Is a participative programme.
It is a very effective approach to improving
our work,environment and total quality.
It becomes a base for continuous
improvement in the organisation
5s is a systematic approach to good
It is today gaining strong support in most
industries, especially in Japan and there
are increasing number of companies
which are implementing 5s with greater
involvement of people within the
Why is it becoming popular among
companies in Japan? Simply because:
1. Workplace becomes clean and better organised
2. Shopfloor and office operations become easier and
3. Results are visible to everyone insiders and outsiders
4. Visible results enhance generation of more new
5. People are automatically disciplined
6. People become proud of a clean and organised
7. Resultant good company image generates more
Some significant benefits observed
at companies practising 5s include:
1. Happier employees with high morale.
2. Greater people involvement.
3. Low employee turnover.
4. Increased number of suggestions.
5. Better use of floor space.
6. Less work-in-progress and inventories.
7. Better flow of work.
8. Low machine breakdown rates.
9. Low accident rates.
10. High yield of materials.
11. High product quality.
The assumption why 5S is becoming so
popular in Japan in recent years and in other
countries today is that it emphasizes a people-
oriented and also practice-oriented approach.
5S expects everyone-indeed everyone-to
participate in it.
It is based on the belief that every individual
can contribute to improving his/her workplace
where he/she spends one-third of his/her life.
What is 5S?
The concept of good housekeeping has been with the
Japanese for a very long time.At home and in school
,children are disciplined to adhere to good housekeeping
practices.However, it was only in the early 1980s that
good houskepping became a pertinent issue in Japanese
industries as companies realised its powerful contribution
to productivity and quality improvement.
The basis for good housekeeping in Japanese
companies is a concept popularly known as 5S.This
stands for the five good housekeeping concepts in
Why a “5-S”movement
1. Human beings feel good if work place is clean and well
2. Helps in reducing time
a. For searching things
b. For handling
3. Helps in reducing
a. Waste, inconsistencies & strain
b. Unnecessary items & reserve stock
c. Space requirement
d. Machine downtime
e. Rejection / Rework
f. Number of accidents
a. In seeing things more clearly
b. In changing mindsets-develop a proactive attitude
Meaning of “5S”
1. Segregation (SEIRI)
2. Arrangement (SEITON)
3. Cleaning (SEISO)
4. Maintenance of standards (SEIKETSU)
5. Discipline (SHITSUKE)
What is 5S??
5S Original Japanese Meaning in English
1S SEIRI Sort out unnecessary items in the workplace
and discard them
2S SEITON Arrange necessary items in good order so
that they can be easily picked for use
A place for everything
Everything in its place
3S SEISO Clean your workplace thoroughly so that
there is no dust on floors,machines and
4S SEIKETSU Maintain high standards of workplace at all
5S SHITSUKE Train people to follow good housekeeping
It helps to segregate necessary and unnecessary items
and eliminate unnecessary items. It essentially means
organising / putting things in order.
1. Go through what you have
2. Segregate/identify what you need
3. Categorise needed/not needed items
4. Discard What Is Unnecessary
INDICATOR OF SUCCESS
1. Decrease in unnecessary items and reserve stock
2. Percentage of area / space saved
Arrangement --- SEITON
This step essentially means arranging items efficiently,for
easy accessibility and using them in best order
1. Set things in order by creating a place for everything.
2. Put everything in its place
3. Keep accessibility as easy as possible.
4. Use the principle of wide range and shallow depth for
INDICATOR OF SUCCESS
1. Time saved in searching
2. Time saved in handling material
How to promote good order
Putting in order
Things needed Things not needed
But still needed
Place as close
Place as close
Place a little
Enclose in a sepearate
usefull and move
to designated place
This step eliminates dirt, dust and other foreign
matter to make workplace clean and polished.
1. Clean equipment, tools, furniture, records,etc.
2. Keep the workplace spotless
3. Sweeping, wiping, polishing, painting,etc.
INDICATOR OF SUCCESS
1. Reduction in machine downtime
2. Increased life of the machine parts
3. Reduction in number of accidents
4. Reduction in rejection / rework
Maintenance to standards ---SEIKETSU
This Step is Combination of segregation (seiri),
arrangement (seiton) and cleaning (seiso). As as,an
on-going programme to maintain a clean and well –
1. Create standards and initiate steps to maintain them
2. Devise ways to
a. Expose hidden problems
b. Surface abnormalities
3. Create visual control systems
Indicator of success
1. Number of areas / covers made transparent
2. Number of new problems exposed and solved
What is an Abnormality ?
