for 10~30 min.
• Small Part: Quantity required for 2~4 hr.
• Time required for minimum movement
considered
• Quantity allocation by area unit

14. 4. Visual Control
This is to allow trouble to be identified visually by everyone.
Tool for
Visual
Control
Indication of Location and Goods Depot
(Place to go to take goods)
T/Time Indication
Productivity Control Table Per Time
(Status of Production and Input)
Notice of Standard Work Instruction
(Work Order, Inspection Contents, Standard Quantity
In-Process)
Signboard(Right Position Signboard, Part Table)
Alarm Lamp for Abnormal Conditions
Identification Marking

15. 4. Visual Control
① Are there any tools to identify the troubles as seen by naked eyes
in your field?
② Are those tools structured to be identified easily by everyone(including
personnel who is not concerned in the matter).
③ Can everyone visually identify the production status if approaching to the
production line right now?
④ Is a system structured so that the contents and corrective actions for
quality defectives can be identified by everyone if the quality defectives
are occurred?
⑤ Can personnel in charge of clean-up be identified if it fails to clean
every corner in a factory?
⑥ Is a monthly improvement plan established and operated, and also is the
progressive status controlled with a method of color marking, etc.?

16. 5S - Image by step
Image
Ⅰ Step Ⅱ Step Ⅲ Step Ⅳ Step Ⅴ Step
Sequence
conditions
5 S 3 C Visual management
Seiri Seiton Seisoh Seiketsu Shitsuke
Correct
position
Correct
container
Correct
volume
Remove partition,
In a straight Line
Current production
state board
Error
alarm
Organizing of
needed items is
performed
- Cleaning rules
(objection to be
cleaned, a person in
charge, time, cycle,
check points) are
regulated, and
autonomous check and
evaluation are
performed
- Public facilities (toilet,
lounge, dressing room)
are kept in clean state
- Floor and outer of
factory are kept/
managed in clean state
- Cleaning tools are
provided
- Cleaning is
performed with
cleaning cycle and
object not clear
- Jig & Fixture kit is
open and arranged
in place easier to use
- Needed items and
unneeded items
divided and the latter
is removed
- Ceiling or steam pipe
of wall face is
preserved in clean
state
- Even hidden places
are being cleaned
- Workplace Image is
smart, continuous
environmental
improvement activities
Are performed
- Cover is transparent
enough to see the
inside, and cleaned
- The results of actions,
associated with
improvement activities
are appeared
gradually
- Events are held
regularly to promote
attitude of activities
- The whole employees
are satisfied with work
environment, and have
self-confidence
- There is long term
environment plan, and it
is carried out as
scheduled
Person in charge of
cleaning is designated
and individual autonomy
management is
performed
Periodical management
is performed,
even though hidden place
The entire of factory is
maintained cleanly by
habituation of all
employees

17. 3C – Image by step
Organized so that
Workers can
handle easily
Passage/Depot
are divided
Organized to be able
to see what is in
where
Organized to allow
first-in first-out
Image
Ⅰ Step Ⅱ Step Ⅲ Step Ⅳ Step Ⅴ Step
Order
Conditions
Operated according to
3C operation basis;
- continuous version up is
performed
- There is operation basis
so that 3 C can be
obeyed
- There are Correct
position markings of
workbench or parts
mounts by line process
- Being marked in order to
be able to things (parts)
that is under the control
within district
- Basis of division per
district is set up
- Places for lay
parts(things) on are
set and divided
- Basis that controls the
height of storage
presents
- Be organized to be
able to use parts in the
order of their
warehousing
- L/No is specified and
organized to be able to
handle easily
- Correct part/ defective
part/ remains are
classified and
controlled
- Organized to be able to
store Jig/tools as open
type
- 3C has habituated and
maintained
- Continuous improvement
Activities, connected with
material handling
Improvement proceeded,
and effect of improvement
realized
- Standardization/ using
in common of
container are
proceeded
- Be managed to be able
to see the change of
inventory
- Container becomes
Standardization/
common in use and is
made of usable
structure
5 S 3 C Visual management
Seiri Seiton Seisoh Seiketsu Shitsuke
Correct
position
Correct
container
Correct
volume
Remove partition,
In a straight Line
Current production
state board
Error
alarm

