This document provides an overview of 5S training and awareness. It describes the history and objectives of 5S, which is a structured program for implementing workplace organization and standardization. The 5S methodology represents 5 disciplines - Sort, Set In Order, Shine, Standardize, and Sustain. Examples are given for each discipline, as well as how to create a visual workplace and the benefits of practicing 5S, such as improved productivity, quality, and safety.

1. 5S TRAINING & AWARENESS
Presented By: Yogesh Deshmukh, ESFL
Waluj

2. HISTORY OF 5 S
• THIRTY YEAR AGO RESEARCHERS STARTED STUDYING SECRET OF SUCCESS OF A JAPANESE
MANUFACTURING COMPANIES.
• HIROYUKI HIRANO WHO DEVELOPED 5S WITHIN HIS OVERALL APPROACH TO PRODUCTION
SYSTEMS .
• WHO PROVIDE A STRUCTURE FOR IMPROVEMENT PROGRAMS.
• HE POINTED OUT SERIES OF IDENTIFIABLE STEPS EACH BUILDING ON ITS PROCEDURE .

3. OBJECTIVES
• DEFINE AND UNDERSTAND IMPORTANCE OF 5S METHODOLOGY
• IDENTIFY AND OVERCOME WITH PRODUCTIVITY
• IMPROVEMENT IN QUALITY OF WORK
• PRACTICE OF EFFICIENCY IN ALL TIME

4. WHAT IS 5S?
• 5S IS A STRUCTURED PROGRAMME TO IMPLEMENT WORKPLACE ORGANIZATION AND
STANDARDIZATION .
• 5S REPRESENTS 5 DISCIPLINES FOR MAINTAINING A VISUAL WORKPLACE
1. SEIRI :SORT
2. SEITON : SYSTEMATIC ARRANGEMENT
3. SEISO :SHINE
4. SEIKETSU :STANDARDIZE
5. SHITSUKE :SUSTAIN
• IT IS A BASIC STRUCTURE TO KAIZEN AND LEAN IMPLEMENTATION PROGRAMME LIKE TPM .

5. 1S SORT
DEGREE OF NEED FREQUENCY OF USE STORAGE METHOD
LOW -THINGS YOU HAVE NOT USED IN
THE PAST YEAR .
-THINGS YOU HAVE USED ONCE IN
THE LAST 6-12 MONTH
-ASK TO AUTHORIZED PERSON TO
TAKE DECISION.
-ASK OTHER PLANT ABOUT ITS
AVIABILITY
-THROW OUT OR KEEP AT DISTANCE
.
MEDIUM -THINGS YOU HAVE USED ONCE
OVER PAST 1-6 MONTH
-STORE IN CENTRAL WORK PLACE
-IF OTHER PLANT REQUIRES THEN
SHIFT PART OF MATERIAL
HIGH -THINGS USED ONCE IN THE WEEK
-THINGS USED DAILY
-THINGS USED HOURLY
STORE NEAR THE WORK SITE.
USE TAG FOR THE MATERIAL

6. TAG SYSTEM
RED TAG: FOR UNWANTED ITEMS YELLOW TAG: FOR STORE MATERIAL

7. SORT
Before
After

8. 2S-SET IN ORDER
• PRINCIPLE:
• FUNCTIONAL STORAGE
• SEARCH ELIMINATION
• MEANS: ARRANGE ESSENTIAL ITEMS IN ORDER FOR EASY ACCESS
• A PLACE FOR EVERYTHING
• EVERYTHING IN ITS PLACE AFTER USE

9. Usable
items
Yes No
Is it
identified
Does it have
storage
pace
Put away/record
room
Using today
Keep it
closer to
place
Make
identified
Make space
Tag/Label it

10. SET IN ORDER
Before After

11. SHINE
PRINCIPLE:
• CLEANING AS INSPECTION
• DEGREES OF CLEANLINESS
MEAN:
• ELIMINATE THE SOURCES OF DIRT
• CLEANING AS A FORM OF INSPECTION
• CLEAN EVERYTHING INSIDE OUT AND TOP TO BOTTOM
• MAINTAIN SHINE CHECKSHEET

12. 3-STEP APPROACH TO SHINE
• MACRO: WALLS,CEILINGS,LIGHT,STORAGE,CABINATE,TOILET,JUNK
YARDS, SHELVES FILLING CABINETS, COMMON AREAS ETC..
• INDIVIDUALS: INDIVIDUAL WORK
STATIONS,CHAIR,DRAWERS,COMPUTER,OFFICE STATIONARY, CABINET
SHELVES ETC. CLEAR AWAY
• MICRO: MEASURING INSTRUMENTS, SENSIBLE
INSTRUMENTS,GAUGES,VERNIER CALIPERS, CONTACT SURFACES ETC..
INDIVIDUAL
MACRO
MICRO

