The document describes the 5S methodology, which consists of 5 steps - Sort, Set In Order, Shine, Standardize, and Sustain. The methodology aims to create a clean, well-organized, safe work environment through eliminating unnecessary items, properly storing and labeling necessary items, cleaning the workplace daily, standardizing processes, and sustaining these practices over time. Implementing 5S results in increased workspace, higher productivity, and improved safety. Each of the 5 steps is then further explained in detail, outlining the goals, key activities, success indicators, and checklists for evaluating implementation of each step.

1. “5-S METHODOLOGY”

2. • 5S is an approach originally developed in Japan for better
house keeping. Now it is been utilized for keeping better work
place.It includes 5 steps which are to be followed sequentially.
• Following Japanese terms collectively are as called 5S
• 1S - Seiri or Sort
• 2S - Seiton or Set In Order
• 3S - Seiso or Shiny Clean up
• 4S - Seiketsu or Standardize
• 5S - Shitsuke or Sustain
• By Implementing 5S one will get to know how cleanliness,
orderliness, safety practises and better work environment
results in increased free space, higher yield and transparency
in work.

3. REQUIREMENTS OF 5S
• To implement 5S following are the requisites
1. Consciousness for
a. Strong determination
b. Training
c. Constant Efforts
2. Ability to
a. Judge what is important
b. Attention to details
3. Continuous implementation through total employee
participation and better communication

4. 1ST ‘S’ – SEIRI OR SORT
Step 1 : Tagging the following
a. Not needed at all
b. Needed But Not Now
c. Needed But Not Here
d. Needed But Not So Much
Quantity
Step 2 : Entry in Red tag Register
Step 3 : Assign Red Tag area and
dump the scrap
It aims at taking out unnecessary items and
dumping it into garbage(i.e Red Tagging)

5. Action during Seiri

6. KEY INDICATORS
Indicators of success
1. Decrease in unnecessary items and reserved stocks
2. Reduction in sq.ft area consumed
Checklist –
• Do you find items scattered in your workplace?
• Are the boxes ,papers and other items left in a
disorganized manner?
• Are there equipment and tools on the floor ?
• Are all items sorted out and placed in designated spots?
• Are tools and stationary properly sorted and stored ?

7. RESULT FROM SEIRI
Created
free space

8. 2ND ‘S’ – SEITON OR SET IN ORDER
• It aims at arranging the necessary items in proper
order so that they can be easily picked up for use
• Steps for Seiton
1. Systematic Arrangement is a form of standardization
2. 3 Keys are the basic rules for Storage
3. Fixing Position
4. Fixing Quantity
5. Signs for Storage of Work-in Progress

9. SYSTEMATIC ARRANGEMENT
KEYWORD 3 POINTS 3 KEYS
- Anybody
- Immediately
1. Can see
2. Can take out
3. Can return
1. Where?.. Fix position
2. What? …Fix items
3. How many? Fix quantity
3
KEYS
It answers the question
What items are to be kept ,where and in how much quantity
?

10. RULES FOR STORAGE
1.Search – Free
2.Count – Free
3.Air – Free
4.Climb – Free
5.Bend – Free
6.First – In, First – Out
7.Heavy/ Tall Things On Bottom Shelves
8.Fast Moving Materials Close To Point-of-use/ Point-of-issue
9.Adequate Lighting
10.Adequate Ventilation

11. Street
numbers
Address of bin:
A32=Block A,
Street 3, House
2
House
numbers
Block tables
Fixing Position

12. TOOLS
• For Eg. Colour coding for files/tools, tool organizer to
organize tools, shelf colour/tagging etc.
• The purpose of 5S Seiton is to find a place for
everything within your working area, everything
should be located as close as possible to where it is
needed and at a location that is both safe and easily
reached
• Following are few eg.

13. EXAMPLES
Before
After

14. Seiton for Store
Make your Store:
• Search free
• Air free
• Climb/Bend free
• Count free
• FIFO
• Warehouse is where material is dumped in any quantity.
• Store has Reserved Seats.

