Basic 5S Training Material

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5S
Training module
on

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5S BASIC TRAINING
What is 5S and why do
we want to do it?

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What is 5S and why do we want to do it?
5S is short for:
1S - Sort,
2S - Set in Order,
3S - Shine,
4S – Standardize,
5S - Sustain

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What is 5S and why do we want to do it?
5S represents 5 disciplines for maintaining a visual
workplace.
(visual controls and information systems).
These are foundational to Kaizen (continuous
improvement) and a manufacturing strategy based "Lean
Manufacturing" (waste removing) concepts.
5S is one of the activities that will help ensure our
company’s survival.

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What is 5S and why do we want to do it?
5S
Seiri
Sorting
Seiton
Systematic
Arrangement
(set in Order)
Seiso
Spic
& Span (Shine)
Seiketsu
Standardisation
Shitsuke
Self
Discipline

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5S
1. Sort - All unneeded tools, parts and supplies
are removed from the area
2. Set in Order - A place for everything and everything is
in its place
3. Shine - The area is cleaned as the work is
performed
4. Standardize - Cleaning and identification methods are
consistently applied
5. Sustain - 5S is a habit and is continually improved
Also - Work areas are safe and free of hazardous or
dangerous conditions

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The Good, Bad and the Ugly

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The Good, Bad and the Ugly

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1.SORT
1.SET CLEAR STDS
DEFINE “ NECESSARY ITEMS”
DEFINE “ UNNECESSARY ITEMS” LYING
UNTOUCHED/NON-MOVING FOR
1M? 3M? 6M? 1YEAR?
2. SORT OUT
WHAT IS NECESSARY,
WHAT IS NOT NECESSARY, WHAT IS DOUBTFUL
1. Sort - All unneeded tools, parts and supplies are removed
from the area
DON’T PLACE UNNECESSARY
THINGS IN THE WORKPLACE

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BEFORE AFTER
1.Sort Examples

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BEFORE AFTER
1.Sort Examples

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1.Sort Examples

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How this is bad “5S”?
1.SORT

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2.SET IN OREDR
KEEP ONLY NECESSARY THINGS IN
ORGANISED FASHION
A PLACE FOR EVERYTHING &
EVERYTHING IN ITS PLACE
2. Set in Order - A place for everything and
everything is in its place

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2.Set In Order Example
A PLACE FOR EVERYTHING & EVERYTHING IN ITS
PLACE

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2.Set In Order Example
A PLACE FOR EVERYTHING & EVERYTHING IN ITS
PLACE

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2.Set In Order Example
A PLACE FOR EVERYTHING & EVERYTHING IN ITS
PLACE

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3.SHINE
 REMOVE DIRT FROM EVERYTHING
 INSPECT AND CLEAN THE AISLES,
 GODOWNS, SCRAP YARDS AND GARDENS
 CLEAN UP WORK PLACE, MACHINES AND
TOOLS AFTER USE
 IDENTIFY ROOT CAUSES OF NOISE,
 SPIC AND SPAN LEADS TO REDUCTION
 IN BREAKDOWNS OF PLANT & MACHINERY
Shine - The area is cleaned as the work is
performed

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Shine Examples
3. Shine - The area is cleaned as the work is performed
(best) andor there is a routine to keep the work area clean.

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Shine Examples

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Shine Examples

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Shine Examples

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4.STANDARDIZE
MAINTAIN AND IMPROVE STANDARDS OF
1. SORTING
2. SET IN ORDER
3. SHINE(CLEAN)
Standardize - Cleaning and identification methods
are consistently applied

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Standardize Examples

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Standardize Examples
•Clear, shiny aisle ways
•Color coded areas
•Slogans, banners
•No work-in-process ( WIP )
•One-Piece Flow
•Standardized Work Sheets

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Standardize Examples
DEVELOP STANDARDS,CREATE VISUAL CONTROLS

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5.SUSTAIN
Sustain - 5S is a habit and is continually improved
5S is a simple concept with powerful results.
 DEVELOP ACTION PLAN FOR
 MAINTAINING SET STANDARDS
 GIVE UNAMBIGUOUS INSTRUCTION TO WORK
ASSOCIATES
 CARRY OUT 5S AS A MATTER OF HABIT
 CONDUCT SELF AUDIT

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Sustain Examples
Effective 5S Supports work is easy to SUSTAIN

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Overall 5S Structure

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The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S

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The Good

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Key Deliverables
Cleanliness involves cleaning every aspect of the
Organization and the removal of dirt, dust,
oil, scraps on the floor, & garbage.
Key Deliverables
Increased
Safety
Increase
d
Efficienc
y
A clean Systematic Organization results
in increased safety and efficiency.

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HOW TO IMPLEMENT
 IDENTIFY A COMPANY WIDE 5S CHAMPION
 DIVIDE THE ENTIRE PREMISES INTO ZONES
 IDENTIFY ZONE LEADERS,FACILITATORS AND MEMBERS
 IMPLEMENT FIRST 3S’s (1S,2S,3S)
 EXTEND IMPLEMENTATION TO 4TH S & 5TH S
 PREPARE THE AUDIT PLAN AND CONDUCT THE AUDIT AS PER
SCHEDULE
 STEERING COMMITTEE CONDUCTS SURPRISE AUDIT ONCE A
MONTH OF ALL ZONES, ASSIGN MARKS AND RECORD THEM
ON THE AUDIT SCORE SHEET TO BE SENT TO 5S CHAMPION

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Any
Questions,
???
Thank you