An abnormality is any gap between actual performance
and the appropriate standard
What is the visual control ?
A visual control communicates required important
information to people who need it.
It grabs one or more of our senses in order to :
Alert us to an abnormality
Help us monitor quickly
Promote adherance and prevention
Enable successful self management
Reduce errors / waste by making problems visible
Identify gap between standard and actual performance
Help in early identification of problems
Visual control system
A 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
1. Illustration of correct manual operation
2. Part containers colour coded to match the parts
3. Red colour light above the line that goes on when
help is needed
Important Points for preparation of
1. Easy to see from distance
2. Easy to understand
3. Ensure correct location/ placement
4. Use colours for brightness/contrast
Important areas of visual displays
1. Instructions to people to avoid “OPERATION ERRORS”
2. Danger alerts/cautions
4. Equipment Designations
5. Planned programmes
6. Preventive maintenance/Calibration displays
Discipline --- SHITSUKE
This step is to ensure that everyone sticks to the
rules scrupulously and makes it a habit
Create general awareness about 4S
Training to everyone
Share success to get more enthusiasm
INDICATORS OF SUCCESS
High employee morale
Involvement of people in the movement
The Elements of “5S”
O RG ANISING /PUTTING
things in order sorting
1.Rem oving what is not needed
2.Keeping what is needed
Keeping things clean and
polished,No trash or dirt
anywhere in the workplace
ARRANG EM ENT
Placing things so that people
can easily reach what they
need whwnever they need it
M AINT.O F STANDARDS
M ainting cleanliness after
organisation ,arrangem ent
and cleaning and establishing
Adherance to standards developed
through 4S steps by allem ployees of the
5 Levels of housekeeping
1. Horizontal surfaces/floor full of unwanted material.
2. Vertical surfaces / areas near walls having clutter.
3. Horizontal ,vertical surfaces clean and have no unwanted
items.However,storage areas, record rooms disorganised.
4. Storage areas ,machines,offices are clean.All materials
,furtinuture,documents properly organised,labelled and
5. Factory/office is immaculate at all times.
Level 1 of Housekeeping
Work area is in level 1 of housekeeping if,
Cigarette butts/Gutkha pouches
Scraps of paper
Tools (Used or Unused)
Packing and clamping materials
Left -over raw material
Unused equipment,machine etc
are scattered around all over the workplace.
Corrective action for level 1
Look at all horizontal surfaces
Examine the entire work floor.Eliminate all garbage and
non- 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 the floor tabletops
HINTS FOR IMPROVEMENT
Do not put anything directly on the floor
As much as possible, throw/dispose off things that have no
clear foreseeable use.
Level 2 of housekeeping
Work area is in level 2 of housekeeping if there is no litter or
unused material on the 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
Corrective 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 hand
Hint for improvement
Divide responsibilities (For area and walls)
Level 3 of housekeeping
Work area is in level 3 of housekeeping if the walkways are
clear and the factory/office is clean,but the
tools,materials,papers and files are still disorganised 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
Corrective 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
Make the above area distinct and clear
HINT FOR IMPROVEMENT
Remove the back and sides of all the storage cabinets
Level 4 of housekeeping
At 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
Tools/files are colour coded and numbered
Further improvement at Level 4
Clean ,straighten and organise automatically
Storage system designed for “First In First Out”
Develop other visual controls
Hints for improvement
Scrap and chips should fall directly into waste
Make a model line with super market type display
of parts and tools
Well defined scrap & waste collection & disposal
Level 5 of Housekeeping
At level 5,the work place is immaculate at all times.It
Constant and continual cleaning by all employees
Origins of rubbish are removed so that dirt,clutter and
garbage are eliminated at source
Tools,items and materials can be found at a glance
Inventory levels can be found visually
Production runs smoothly
High product quality achieved
In third rate workplace ,people leave trash and
no one stops to pick it up
In second rate workplace, people leave trash but
others pick it up
In first rate workplace, no one leaves trash,but
people would pick it up, if they saw it.
What does 5(S) require?
