5S Manual with 8 benefitsof it

1. 5S
LET US MAKE 5 S THE BASIC
WATCH WORD IN THE WORK PLACE

2. WHAT IS 5 S ?
5 S CAN BE DEFIND AS
1. SEIRI: SORTING
Sorting means removal of unnecessary elements from
workplace.
• Look around your area and ask yourself ‘Is it really
necessary for all items to be there’
• Separate ok, rework able and rejected items.
• Rework the rework able items and dispose off rejected
items.
• Remove waste /old(unnecessary ) records / materials etc.

3. 2. SEITON : SYSTAMATISING
Systematizing means arranging things in order of their
requirement.
• Fix a place for everything & keep everything (materials in
its place).
• Fix locations for placing items / materials as per needs so
that they are easily accessible & easily used.
• Label the items properly so that they can clearly identified.

4. 3. SEISO : SWEEPING
Sweeping means cleanliness and neatness in the factory.
• Cleaning of workplace /machines / racks etc. by self.
• Machine oiling / dust & dirt removing.
• Marking & paint of gangway.
• White washing of walls / painting of structures.
• Painting of racks /work tables / benches /doors etc.
• Tidiness – proper lighting / wiring / fitting etc.
• General replacements & repairs of damaged items /
fittings/floor etc.

5. 4. SEIKETSU : SANITIZING
Sanitizing means system to keep SEIRI ,SEITON & SEISO
operative.
• Even a clean workplace with proper arrangements will
soon become dirty if SEIRI , SEITON & SEISO not
continuously repeated.
• Make methods & procedures for removal of rejected,
unnecessary materials from workplace, for systematic
arrangement (House keeping) & general cleanliness.
• Make action plan with time frame for implementation.
• Train, educate and involve people in implementation.
• Document the procedures & give complete instructions
with flow-charts, checklists etc.
• Divide the activities for cleanliness & upkeep in daily,
weekly, monthly & yearly basis and carry out religiously.
• Continuous inspection (Internal audit) of the above.

6. 5. SHITSUKE: SELF DISCIPLINNING
Self Discipline means stick to self-disciplining
• Follow voluntarily the rules & procedures made for SEIRI,
SEITON & SEISO.
• Self example for self discipline.
• Adhere to timings & follow prescribed operation
standards, work instructions etc.
• Have inner feel for 5 S and enjoy in practicing it.

7. THE 5 S CONCEPT – EIGHT IMPORTANT BENEFITS
BENEFIT 1: -
Enhanced efficiency and cost reductions - Zero inefficiency
• Elimination of excess work – in – process inventory.
• Elimination of excess storage space such as in warehouses, or shelves and
in cabinets.
• Elimination of excess pallets, trucks and fork – lift trucks.
• Elimination of unused space and equipment.
• Elimination of unnecessary looking, evasion and avoidance.
• Elimination of activities such as fetching, placing, counting and carrying that
have no value.
BENEFIT 2: -
Enhanced safety – Zero accidents
• With well – looked – after machinery and equipment, it is easy to detect
problems and dangers.
• Sufficient passageways and rest areas can maintain by having clearly
arranged storage areas.

8. • Goods can be prevented from collapsing if safety is taken into consideration
when they are stored.
• If fire extinguishers and escape exits are clearly marked, the impact of
unforeseen disasters, such as fires and earthquakes, can be reduced.
BENEFIT 3: -
Enhanced maintenance – Zero breakdowns
• Trash, dirt and dust are the arch enemies of machinery and equipment and
greatly reduce their life
• You can judge the condition of a machine easily if filings, sward and oil
leaks are eliminated and the machinery is cleaned regularly.
• Breakdowns can be prevented by daily inspection and servicing.
BENEFIT 4: -
Enhance quality – Zero faults
• If faults occur in dirty worksites, they are inconspicuous, but they will be
easily spotted in a clean, well – ordered workplace.
• If specified objects from specified locations are used, parts discrepancies
will not occur.

9. • A clean worksite raises the consciousness of the work force with regard to
production.
• This proper storage of measuring equipment and inspection machines for
maintenance of quality is a prerequisite for zero defects.
BENEFIT 5: -
Diversification – Zero steps
• The proper organizing of molds, jigs and tools eliminates the inefficiency of
“ Searching”
• Immaculate machinery and clean worksites are the key to greatly –
enhanced work efficiency.
• With the thorough incorporation of the 5 S strategy, a worksite can be
established with which even trainees can become familiar immediately.
• No more use of wrong fixtures.
BENEFIT 6: -
Pleasant surroundings – Zero stress
• In work areas where there is trash and dirt, people experience stress.
• In workplaces where the 5 S strategies have not been introduced,
absenteeism is high.

10. • If the work force embraces the 5 S strategies, there is great activity.
• In factories where anyone can see clearly what is going on, there is
motivation to work efficiently, constantly and effortlessly.
BENEFIT 7: -
Enhanced reliability – Zero complaints
• Products from a clean factory have no faults.
• Products from a clean factory are not excessively costly.
• Products from a clean factory never fail to meet deadlines.
• Products from a clean factory have no defects.
BENEFIT 8: -
Corporate growth – Zero deficits
• People who work according to the 5S Strategy are lively and trusted by the
people in the community.
• The customer is satisfied because there are no inefficiencies, no injuries, no
breakdowns and no defects.

11. • The factory will grow if sorting, systematizing, sweeping, sanitizing and
training & discipline are well established and become second nature to the
workforce.
HOW TO ACHIEVE ‘5 S’ :-
5 S can be achieved very easily by every employee by having a close look at his
work place . He is to ensure that
1) No rejected / unwanted items are lying at his workplace.
2) All items are kept in proper locations / order.
3) Everybody should co-operate each other in keeping his and other’s area and
the machines clean.
4) Follow the rules and regulations and maintain required standards.
PLEASE CHECK :
1) Do you have any unuseful thing around you ?
2) Are all the required things kept at their allocated places ?
3) Are you following the timings?
4) Are you following the operation standards ?
5) Let us all review 5 S ?