18. Visual management - Image by step
Visual marking is made
to parts/equipment/
districts
Attachments such as
Current state board is
replaced and
controlled regularly
Organized to be able to
see the abnormal
conditions
Organized to be able to
share production/ quality
situation
Image
Ⅰstep Ⅱstep Ⅲstep Ⅳstep Ⅴstep
- Current state board is
controlled regularly
- Attachments are
replaced regularly,
and shared by
employees
- Able to see work
guide, sequential
inspection, and
production plan by
time zone to actual
result loss
- There is marker that
allows visual
management
- Nameplate
recorded/controlled
regularly.
Power Distribution
panel, S/W/
equipment name
CTQ process, Time
Check
- Alarm lamp is
installed and used
- Be operated so that
upon changing 4M,
anyone can know it
(Process signboard
etc.)
- Rules about 4M
change are
managed, especially
changed process is
managed
preponderantly
- Production/quality
situation shared, and
current Mfg. state
board is operated
- Rreconsideration
meeting
reconsideration
meeting is held
regularly, and
situation of abnormal
symptoms is shared
- RTY system is
established, and data
upgraded regularly
Order
Conditions
R/time of information on
abnormal conditions
is shared and processed
quickly
- R/time on Error is shared
and linked to
Improvement Activities
- Be systematized so that,
upon abnormal conditions
occurring, anyone can
realize it and it shall be
not reoccurred
5 S 3 C Visual management
Seiri Seiton Seisoh Seiketsu Shitsuke
Correct
position
Correct
container
Correct
volume
Remove partition,
In a straight Line
Current production
state board
Error
alarm

19. 1 5 S Seiri
:To dispose unnecessary
things immediately by
classifying necessary and
unnecessary things.
1) Objects :
① JIG and molded mount Tool kit,cleaning tool kit②
③ Indoor and floor
④ Original/subsidiary materials warehouse
⑤ Factory outer office⑥
2) Progress activities according to a management basis by
section → Division/item name/department/reason should be
specified
- Red Card
(division, item name,
department, attachment
reason, attachment date)
Seiton
:To show necessary things in
designated place for
allowing that to be identified
and used easily by
everyone.
1) Organizes needed things
2) Checks storage place
3) Determines storage place: using easier method to follow
4) Marks storage place: position, item name
5) Maintains/checks: marking visibly
(marks in thing itself or classifying using color)
- Designates storage place
for defective products
- Performs 3C
Seisoh
:To make a work field clear
by removing dust,
contamination, foreign
materials, etc.
1) Uses a broom(prepare cleaning tools)
2) Arranges section line: passages, floor lines of correct position
① Passages: straight lines,passing direction marking
② Entrance:dotted lines Position lines:place designation③
④ Designation of line thickness and color
3) Remove and improve the causes of dust or dirt: oil leaks, piping
leaks, particle blowing
4) Thorough cleaning: cleaning of oil soaked into floor, painting,
wall, stepped area
- 5S MAP
- Signboard to divide 5S area
- Cleaning rules :
Designating a person in
charge of cleaning,
method, tool, location,
period (time)
Seiketsu
:To maintain and improve
3S activities of Seiri,
Seiton and Seisoh.
1) Periodic check and evaluation of clearing-up, organizing or
cleaning status
2) Selects and executes continuously a month key theme ex) floor
cleaning
3) Checks the causes of dilapidation : is it too complicated ?
Is it too distant?
Does not it move back against work action?
4) Filming of the pictures or VTR of dilapidated place.
- 5S evaluation
Shitsuke
:To make oneself familiar
with an attitude to
obey learned matters and
designated matters.
1) Leader’s leadership
2) Proceeds activity on a principle that total personnel attend
NO. Purposes Remarks
T5S methods
Items Contents

20. 2 3 C Standardization of how
to place things
Where … Correct
position
What … Correct thing
(Correct container)
How much … Correct
volume
1) Uses signboard so as to be able to know place and amount of
parts correctly
2) Regulates amount of stock: marking of load height, amount
(max,min)
3) Attaches item name and ID card to each part and thing
4) Standardization of used container (size,amount etc)
5) Clears up of JIG tool – Piling table open/drawer-in
arrangement
6) Storage place is marked with line, positioned so as to be able
to search easily like supermarket
- Signboard
- Standardization of
container
- Connected with material
handling improvement
activity
To perceive abnormal
conditions of working field
quickly, to restore in normal
conditions and to minimize
loss
1) Indication light
①Call indication : Demand of parts
②Abnormality indication : Indicates situation of assembly
line, abnormal assembly state etc.
③running indication : Indicates production situation/
machine running
④Progress indication : Indicates work progress
2) Signboard : Attaches and manages signboard periodically in
order to be able to know 4M change etc.
3) Defects indication : Attaches/positions markers in a such way
that positive/negative distribution within process is definite
4) Production management : Indicates productive situation of line
①Plan/result management
5) Attaches and manages the signboard about how to work
equipment
- Error Alarm
- Current state board
- Work guide/new process/
sequential inspection card
etc.
- OS&D Table,TAG
District division indication
- Current state board of
Production management
- Plant check table (lubrication
record table etc.)
3 Visual
management
NO Purposes RemarksItems Contents
T5S methods