The document outlines the 5S program, which aims to improve workplace efficiency through five key principles: Sort, Set-in-order, Shine, Standardize, and Sustain. It emphasizes the importance of involving all employees in creating a productive and organized work environment, and provides guidance on planning, implementing, and sustaining these practices. Ultimately, the goal is to develop a culture of continuous improvement and operational excellence.

2. Introduction to 5S
Introduction to 5S

3. Contents
2. What is 5S?
3. Planning Stage
4. Implementing Stage
5. Sustaining Stage
1. Objectives of 5S program?

4. Objectives of a 5S Program
Objectives of a 5S Program

Developing Kaizen-minded people at
workplace(workplace standardization).

Developing managers and supervisors
for practical leadership.

Improving infrastructures for
introduction of advanced Kaizen
technologies.
01-4

5. What is 5S ?
• The beginning of a healthy, comfortable and productive
life for everyone at work.
• Company-wide participation program involving everyone
in the organization.
• A very effective approach for motivating people, and
improving productivity and the work environment .
• 5S is an acronym for five Japanese words that are Seiri,
Seiton, Seiso, Seiketsu and Shitsuke.
01-5

6. What is 5S ?
6
Sort
Sort Seiri
Seiri
Set-In-Order
Set-In-Order
Seiton
Seiton
Shine
Shine Seisou
Seisou
Standardize
Standardize
Seiketsu
Seiketsu
Sustain
Sustain
Shitsuke
Shitsuke
1.
1.
2.
2.
3.
3.
4.
4.
5.
5.

7. What is 5S ?
7
 Remove all items from the workplace that
are not needed for current production or
administrative operation.
 Keep “only what is needed, only in the
amount needed, and only when it is needed”.
Keep it
Red Tag Discard
No Tag
Sort
Sort
1.
1.

8. What is 5S ?
01-8
Why Sort is important?
 Space, time, money,
energy and other
resources can be
managed and used
most effectively
 Problem and
annoyances in the work
flow are reduced.
 Communication
between employees is
improved.
 Product quality and
Productivity is
enhanced.

9. What is 5S ?
9
Arranging needed items in the way easy to
use and labeling them so that easy to find
and put away(visual management)
Set-In-Order
Set-In-Order
2.
2.

10. What is 5S ?
 Arrange needed items so;
 it is easy to use.
 label them so that anyone can find them easily and
put them agin.
 Set-in-order is important because it eliminates;
 Time spent searching for an item
 Motion wests
 Difficulty returning item to its original place
 Excess inventory
 Reduce damage
 safety
01-10
Set in order

11. What is 5S ?
 There are two strategies correspond to set-
in-order;
1. Visual Control
2. Motion Economy
01-11

12. What is 5S ?
 A visual control is any communication
device used in the work environment that
tells us at a glance how work should be
done.
 We can implement standardization in such a
way that all standards are identified by
visual control.
01-12
1. Visual Control Strategy

13. What is 5S ?
 common visual control techniques;
1. Signboard strategy
2. Painting strategy
3. Color-code strategy
4. Outlining strategy
5. Visual Management Board
(Kaizen board) Strategy
01-13
Visual Control Techniques

14. What is 5S ?
1. Signboard strategy
signboards are used to identify what, where
and how many
There are three types of signboards
• Location indicator
• Item indicator
• Amount indicator
01-14

15. What is 5S ?
2. Painting strategy
Is a method for identifying locations on floors
and walk ways
01-15

16. What is 5S ?
3. Color-Coding strategy
01-16

17. What is 5S ?
4. Outlining strategy
01-17

18. 5. Visual management board for 5S
promotion
1100mm
1700mm
1500mm
Refer to
Attachme
nt A Format
Refer to
Attachment B
Face
①
Face
②（ B
ack
side)
Face ①
What is 5S ?