13. 4S: STANDARDIZE
• PRINCIPLE:
• 5S STANDARDIZATION
• VISUAL MANAGEMENT
MEAN:
• ESTABLISH GUIDELINE
• MAKE STANDARD AND GUIDELINE VISUAL
• MAKE STANDARD S SO THAT ANY ABNORMALITY BECOME VISIBLE
• USE VISIBLE TOOL

14. 5S:SUSTAIN
• PRINCIPLE:
• HABIT FORMATION
• DISCIPLINED WORKPLACE
MEAN:
• TRAINING
• BEFORE AND AFTER PHOTOS
• DAILY 5S FIVE MINUTE ACTIVITIES
• SELF DISCIPLINE

15. HOW TO SUSTAIN 5S ?
• GET MANAGEMENT COMMITMENT
• GET EVERY ONE INVOLVED
• GET APPROVAL FROM MANAGEMENT FOR 5S .
• INVOLVE TOP MANAGEMENT WHEREVER NECESSARY
• START PROMOTIONAL ACTIVITIES IE..SUGGESTION BOARD, EMPLOYEE OF THE
WEEK BOARD
• GEMBA WALK BY MANAGERS AND GENERAL MANAGER
• USE 5S PLATFORM TO LAUNCH OTHER CONTINUOUS IMPROVEMENT
PROGRAMMES.

16. CREATING A VISUAL WORKPLACE
• 5S CAN BE IMPLEMENT BY USING VISIBILITY TOOLS
• USE 5S VISIBILITY TOOLS TO HELP YOU MONITOR RESULT
AND LOOK THING’S EASILY AND QUICKLY.
• NOTE: VISUAL MANAGEMENT IS NOT DECORATION
MANAGEMENT IE.OFFICE PARTY IS NOT PART OF VISUAL
MANAGEMENT .

17. 3 . TYPES OF VISUAL PROGRAMMES
• MAINTAIN VISUAL DISPLAY : TO SHOW
DIRECTION MACHINE TEMPRETURE,HOT
PART,ACCESS,GANG WAY ,HIGH RISK AREA
• VISUAL METRICS: TO SHOW PARETO CHART
AND GRAPHS, QUANTIFY THE GRAPH OF
ACHIEVEMENT
• VISUAL CONTROL: CREATE AN ERROR PROOF
ENVIORNMENT TO PROMOTE ADHERENCE
TO STANDARD .

18. BENEFITS OF VISUAL METRICS
• PROCESS CYCLE TIME REDUCTION
• ON TIME DELIVERY
• WIP BACKING
• PRODUCT RECOVERIES
• REWORK REDUCTION
• QUALITY IMPROVEMENT

19. 5S AND SAFETY
• USE PROTECTIVE EQUIPMENT IN THE LAB
• INSTALL PROTECTIVE COVER ON EQUIPMENT AND MACHINE .
• LABELS OF WARNING SIGN PROMINENTLY
• IE.HIGH VOLTAGE,HEAT SURFACE,SLIPPY AREA ETC.

20. 5S AND QUALITY
• PROVIDE ON SITE TRAINING ABOUT 5S
• TRAIN NEW STAFF ABOUT WORKING WITH 5S AND
SAFETY
• EDUCATE STAFF TO RECOGNISE AND PREVENT
MISTAKES

21. BENEFITS OF PRACTICING 5S
• THE WORKPLACE BECOME CLEANER,SAFER,WELL ORGANIZED AND MORE PLEASANT .
• FLOOR SPACE UTILIZATION IS IMPROVED .
• WORK FLOW BECOME MORE SMOOTHER AND MORE SYSTEMATIC AND NON VALUE ADDED
ACTIVITIES ARE REDUCED.
• TIME FOR SEARCHING TOOLS, MATERIAL WILL BE MINIMIZED.
• MACHINE BREAKDOWNS ARE REDUCED SINCE CLEAN AND WELL MAINTAINED EQUIPMENT .
• PRODUCTIVITY AND QUALITY IMPROVES TOGETHER WITH REDUCTION IN BREAKDOWN AND
PRODUCT RECOVERIES .
• THE MORAL SATISFACTION OF EMPLOYEES IMPROVES.

22. •THANK YOU