5S is a set of techniques that involve identifying and storing the items used, maintaining the items and workplace in a clean and orderly condition, standardizing best practices, and sustaining the processes. The 5S methodology was developed in Japan and includes techniques like sorting, systematic arrangement, shine, standardize, and sustain. Implementing 5S results in improved quality of life, increased efficiency, easier detection of problems, and reduced waste. The five S's are sort, set in order, shine, standardize, and sustain. Regular audits and employee involvement are needed to sustain 5S standards.

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2. What is 5S ?
5S is a simple but highly effective set of techniques
5S methodology was developed in Japan
5S is the foundation for any continuous improvement
5S removes waste from work environment through
better workplace organization, standardization, visual
communication and general cleanliness
5S factories are so well organized that abnormal situations
will be readily apparent

3. Why 5S ?
A better Quality of life Clean Shop floor and Office
Gain Space and can detect problems more easily
No special effort for visits and audits of Customer, Supplier and Top
Management
Easy to locate tools, documents, parts leading to Higher Efficiency
Easy to reduce MUDA(Waste)

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What Are The 5S’s ?
5S’s Japanese English Meaning
1 S SEIRI SORT Remove unwanted items
2 S SEITON SET A place for everything and everything in
its place
3 S SEISO SHINE Cleaning with meaning
4 S SEIKETSU STANDARDISE Establish Standards for first 3Ss
5 S SHITSUKE SUSTAIN Sustain & improve the first 4Ss
The 5S-method is a five principals program for safety, cleanliness
and order at your own workstation.
The 5 S are:
 It can be realized in production as well as in office areas.

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SERI - (SORTING)
Meaning Distinguish between necessary and unnecessary items and
eliminate the unnecessary items
Activity • Establish a criteria for eliminating unwanted items.
• Eliminate unwanted items either by disposing or by
relocating.
Success Indicator
Area saved or percentage of space available
What is unnecessary
• Item is not needed
• Item is needed however quantity in stock is more than what
is needed for consumption in near future
Do not hesitate to throw
away what is not useful!

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Identifying unnecessary
• Things fallen back / behind the machine or rolled under it
• Broken items inside the machine
• Stock of Rejected items
•Small quantity of material no longer in use
• Broken fixture, tools, bits, etc, may be lying
•Material brought for some trial, still lying even after trial
• Old fixtures, tools not in use, damaged equipment parts, etc.
• Shelves and lockers tends to collect things that nobody ever uses, like
surplus, broken items etc.
• Dust, material not required seem to gather in corners
• Posters,bulletins on wall, damaged or unwanted files, papers, stickers
• Remains of torn notices, cello tape pieces
• Unwanted table, rack, trolleys, bins, etc.

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BEFORE AFTER
Location : All areas
Kaizen Theme : Work place improvement
Old reports & document boxes available in
all the areas
All the boxes moved to the
record room
No boxes available at shop
floor

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BEFORE AFTER
Location :Main Cell
Kaizen Theme : To eliminate dumping of material
Rack eliminated
Unwanted things lying in the rack

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SEITON - (SYSTEMATIC ARRANGEMENT)
Meaning • To determine type of storage and layout that will ensure easy
accessibility for everyone.
Activity • Plan storage of items based on its use, function & frequency
• Creating place for everything and keep everything in its place
Success Indicator
• Time saved in searching
• Time saved in material handling
How to achieve Systematic Arrangement?
• Label each item and fix location to prevent searching
• Prevent mistakes with coding by shapes & color
• Follow first in first out rule
• Put the things back to their location after their use

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• Color code wires, ducts, pipes, fixtures, trolleys, oil, etc.
• Store blades, dies, other important consumables in the protected place
• Maintain blades, dies regularly by applying rust preventive, oiling etc.
• Designate a place for each component / part
• Decide on how much quantity to be stored
• Fix location for Registers or any other frequently used documents
• Safety aspects – fire prevention, pollution, leak, spillage
• Put the tools or fixtures in the order you need them
• Identify location for tables, stands, trolleys, bins, etc.
• Label Instruments & Measuring Devices
• Show direction of flow
What To Do?