19. Face
②（ B
ack
side)
⑨
①
② ⑲
A
Photograph
Face
①
Removable
board
Face ② Photograph
of the 5S
points
Size:
Approx.3 ｃｍ X4 ｃ
What is 5S ?

20. Attachme
nt A
Image of
5S points Map
Line
No.9
60
1
43
8
45
12
5
60
35
8
60
35
Color Label
Grade A
(Major)
Grade
B
(Middl
e)
Grade
C
(Minor)
Photograp
h No.
Everybody understand
－ What Grade of 5S points
－ Where is it ?
－ Improved or Not
improved
35
35
Before
improvement
After
improvement
Markin
g
What is 5S ?

21. What is 5S ?
 The process of removing motion waste
involves eliminating unnecessary motion
from existing operation.
 By locating items in the best location
possible, we can minimize motion waste.
 Even more important than removing motion
waste is asking “why it occurs in the first
place”.
01-21
2. Motion Economy Strategy

22. What is 5S ?
 Below are three examples of elimination
motion waste;
1. Keep frequently needed items close to you
and seldom needed items away.
2. Frequently needed items are arranged for
easy retrieval ergonomically.
3. Keep the processes close to each other and
eliminate zig-zag motion between them. 5S
map can be used to do the analysis.
01-22
Implement Motion Economy

23. Tool Box
Ex: 30 Second Rule
What is 5S ?

24. What is 5S ?
24
Shine
Shine Seisou
Seisou
3.
3.

25. What is Shine
 Shine means keep everything swept and
clean.
 Shine is a way to keep everything in top
condition so, when someone needs to use
something, it is ready to be used.
 When Shine, we can’t avoid inspecting the
item at the same time. Therefore Shine and
Inspect come together.
Page 25 of 65
What is 5S ?

26. Benefits from Shine
 Clean and comfortable workplace.
 Increase visibility to defects when it occurs.
 Helps to maintain safer workplace.
 Good working environment increase morale.
 Early detection of machinery and equipment
failure.
Page 26 of 65
What is 5S ?

27. What is 5S ?
27
Standardize
Standardize
Seiketsu
Seiketsu
4.
4.

28. What is Standardize
 Standardize is the method you use to maintain
the first three pillars (Sort, Set in order and Shine)
 Make it a rule to perform given work in the given
manner.
 Standardize is different from the first three pillars
because it is a method used to sustain the first
three pillars rather than housekeeping activity.
Page 28 of 65
What is 5S ?

29. Benefits from Standardize
 The basic purposes are to;
1. Lead to workplace standardization
 prevent setbacks in the first three pillars
 Make implementing them a daily habit
 Ensure that all the three pillars are maintained in their
fully implemented state.
2. Lead to work standardization
 Muda elimination
 Quality improvements
 Cost improvements
 Delivery time improvements
 Process improvements
Page 29 of 65
What is 5S ?

30. What is 5S ?
01-30
Sustain
Sustain
Shitsuke
Shitsuke
5.
5.
Means making a habit of properly maintaining
correct procedures

31. Some techniques to sustain
 5S Slogan
 5S poster
 5S newsletter and kaizen board
 5S audit
 awarding systems
 Big cleaning day
 5S month
 Benchmarking tour
Page 31 of 65
What is 5S ?

32. What is next ?
32
What is 5S ?

33. 2. Planning Stage
1. 5S organization structure
2. Recognition of current
condition
3. Deciding activity range
4. Goal setting
5. Planning stage
6. Budgeting
7. Kick-off
33
Steps for planning

34. Planning Stage
01-34
1. 5S Organizational Structure

35. 5S Promotion office duties
 Prepare over all 5S implementation plan at
company level.
 Follow up standardize 5S activities at the
company.
Perform any other 5S related activities.
Organize Training
01-35
Planning Stage