Consciousness revolution through,
3. Constant efforts
1. To see / judge what is important
2. Attention to details
Continuous implementation through
Total participation by all employees
8 crucial points for successful
implementation of 5S
PARTICIPATION BY ALL PEOPLE
5S programme should be participated by all People in the
One day should be set aside for the launching of the
6 objectives or why’s of 5S programme should be
understood by all people in the organisation,
1. A clean workplace is high in PRODUCTIVITY
2. A clean workplace has high QUALITY
3. A clean workplace keeps COST down
4. A clean workplace ensures DELIVERY on time
5. A clean workplace is SAFE for people to work
6. A clean workplace is high in MORALE
The programme would be more effective when it is
included in the small group activities like Quality Circles.
The programme requires top
The programme should be practised during
working hours as an authorized programme,but
should not be treated as casual or extra activity
during overtime or off duty hours.
Everyone should be officially informed of the
significance of the programme.
The CEO should personally make an official
announcement of the launching of the programme
at an information sharing meeting attended by all
people of the organisation.
The CEO should take leadership of
The CEO himself should be keen and committed
and have a vested interest in the programme.
The CEO should not delegate the leadership to
The CEO should exercise his leadership in 5S
The programme should be
supported by all
Such doubts “Why are the disposal notices posted for
SEIRI ? ” “ Why is 5S improvement for shopfloor
improvement?” should be eliminated.
Each committee member should keep everyone informed of
the current progress of 5S implementation on a
Each committee member should encourage and guide his
people for involvement in 5S implementation activities.
5S Programme should be self- sustaining
Banners,slogans,posters and newsletters should be fully
utilized to draw attention of everyone to this programme
An easy handbook or a pamphlet illustrating “Why 5S”
“What is 5S” and “How to implement 5S” should be printed
and distributed to everyone.
Periodic 5S implementation review should be conducted by
CEO or an external expert for comments and updating the
Basic in-house training and introduction to model
companies that have successfully implemented 5S
practices would not only provide the necessary skills but
also give an insight into how other companies implement
After the company has attained a certain level of
implementation,participation in “Inter- company 5S
competition” should provide greater motivation for further
The CEO should make a periodic factory
tour in person
The CEO should tour the factory from time to time
and point out strengths and weaknesses of 5S
implementation in each workplace.
The CEO should advise 5S steering committee to
take corrective action in the areas identified.
The CEO should check the progress of the
The CEO should give recognition to improved or
The programme should generate
sufficient impact at the initial stage
Slow implementation of decisions by the 5S
steering committee should be avoided.
“Disposal notice” approach for SEIRI which is the
first step to 5S should especially be implemented
company-wide for a specified time before
proceeding to SEITON which is the second step for
Implementation of 5S should go hand –in –hand
with other Kaizen programme
5S especially at SEITON requires certain Kaizen principles and skills
which can be acquired via external or well organised in-house training
SEITON requires logical problem-solving approaches.In this sense,it
can well be a good theme for Quality Circle activities.
SEITON also requires creative ideas from everyone.Therefore,it can
be tied in with and employee suggestion scheme.
Successful implementation of 5S will,by itself,bring about various
tangible results.It is also a necessary step for a company to go through
before implementing advanced management technologies such as
TQC,JIT and TPM because 5S buildsup a solid foundation for
Tangible results expected from 5S
Employees will be disciplined to be more aware of untidy
workplace and motivated to improve the level of
Greater team spirit and co-operation can be built up
through involvement of all within an organisation.
Employees will be disciplined to follow safer and better
ways of work,resulting in lesser risks to accidents.
Employees would be more conscious of improvement
which leads to greater efficiency and effectiveness.
From Machines and Tools
Machine troubles can be detected at an earlier
stage to prevent a major breakdown, when
machines are cleaned daily by people operating
Daily cleaning of measuring instruments will
ensure accuracy and reliability.
Life of machines and tools can be extended
significantly when they are handled with care and
placed in the designated locations.
From materials and Work –in
Flow of materials and work-in-progress will become
Floor space will become organised and possible areas for
improvement can be easily identified by quick observation.
Inventory of materials and work-in-progress will become
clearly visible and easily handled.
Material yield ratios can be improved
From 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.
Housekeeping to Happiness
Housekeeping means Orderliness
Orderliness leads to Cleanliness
Cleanliness leads to Quality
Quality leads to Productivity
Productivity leads to Prosperity
Prosperity means Happiness