15. Two-Bin System
Kanban card
When bin is
empty, card
is placed
here, to be
picked up
periodically by
Purchase
Seiton

16. SEITON
Success Indicator
• Reduction in handling/searching time
Checklist
• Are passage ways and storage places clearly
indicated?
• Are commonly used tools and stationery separated
from those seldom used?
• Are containers and boxes stacked up properly?
• Are fire extinguishers and hydrants readily
accessible?
• Are there grooves, cracks or bumps on the floor
which hinder work or safety?

17. 3RD ‘S’- SEISO OR SHINY CLEAN UP
1/2
• Clean your workplace so that there is no dust. In
workplace, it becomes easy to trace leaks, cracks etc.
• This stage has two goals:
1. Determine and gain agreement on the desired level
of cleanliness
2. Learn how to make new routines so this will
become standardized (in the Seiketsu stage)
• Several questions help this stage to be more than
just "polish until it shines for inspection":
a. How much cleanliness is required for safety, for
ease of use, and to minimize equipment
breakdown?
b. How clean should the environment be for comfort
and morale?

18. SEISO 2/2
c. How will cleanliness improve product quality?
d. While cleaning, do we notice maintenance issues that
should be addressed?
1. Surroundings
2. Equipment
3. Storage Areas
Cleaning Targets

19. Surroundings : What to Clean ?

20. 1. Are there any unnecessary items
around you ?
2. Are all files & folders immediately
accessible ?
3. Is cleaning done every morning ?
4. Is clearing up done every day after
work ?
Maintaining A Spotless Workplace

21. Example of ‘3S’
Factory Surroundings

22. FACTORY ENTRANCE SCRAP YARD
Front area and Scrap yard are comparable

23. SEITONIndicators of Success
• Reduction in machine downtime
• Increased life of machine parts
• Reduction in number of accidents
• Reduction in rejection/rework
Checklist
• Are the floor surfaces dirty ?
• Are machines and equipment dirty?
• Are wires and pipes dirty or stained?
• Are machine nozzles dirtied by lubricants and ink ?
• Are shades, light bulb and light reflectors dirty?

24. 4TH ‘S’- SEIKETSU OR STANDARDIZE
• This phase draws on the notes from the Seiso stage
• A practical target is to have all workers take five
minutes every day to tidy up after themselves
including the time to complete and sign the
checklists
• By dividing the work among all the employees:
a. No-one has a huge burden
b. No-one seems unproductive
c. Morale improves because everyone has a common
purpose
d. Supervisors should monitor compliance with
Seiketsu.
The checklists make this both important and
achievable.

25. What Is To Be Standardised
• Workstation layout, work area layouts.
• Work in Process (WIP).
• Sequence of work.
• Cycle time of work .
• Material and tools used.
• Machines and their process parameters.
• Quality parameters, methods of measurement,
reaction plan and reporting method.
• “ What, Where, When, Who & How ” of work .

26. METHODOLOGY TO PRACTICE ‘4S’
• Preparation of S.O.P.( Standard Operating Procedure) for all the activities to
be carried out to maintain 1S,2S, & 3S.
• Following areas shall be covered while preparing S.O.P. :
• Machine & Equipment maintenance.
• Manufacturing Processes maintenance.
• Work Place maintenance.
• Quality Standards and Procedures maintenance.

27. SEIKETSU
Indicators of Success
• Number of areas/cover made transparent
• Number of new problems exposed & solved
Checklist
• Is the standardization system company-wide ?
• Is the setting, revision , and abolition of standards
encouraged ?
• Have official procedures been laid down for setting,
revising, and abolishing standards ?
• Is accumulation of technology promoted ?
• Are standards being utilized ?
• Are standards up to-date and capable of being put
into practice

28. 5TH ‘S’- SHITSUKE OR SUSTAIN 1/2
• Clear deliverables &
communication.
• Score Keeping
• Continuous improvement
with cyclic mini-5S events.
Tools:
• Training and Awareness of 5S
• Dedicated 5S team
• Clear 5S Map and
Responsibilities/Ownership.

29. SHITSUKE
• Indicators of success
• High Employee morale
• Involvement of people in the movement
• Checklist
• Are regular 5S checks conducted?
• Do people clean without reminder?
• Do people follow rules & instructions?
• Do people wear their uniforms & safety gear
properly?
• Do people assemble on time?

30. THANK YOU