36. Planning Stage
2. Recognition of current condition
by using 5S Checklist and
Photography (Next page)
36

37. Planning Stage
Photography
(1) Fixed-point Observation Type
37
Fix the location of the
camera and do photo
shoots at the same place
both before and after
KAIZEN.
Before KAIZEN After KAIZEN

38. Planning Stage
(2) Random Type
38

39. Planning Stage
3. Decide Activity range
39
Company
-wide
Limiting to
Production
Division
Limiting
to Shop
Limiting
to group
Selecting
model shop
Others
Variety of Alternatives

40. Planning Stage
Decide 5S promotion blocks.
40
Sample
Block C
Block
E
Block F
Block B
Block D
Block
A

41. Planning Stage
4. Goal setting
41
5S
5S
Committee
Committee
Recognition
Of current
condition
1
Evaluation
2
Setting goal
3
Post
4

42. Planning Stage
5. Planning
1) Overall promotion plan
42
Timing
Items 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w
◆ ◆ ◆ ◆
Prepare standard tools in advance rega rdless of stage .
◆ ◆ ◆ ◆
Prepare standard tools in advance rega rdless of stage .
◆
Provide ove ra ll 5S training in introductory period.
◆ ◆ ◆ ◆
Provide 5S training prior to the start of each s
tage of 5S.
Ta ke photographs be fore/a fter ea ch stage.
◆ ◆ ◆ ◆ ◆
Photographs on later s tages can be the
evaluation obje cts for 5S aw arding.
Seiton
Seiso
Seiketsu
Shitsuke
Pre paration of
te xtbook for 5S
introductory
training
5S introductory
tra ining
5S tra ining
Photogra phy
Preparation of 5S
Tools
Basic plan
(stage)
Preparation
Seiri
Date of issue:
Issued by 5S Promotion Office
Overall Plan for 5S Promotion
Month 1 Month 2 Month 3 Month 4 Month 5 Month 6

43. Sort Activity Plan Sheet (Sample)
Planning Stage

44. Planning Stage
01-44

45. Type of cleaning Time Frequency (timing)
Daily cleaning 5 – 10 min.
Minor operation before/after
working hour at each shop
Weekly cleaning 15 – 30 min. Weekend
Monthly cleaning 30 – 60 min. End of month
Big cleaning days 2 – 4 hrs. Before national holidays
Location which is not easy to clean 1 – 2 days
In case of necessity for
assistance request to other
division
45
2) Setup of activity time
In case of 5S activity on Sustaining Stage (e.g. Cleaning)
Planning Stage

46. Planning Stage
3) Training plan
46
5S Committee

47. Planning Stage
6. Budgeting
It is necessary to prepare a budget for 5S activity because it
costs money.
47

48. Planning Stage
7. Kick-off (Declaration of 5S activity)
48
Inform all
employees
of kick-off
Declare
the policy
Explain
the activity
Assemble all
employees
Kick-off

49. Planning Stage
Promotion declaration of 5S activity
49

50. Implementation Stage
Implementing
Sort Activity
01-50

51. Implementation Stage
Procedure For Sort Activity
51
Preparation
Necessary items
Quantification
Set-in-order activities
Making a Shop Stock List
Unnecessary items
Evaluation of unnecessary items
Disposal of unnecessary
items
Red Tag Strategy
Shine Activity In parallel
Set-In-Order activity

52. Implementation Stage
Implementing Set-
In-Order Activity
01-52

53. Implementation Stage
Procedure For Set- in- order Activity
53
Set targets for Set-In-Order Activity
Implementation of Set-In-Order
Decision of schedule and work allocation
Preparation of tools for Set-In-Order Activity
Decision of location, Storage, Indication method

54. Implementation Stage
Implementing
Shine Activity
01-54

55. Implementation Stage
55
Determine shine target area
Start to shine
Preparing proper tools for shine
Determine shine methods
Determine shine assignments

56. Implementation Stage
Implementing
Standardize
Activity
01-56

57. Implementation Stage
Standardize means to set up rules for Sort,
Set-in-order and Shine Activities
It is all about
“Make up the rules and follow
them!”

