5S Module - Key Slides

5S - Workplace Management System
1Creating Value through People & Process Development
Ek Pahla Kadam, Take it .. Keep moving ..

5S is a workplace organization and continuous improvement system
5S is a process for implementing and maintaining a clean, safe, and organized
work area
5S is a system uses a list of five Japanese words: Seiri, Seiton, Seiso, Seiketsu &
Shitsuke
What is 5S ?
Ek Pahla Kadam, Take it .. Keep moving .. General Concept

Benefits of 5S :
It makes problem
visible
Prevents
deterioration
Results in
space saving
Reduces item
retrieval time
Reduces inventory
of items
Eliminates unsafe
condition
Improves
hygiene level
High employee
morale
Improvement in
quality
Reduction in cost
Ek Pahla Kadam, Take it .. Keep moving .. General Concept

• Define what is and isn’t needed in the area to do the job.
Remove items not needed: tools, books, instructions –
prioritize essential items
SEIRI = Sort
• Organize the work area based on ‘A place for everything
and everything in its place.’ Designate locations for files,
tools, equipment, supplies, etc. and label properly
SEITON = Set in
Order
• Clean, sweep, scrub, etc. Cleaning is inspection.SEISO = Shine
• Identify “Best Practices” and document them so they
can be followed by everyone. Use same tools, processes,
and documentation where applicable.
SEIKETSU =
Standardize
• Maintain and review with everyone involved. Continual
reinforcement of the importance of 5S; Audits, Culture
change – make it a habit.
SHITSUKE = Sustain
Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? - Basic Definition

1S - Seiri (整理 ) : Sort : Sorting
Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 1st S SEIRI
1) Remove unnecessary items and dispose them properly
2) Make work easier by eliminating obstacles
3) Reduce chance of being disturbed with unnecessary items
4) Prevent accumulation of unnecessary items
5) Evaluate necessary items with regard to usage / cost factors

Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 1st S SEIRI
Examples of SEIRI :

2S - Seiton (整頓) : Straighten : Set in Order
Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 2nd S - SEITON
1) Arrange all necessary items in order
2) Make it easy to find and pick up necessary items
3) Ensure first-come-first-serve basis (FIFO)
4) Make work flow smooth and easy
5) Prevent loss and waste of time

Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 2nd S - SEITON
Examples of SEITON :

3) Seiso (清掃) : Cleaning : Shine
Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 3rd S SEISO
1) To clean the workplace thoroughly so that there is no dirt
2) Use cleaning as inspection (Cleaning with Meaning)
3) Can also be translated as "sweep" or " Spic & Span"
4) Prevent machinery and equipment deterioration
5) Keep workplace safe and easy to work

Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 3rd S SEISO
Examples of SEISO :

4S - Seiketsu (清潔) : Cleanliness : Standardise
Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 4th S SEIKETSU
1) Maintain high standards of housekeeping & hygiene at all times
2) Maintain cleanliness and orderliness
3) Maintain everything in order and according to its standard
4) Develop standards for 5S and operational Activities
5) Focus on improving Visual Displays

Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 4th S SEIKETSU
Examples of SEIKETSU :

5S - Shitsuke (躾) : Sustain Self Discipline
Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 5th S SHITSUKE
1) keep in working order - ongoing / continuous Improvement
2) Also translates to "Self-Discipline" meaning to do without being told
3) 5S is a habit and it is to be continually improved
4) Keep the 5S going through training, communication & organization structures
5) Allocate time for maintaining, Management Support, Rewards"

Preparatory Steps to Implement 5S is Pilot Project :
Train a Team on 5S – Representation of Top & Middle Management
Select a Model Area / 5S Zone
Start 5S under direction with Top Management and 5S Coordinator
With a small team of with a Small Team
Show the results and deploy horizontally
Ek Pahla Kadam, Take it .. Keep moving .. 5S Implementation

5S Structure of a Process :
ABC Limited, India HR
S. No Area Area Co-ordinator Zone Zone Leader Sub Zone Sub Zone Incharge
PL Office xxxxxxxxx
Office / Cubicles xxxxxxxxx
Store - 1 xxxxxxxxx
Store - 2 xxxxxxxxx
Reception xxxxxxxxx
Meeting Room xxxxxxxxx
Storage Rooms xxxxxxxxx
Cooking Area xxxxxxxxx
Cleaning Area xxxxxxxxx
Dinning Hall xxxxxxxxx
Gate Office xxxxxxxxx
Weigh Bridge xxxxxxxxx
Parking Area xxxxxxxxx
Dispensary xxxxxxxxx
Prepared By : XXXXXX XXXXXX Approved By : XXXXX XXXXX Date : XX-XXX-XX
2 IPST Abdul Canteen Heera Lal
Main Gate Moti Lal
5S Structure and Zone
5S Co-ordinator : Rahul Verma : Imran Khan
1 HR Ram Singh HR Office Panna Lal