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Define how to order the objects
Do not place heavy objects
high up.
Easy to pick up,
easy to put back,
easy to do.
Place the most used
objects at a height
between the shoulder and the
elbow
Make shelves appropriate to
the size and weight that will
be placed there.
Correct
Incorrect

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Define how to order the objects
 Equipment on wheels: define the position by color and write the name
of the vehicle.
 As a general rule, indicate the position of everything that has to be
moved, so as to be able to replace it more easily.
 Mark the position of the objects (marks, labels, ......)

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 Draw very legible marks in the installations to make inspection
easier.
 Do not leave containers
directly on the floor
 use a platform: the parts
will not be soiled, and
corrosion and knocks can
be avoided.
Parts Box
Platform

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 Avoid placing things too far back as it makes them difficult to reach.
Access difficult
Access easy

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 Plan strategies to make
organisation easy
 Marking Makes it Possible to
Replace Documents Exactly in
Order
Badly placed
Well placed

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 Plan a system for easy positioning

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 This functional order must
be organised with the help
of the operators, who can
make proposals to the 5S
work group.
 This will ensure:
• Greater safety
• Improved quality of
parts made
• No time wasting
 Plan a clear system for positioning giving maximum information in a
minimum of time
Indicate the part names
Heightlimit
Indicayte the quantity and the
name of the container
On the
platform
Area line
Mark the area according to
the size of the containers

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BEFORE AFTER
Location : O/T Leak Testing m/c
Kaizen Theme : Proper Arrangements
Provide stand to keep the fixture &
identified
No place to keep fixture, so kept on floor

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BEFORE AFTER
Location : FF Final Assy.
Kaizen Theme : Proper Arrangement
Place has been fixed & identified
No proper place to keep the poly bag, Axle
hole checking pin & upper cap

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BEFORE AFTER
Location : FF FINAL ASSY.
Kaizen Theme: Easy To Identify
No Proper Arrangement for IPIR
And Scrap Register
Now Proper Arrangement Of IPIR By
Keeping Separator.

21. GABRIEL
BEFORE AFTER
Location : O/T Quality Station
Kaizen Theme : Proper Place
Proper place provided & identified
No proper place to keep the master pieces,
due to this master pieces getting damage

22. GABRIEL
BEFORE AFTER
Location : O/T Quality Station
Kaizen Theme : To Avoid Damages
Plug Gauges & Snap gauges kept properly
& identified
Plug Gauges & Snap Gauges kept without
any arrangement

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BEFORE AFTER
Location : O/T Leak Testing m/c
Kaizen Theme : For Easy Identification
Model wise board displayed
No identification for painted outer tubes as
per model

24. GABRIEL
BEFORE AFTER
Location : Main Cell ( Material trolley Area)
Kaizen Theme : Work place Improvement
Material trolleys are not getting parked
properly ,Walls getting Damaged and difficult
to access
Guide ways to the trolley wheels provided to keep
the trolleys only in the guide ways and stoppers
given to avoid damages forming on the walls also
Stopper

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BEFORE AFTER
Location : Manual MIG welding
Kaizen Theme : Proper place and identification
No proper place to display SOP and
defect samples
Proper place provided, colored and
identified the defect samples

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CONTINUAL IMPROVEMENT
BEFORE AFTER
Location : Training Hall
Kaizen Theme : For Easy Identification
Identified line wise in lights & in
switches
Before no identification for lights

27. GABRIEL
BEFORE AFTER
Location : TSG
Kaizen Theme : Proper Arrangement
All the sheet s displayed in folders &
properly arranged
A4 sheet fixed with one pin & no proper
arrangement

28. GABRIEL
BEFORE AFTER
Location : Display Corner
Kaizen Theme : Office TPM
Different types of board pins
used
Board pins
standardized

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VISUAL STANDARDS REQUIREMENT
1. A4 / A3 sheets are to be fixed with 4 pins only.
2. A4 sheet separator to be fixed with 2 pins at the ends.
3. All displays are to be in straight line both horizontally &
vertically.
4. Do not display any sheets on top of the existing display.
5. Do not display damaged / oil soaked / folded sheets.
6. Use one standard pin type in complete board.