58. Standards for Sort
Red Tag Rules
• When to Red Tag
• How to Red Tag
• What’s go on the Red Tag
• more…
Rules for the Red Tag Holding Area
• When to clear out
• How to dispose of items
• more…
Implementation Stage

59. Standards for Set-in-order
• Which items
• Where
• How many
• Who replenishes
• Return all items…
• What to do when items are missing
• Visual standards – signs, lines, labels and
color coding
more…
Implementation Stage

60. Standards for Shine
 Clean and Inspect (C&I)
 Show the task, person responsible, items
needed, frequency, desired workplace
 Where to keep cleaning supplies,
how to replenish when finished
more…
Implementation Stage

61. Implementation Stage
Implementing
Sustain Activity
01-61

62. Let’s sustain the gains !
The Questions Is
“How to Sustain ?
62

63. Let’s sustain the gains !
63
1. Patrolling
a. Top management Patrol
Must
 Check Up the activities Comprehensively
 Give emphasis on sustaining of the activity
 consider committees feedback

64. Let’s sustain the gains !
64
Making a round tour
of workplace

65. Let’s sustain the gains !
65
b. 5S Committee members and Promotion
office Patrol
Must
 Evaluate “5S Check List”
 Record problems on”5S check
findings”
 Tack picture of 5S problems

66. Let’s sustain the gains !
c. Mutual patrol
 Check mutually among 5S groups
d. Self patrol
 5S leader and members check the results of
activity by themselves.
e. Checklist patrol
 Point out the problems by themselves at site as
well as evaluate the results and encourage members to
urge KAIZEN.
f. Camera patrol
 Visibly highlight the problems and progress of the activity
using photographs.
66

67. 2. Use Slogan and Poster of 5S Activity
• It encourage all the participants.
＜ Samples of slogan ＞
“Refresh yourself and workplaces by 5S
activity.”
“Let's maintain current 5S activity and
KAIZEN for tomorrow”
“We polish “Our Minds” as well us our
factories”

68. ＜ Sample of poster ＞

69. Auditing and Guiding 5S Activities
Auditing and Guiding 5S Activities
The purpose of this audit is to outline an approach
Making 5S a success in industrial as well as our
working areas.
CRITERIA FOR 5S AUDIT RATING:
Evaluation Scale 5S Practice 5S Theory Data/Fact
1
(0 - 30 %)
 Nothing at all and no sense
of commitment.
 Not doing 5S at all.
 No knowledge and cannot
explain.
No data.
No improvement effort.
2
(31 – 50 %)
Doing some but not sufficient.
Doing before auditors arrival.
 There is a knowledge but
people do not know how
to practice.
 There is data but superficial.
3
(51 – 70 %)
 Doing what is supposed to
do but need to put more
effort.
 Understand and have
overall knowledge.
 Sufficient data but not in order.
4
(71 – 90 %)
 Almost ok, but not fully
completed yet or insufficient.
Almost ok, but in some are
need further improve.
 Sufficient data and in order.
 Able to explain.
5
(91 – 100 %)
There is a proper evidence of
5S.
5S culture can be seen.
Completely YES  Orderly stratified data.
 Can show and answer
immediately
 Visual Control is functional.

70. Let’s sustain the gains !
3. Awarding System
01-70
Promotion results must be shared by all the members, and
awarding for 5S promotion results according to evaluation
is recommended.

71. Conclusion
Conclusion
71
Objectives of 5S
Objectives of 5S
Create a safe workplace
Create a safe workplace
Create a comfortable workplace
Create a comfortable workplace
Create an efficient workplace
Create an efficient workplace
Subject of 5S
Subject of 5S
5S of place
5S of place
5S of material
5S of material
5S of information
5S of information
5S of mind
5S of mind

72. The end!
01-72
Thank you for
your attention!