Item Activity
Initial
❑ Carry out initial audit and assess present 5S Score
❑ Take as many picture as you can
1S - Seiri
❑ Carry out mega sorting, initial mega drive and later on based on
need
❑ Red tag unwanted items and shift them to RED TAG AREA
❑ Dispose, reuse of store Red tag items as per need and policies
2S - Seiton
❑ Arrange for storage of wanted items based on frequency of use
❑ Store required items systematically – safe and easy to use
Steps to Implement 5S :

Item Activity
3S - Seiso ❑ Carry out mega cleaning – 6 side cleaning with meaning
4S - Seiketsu
❑ Do proper labelling, put Visual Control in place
❑ Make Standard for Daily 5S and implement them
5S - Shitsuke
❑ Continue training & development, various competitions
❑ Carry put 5S Audit at regular frequency
❑ Rewards best Zones , Processes and Contributors
❑ Make 5S a Daily Habit and Life Line of system
❑ Enjoy improved work environment & build upon
improvements on 5S Systems
Steps to Implement 5S :

Common Findings in 1S:
Obsolete :- Parts ( Jigs / tooling ) not required as the design has become obsolete
Defective :- Parts can’t be used as it is (need some correction)
Scrap :- Scrap Items not thrown out
Not in place :- Kept at wrong place
Unnecessary :- Extra / not useful
Mix-up :- Mixed parts .. Needs attention
Un-identified :- Nobody’s baby
Items not used for last 6 months
Obsolete documents, not used but still stored for a long time
Others :- Even what is this part ?… Nobody knows
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 1st S SEIRI – Sorting

Basic Guidelines for Sorting :
Frequencies of use
(Period of queuing)
Grouping Method of disposal
❑ Used less than once a year Not used Throw away
(or discuses with seniors)
❑ Used about once every six months
to a year
Used infrequently Store in a distance Spot
❑ Used about once in two to six
months.
❑ Used about once in a month
Used some times Organize and keep in
work place
❑ Used about once a week
❑ Used once a day
❑ Used all the time
Used often Keep Handy
Keep Nearby
Easily Identifiable

Necessary Unnecessary
Not necessary
now, but
maybe in the
future
Put Red Tag on Not Necessary and Unnecessary Items
❑ Remove non-essential items from work area
❑ Sort through desk drawers, file cabinets, carts, tables, office supplies,
materials, paper work, and discard unneeded items
❑ Remove hardcopy items where not needed
❑ Sort computer files the same as hardcopy files – remove outdated
and unused folders

Follow your company Policy
for disposal of
Unwanted Items
Unwanted capital Items
Look for alternate effective
use
Check within process
Check with other
process
Check with other units
Storage of less frequently
used items
Store them away from
shop floor
May keep them in
process
May keep them in Plant
/ Engineering Store
Follow Spare Part / Raw
Material policy
Follow material storage
policy
Basic Guidelines for disposal of Red Tag Items :

Red Tagging :

Basic Guidelines for Storage :
Check What (Item Identification)?, Where ( Location)? & How Much (Quantity)? When
(Time limit)? Before actually practicing ‘2S’
Decide appropriate location for every thing and display identification mark for every
location
Items stored should have the Identification Mark including purpose of storage & its
review date
Every thing should be cleaned thoroughly before they are stored at its pre fixed location
Location and storage of the items should be easily access to all
Clear identification and visibility for the location
Training and information to all
FIFO should be ensured
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 2nd S SEITON – Set in Order

• Ideally nothing stored more than a step away.
• Improve efficiency by eliminating time lost looking for
items.
One Step Rule:
• Organize workplace to allow any tool, information or
material to be located and retrieved within 30 seconds.
• This includes computer files!
30 Second Rule:
• Immediate work area layout to minimize twisting.45 Degree Rule:
• Store things above the knees and below the chest.Strike Zone Rule:
• Locate heavy items to eliminate bending, stooping or
unnecessary arm movements during lifting.
The higher the
pounds, the closer
to the knuckles:
Basic Guidelines for Storage :
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 2nd S SEITON – Set in Order

Basic Guidelines for SEISO :
Create a spotless workplace
Identify and eliminate causes of dirt and grime
Remove the need to clean
Sweep, dust, polish and paint
Eliminating trash, filth, and foreign matters for a cleaner
workplace. Cleaning as a form of inspection
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 3rd S SEISO – Shine & Sweep

Basic Guidelines for Cleaning :
• Six side cleaning for all
• Refurbishing everything
• Make things easy to clean
It means……
• Check Items – to be cleaned
• Tools to be used – to be used for cleaning
• Frequency of cleaning & inspection – when to clean
• Person In charge name – responsibility for cleaning
Prepare a check
list containing
following
information:
Divide entire work place into
small zones
Define the responsibility of
person ( Area wise)
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 3rd S SEISO – Shine & Sweep