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SEISO - (SHINE)
SEISO is keeping the workplace clean and also inspecting
while cleaning
Meaning
Activity •Spend at least 5 Minutes daily for cleaning
•Use appropriate tools for cleaning
•While Cleaning also inspect for damage,defects and potential
problems
•Clean the Hidden areas also
•Cleaning without care can cause more damage
•Inculcate the mindset “It is My Duty to Clean My Place”
Success Indicator
• Equipment Life is Improved
•Future problems are proactively identified and corrected

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This involves finding solutions of improvement for places difficult to
clean (for this use sheets indicating difficulty of access filled in during
the intial cleaning).
In a place of difficult access, dust, residues and dirt accumulate.
Superficial cleaning is not sufficient.
Difficult places also have to be cleaned, but above all, propose ideas
that will make cleaning simpler.
Identify places difficult to clean and correct the situation

33. GABRIEL
This involves, after identifying the sources of dirt during the
optimization phase, resolving the problem and as far as possible
eliminating the dirt.
The only way to succeed in having a lasting state of cleanliness is not
to clean all the time, but to avoid soiling in the first place.
Seek the causes of dirt and correct the situation

34. GABRIEL
 Places difficult to reach, if they are not changed, are a source of
discouragement for individuals and go back to being dirty again.
 Continue to complete the sheets with indications (anomalies, dirt,
difficult access, observations).
 After repeated cleaning, the difficulties become clear and note must
be taken of them.
 Propose solutions for improvement to the work group who will make a
combined report.
 The work group will use the good ideas, will ensure that the work
decided on is done quickly, will comment on the work refused and
see that the improvement sheets are displayed
Identify places difficult to clean and correct the situation
I ’m fed up
with this!

35. GABRIEL
 This involves the efficient
cleaning of the installations
and the environment,
understanding the
necessity for this task
 Carry out all the
cleaning in company
with the members of
the team and the 5S
work group taking
account of the safety
instructions.
 Indicate the places
with a problem with a
label indicating the
nature of the problem.
3s - Spic and Span (Clean) the installations
Water leak
Oil Leak
Missing part
Broken cap
Displacement
Deformation
Deterioration
Missing nut
Twisted part
Lost cap
Etc.

36. GABRIEL
Spic and Span - Cleaning equipment
Rag
Brush
Bleach
Sweeping brush
Vacuum cleaner
Paint
Paint brush
Other equipment

37. GABRIEL
BEFORE AFTER
Location : FF FINAL ASSY.
APS Theme : To Avoid Dust
Trolley & Bins are changed now dust and oil
will not stay
Dust & Oil stays at bins and trolley

38. GABRIEL
BEFORE AFTER
Location : TT Outer Tube Cleaning m/c
Kaizen Theme : Eliminate Cleaning
Oil from components spilling
on to the floor
Tray provided to prevent oil spill

39. GABRIEL
BEFORE AFTER
Location : O/T Cell (BTA)
Kaizen Theme : To Avoid Handling Leakage
All stand changed in inside
While keeping in draining stand oil spilling
at floor

40. GABRIEL
BEFORE AFTER
Location : Cell 3 BTA M/c
Kaizen Theme : To Avoid Leakages
Concentricity gauge provided inside the
machine
Coolant oil getting leak from outer tube
while checking Concentricity

41. GABRIEL
BEFORE AFTER
Location : Cell (9 & 8) – VMC M/c
Kaizen Theme: Easy Flow of Chips
Now provided wide channel, now chips flow
easily
Chips struck in m/c channel due to this
coolant getting overflow

42. GABRIEL
BEFORE AFTER
Location : O/T cell
Kaizen Theme: Easy to Clean
Provided fiber sheet inside the m/c.easy to
clean
Chips were flashing on the m/c
window,difficult to clean

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SEIKETSU- STANDARDISE
“Define the standards that will enable the workstation to remain
free of unnecessary items, orderly, spotless and inspected
while specifying how to eliminate the causes of dirt, grime, leak
and clutter.”
Meaning
Activity • Establish uniform standards and procedures for labeling,
color codes, indicators and safety norms
• Display visual signage and control wherever possible
• Establish proper Checklists, Responsibility Lists and
Schedules
Success Indicator
• Increases Quality & Productivity
• Safe & Ease Working Conditions
• Mistakes are Eliminated
• Ownership and sense of pride among employees

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Seiketsu
 Following of earlier 3S
 Standardized work procedures,
 Maintaining safe & hygienic conditions in work place contributing to
a serene atmosphere.
Steps to Seiketsu
 Develop standards/ Evaluation criteria with workmen (Sop's
housekeeping standards)
 Establish checking procedure
 Establish feedback procedures

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2‘S STANDARD
CIT
OIL BARREL
STORING AREA.
Max - 3 Min - 1
Always Keep barrel
In vertical condition.
Always ensure barrel
Top should be sealed.
KEEP THE AREA CLEAN AND
NEAT AS PER THE DISPLAY
DO NOT KEEP ANY EXCESS
OIL BARRELS OR OTHER
THINGS
RESPONSIBILITY: LOADING PERSON & STORES SHIFT
INCHARGE.

