The document provides information on implementing the 5S methodology. It includes: 1. An overview of the 5S implementation process which involves sorting, setting in order, shining, standardizing, and self-discipline. 2. Details on the "shine" element which involves adopting cleaning as a daily activity and inspecting defined areas. 3. Examples of ways to prevent dirty floors like using oil collection mats and locating waste oil tanks outside work areas. 4. Actions needed to standardize processes like developing visual controls and assigning responsibilities. 5. The importance of self-discipline which includes recognizing 5S achievements to create good habits.

1. Draw 5S Plan
lay out
Explain 5s
elements to
all staff
Select the
Task force
members
5S Implementation Process
5S Roll Out
Step 1:
Sorting out
carry out
workshop
Revamp-
Major 5S
Step 2:
Set in order
Step 3:
Shine
Scan the
Premises
Step 5:
Self
Discipline
Step 4:
Standardize

2. 5S step 3 implementation
Shine (Seiso)

3.  Adopt cleaning as a daily activity and as a part
of inspection. Clean the workplace before
starting of the job and before closing the job.
Put aside 10 or 15 minutes for the same
activity per day.
 Clean and inspect defined areas, workplace,
machines and other items.
 Cleaning indirectly helps to check or inspect
each and every part and place. Hence, it should
be a habit.
 Take remedial action to prevent re-occurrence.
 Schedule as needed paint coating on buildings,
floors, machinery and equipment, during non
productive times
SEISO (SHINE)

4.  Find ways to prevent dirt and
contamination.
 Sweeping checklists are applied
throughout the day for each of the
common areas
 Safety inspections are performed on a
regularly scheduled basis
 Workers should be responsible to clean
the machines, tools, work benches in
their individual workplace.
 Sweepers should be responsible for the
common areas outside and inside the
premises

5. Oily floors are a common
problem created by:
 Oil leaking from engines,
transmissions and brake
systems and spoiling the floor
 Keeping the transmission and other parts on the
floor, spilling the oil.
 Draining the oil into a pan, spilling it on the floor.
 Carrying the oil pan to a waste oil drum and
carelessly emptying it in the drum.
 Note the condition of floor in the photograph.
Use 5 Whys or cause-and-effect methods to find
the root causes of slippery floor and take
appropriate corrective and preventive action.

6. WHY 1
Used Engine oil is
Emptied in a drum
manually causing
it to spill on the
floor
Ask "WHY" five times - get to the root
cause of why the working bays get dirty
Proper oil collector
is not used for
draining the oil.
WHY 2
While carrying it to
the drum, oil spills
all over the place.
WHY 3
The oil drum is
located at a long
distance
WHY 4
Manual transportation
of the used
engine oil is the main
cause of oil Spilling on
the floors
WHY 5
Root
cause
Conclusion: The used oil should not be transported
manually to the waste oil drum

7. Air line to
oil drain
trolley
pump
Oil drain trolley with
evacuation pump
A
B
c
Method of preventing oil
spillage on the ground
Waste oil tank located
outside the working
area(hidden from view)
PVC
/FRP
WASTE
OIL
TANK
Waste oil sucked by the
purchaser’s tanker
Making use of the root cause analysis, the task force
came up with the above solution to prevent oil spillage.

8. Floor rubber mats can be laid under the car
lift to prevent leaking engine and
transmission oils spoiling the floor. There is
no special rubber quality required, local
grades of thick rubber sheets would be ok.
The rubber sheet can be washed with a
chemical or detergent frequently.

9. 5S Step 4 implementation
SEIKETSU(STANDARDIZE)

10. Wake up Sleeping Beauty
!!!!

11. SEIKETSU (Standardize)
•Establish standards.
Develop visual controls to
expose abnormality.
•integrate with daily work
management.
•Prevent deterioration
using 5W & 1H strategy.
Standards improve reliability and consistency.

12. Actions items
1. Take “before” photographs.(See module 2 for
before photos)
2. Check that the first three S’s are
implemented properly.
3. All team activity documents/check lists
should be publicly displayed on a 5S board.
4. Establish the routines and standard
practices for regularly and systematically
repeating the first three S’s.
5. Create procedures and forms for regularly
evaluating the status of the first three S’s.
6. Standardize red tag procedures and holding
area rules (see Seiri).

13. 7. Standardize procedures for creating shadow
boards, position lines, and labeling of all items
(see Seiton).
8. Standardize cleaning schedules using the “5S
Owner Check Sheets” (see Seiso).
9. Standardize “single-point lessons” for
documenting and communicating 5S procedures
and improvements in workplace and equipment.
10. Create a maintenance system for
housekeeping. Make a schedule for cleaning of
the workplace. A common approach is to ask a
cross-functional team to do it.
11. Inter-departmental competition is an effective
means of sustaining and enhancing interest in 5S.
12. Assign responsibility to individuals for a work
area and machinery.

14. Check out
Kaizen suggestion form.xlsx
13. Regular inspection/audit and
evaluation by a special team (including
senior management persons) to be
continued.
14. Instead of criticizing poor cases,
praise and commend good practices or
good performers.
15. Take “after” photographs and post
them on the 5S board(s).
16. Complete evaluation using 5S levels of
implementation with the facility manager
or the authorized persons in the
organization

15. 5S activity Board

16. •Create an environment
through slogans, posters
and other visuals
•Set an example, from a
habit.
•Conduct audits to evaluate
approach and results.
Recognize 5S achievements
5. SHITSUKE (SELF DISCIPLINE)
Action speaks louder than the words
March04 audit.xls

17.  Fix up a day when your workshop staff
takes a break from the usual boring schedule.
 Announce at least 3 winners who have
scored maximum points in the 5S audit.
 Distribute T shirts or badges to winners.