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
Spare and raw material to be stored
Quantity and location of items to be stored
Color coding, visual marking and displays
Items to be cleaned – frequency and responsibility
“What, Where, When, Who & How ” of work
Basic Guidelines for Seiketsu :
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 4th S SEIKETSU - Standardisation

5S Activity List :
ABC Limited, India TQM
Process Name : XXXXXXX Process Co-ordinator : ABCD … XYZ
S. No. Zone No.
Zone Area /
Location / Floor
Sub Zone 5S
Coordinator
Sub Zone Team
Members
Key Action Points Responsibility Frequency
Prepared By : Process Person Date : xx-xxx-xxApproved By : Process 5S Coordinator
3
5S Zones & Activity List
1
2
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 4th S SEIKETSU - Standardisation

Basic Guidelines for Shitsuke :
Progress monitoring through Audit Scores
Improving ownership by Allocating Areas
Visual communication through Fixed Point Photography
Continuous Training to all employees
Periodic Audits at all levels
Encouraging house-keeping projects through Total Employee Involvement
5S is not one time activity, it’s a Continuous IMPROVEMENT PROCESS
No TQM, AM, ISO.. Kaizen, Projects are possible without 5 S
5S ……. a way of life.
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 5th S - SHITSUKE

5S Audit Check Sheet :
ABC Limited, India XYZ - Process
0 1 2 3 4
1 Materials, parts or components
2 Machines and other equipment
3 Jigs and tools
4 Visual control
5 Containers
6 Location indicators
7 Item Indicators
8 Kansans
9 Jigs and tools
10 Material storage
11 Floors & gangways
12 Machines and other equipment
13 Internal box cleanliness
14 Cleaning Responsibilities
15 Habitual cleanliness
16 Concerns sheets
17 Spill kits
18 Operation standards
19 PPE
20 Guard checks & sheets
21 Training
22 Tools and parts
23 Stock control
24 Cleaning routine
25 Product I/d
Actual Score :
Notes:
Score : 0 = Very Poor 1 = Poor 2 = Average 3 = Good 4 = Very Good
5S Audit Check Sheet
Total
Sustain-Self
Discipline
Is everyone adequately trained in 5S procedures? (Ask what 5S is)
Are tools and parts being stored correctly?
Are any Kansans over stocked?
Is cleaning routine present & are all tools & materials available?
Are all parts clearly identified? Route Cards/Non-Conforming Notes?
Standardise
Are concerns regularly being generated & acted upon?
Are spill kit contents being maintained?
Are Operation Standards written, clear and actively used? (Ask an Operator)
Is PPE being worn in line with assessment?
Have checks been carried out & documentation completed?
ShineandSweep
Are floors/gangways kept clear, clean and free of waste, water or oil?
Are the machines/work surfaces kept clean & free of shavings and oil?
Are all boxes being used clean & free from debris?
Is the person responsible allocating cleaning duties? (Lead Operator)
Is the set standard ( photo ) being maintained?
SetinOrder
Are Kanban locations clearly marked with correct part no.'s?
Are shelves clearly marked with gauge or component no.?
Are boxes in correct location and not stacked too high?
Are gauges and tools arranged to facilitate picking them up and returning them?
Is stock rotation ( FIFO ) being adhered to?
SORT
Does the area house tubes or components not used on line?
Are there any unused machines or other equipment around?
Are there any unused gauges, fixtures or similar items around?
Is it obvious which items have been marked as unnecessary?
Are any unused cardboard or plastic boxes on line?
Audit Area :
Audit Date :
5S No Check Item Description
Score
Name of Auditor :
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _5th S SHITSUKE – 5S Audit

5S Audit Score :
ABC Limited, India XYZ - Process
Before - Period After - Period 1 After - Period 2
1 Seiri 15 17 17
2 Seiton 12 12 18
3 Seiso 14 15 19
4 Sheketsu 10 11 13
5 Shitsuke 8 10 12
59 65 79
Prepared By : 123 Date : xx-xxx-xx
S. No Item
5S Score
5S - Score _ Radar Chart
Total Score
Approved By : 789
0
5
10
15
20
Seiri
Seiton
SeisoSheketsu
Shitsuke
Before _ P1 After _ P1 After _ P2
Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _5th S SHITSUKE – 5S Audit

Motivation and Celebration :
How to Implement? – 5th S SHITSUKE

Thank You
Contact : Dinesh Sharma
Cell No. : +91 9589004005, 9589892468
e-mail : dinesh@ekpahlakadam.com
e-mail : ekpahlakadam@yahoo.com
Connect : facebook.com/ekpahlakadam
Website : ekpahlakadam.com
Your Queries & Feedback Please

5S Module - Key Slides

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