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Standard

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SHITSUKE- SUSTAIN
“Management should encourage co-workers to keep up the
good habits acquired by supporting them and helping them to
comply with and improve on the standards”
Meaning
Activity • Provide continuous guidance and training
• Conduct regular 5S audits , display the result
• Analyze audit findings & act
• Create Interest & Involvement thro’ publicity & competitions
• Ensure everyone is committed to “5S is my Responsibility”
• SHITSUKE is perhaps the toughest of the 5S’s
Success Indicator
5S Becomes Habit

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Gains and benefits for company and employees
The advantage of the 5S method is to continuously implement and
maintain order and cleanliness in the plant in a structured way. The
methodology is based on teamwork and can be applied to all areas.
The activity 5S consists of 5 principals and offers numerous
advantages for the company as well as for the employees.
The basic advantage for the plant is to arrange the spaces clear.
Consequently we achieve an organized and structured operation
which will increase productivity.

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The method allows the employees to work in a clean environment
and to feel well at their workstations. In addition it offers the
employee the possibility to feel more connected with his/her work
by i.e. submitting proposals for improvement which will be
implemented as soon as possible.
The major advantages are:
 Sensitization of the employees for safety, order and cleanliness
at their workstations
 Take over more responsibility
 Basis for standardization (i. e. labeling, implementation shadow
board monitoring) and continuous improvement
 Increased transparency of the process
The 5S-method is a good way to involve every people in a same
plant project.

50. GABRIEL
S .N Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 No Trolleys/Boxes in front of the Display Boards
2 Arrangements of Files & Registers in File Rack
3 Display Boards are in identified Location
4 No Uneeded Equipments/Trolleys/Boxes near Common Display Area
5 Uneeded Equipments/Trolleys/Boxes in Front of Fire Extinguisher Marking
6 No Filter Paper overflow from the Collection Box
7 No Oil Spillage near Filter Paper Collecting Box
8 No Chips on the floor near Chip Collecting Trolleys
9 Cleanliness of Chips Trolley
10 No Trolleys parked outside the identified location
11 No Machined Outer Tubes are in Blue Trolley
12 All the MachineTrolleys & Bottom Tray should free from Chips & Burr
13 Chips collecting trolley parked in correct position
14 No Supplier Bins are used for collecting spillage
15 Tool Rack I & 2 located in identified location
16 Tools & Fixtures in Rack - 1 & 2 are located in identified location
17 All available Tool in Rack 1 & 2 ready for use
18 No Parts/Tools laying on Concentricity Checking gauge station
19 No Chips on Gauges(Ring Gauge/Plug Gauge/Concentricity Gauge etc )
20 All Parts/Tools laying in identified locations on the machines
21 Is Drain Locators are in Good Condition
22
All gauges & Registers(Bottom Rack) stored in identified location in Quality
Station 1(Near Cell 3& 4)
23
All gauges & Registers(Bottom Rack) stored in identified location in Quality
Station 2 & Rack (Opposite to Cell 5)
24 Is JH happened on JH Time & Updated Check sheet available
25 Kettles kept in identified location & Cleaned
26 Oil Drum Trolley parked in Identified Location
27 Files & Registers arranged properly in SOP station
28 Machine Gaurds in its position
29 Rejection Trolley parked in identified location
30 Rejection Trolley Boxes free from Chips
31 Is Daily Rejection Disposed
32 All the Machine Gaurds(Achralic sheet) in Good Condition
33 No Chips & Oil on Shop Floor
Rating Criteria : 30/
33 - G, 27/
33 - Y, < 27/
33 - R Zone Leader to Audit Daily Auditor to audit on every S aturday
P/managers/TPS/5S/O/T Cell checksheet
Common Points
Near Machine
Rating
S ignature
O/T CELL 5S DAILY MONITORING SHEET GABRIEL, H
Zone leader : DILIP REDDY Auditor : MURALIDHAR BHAT Year :2009 Zone : FF Area :O/
T Cell Month :

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THANK U