5 ' S , Need for 5 ' S

1. 5S- HOUSE KEEPING
OR
WORK PLACE
MANAGEMENT

2. 5-S: HOUSE KEEPING
WHAT IS 5-S
SEIRI CLEARING
SEITON ARRANGING
SEISO SWEEPING
SEIKETSU CLEANLINESS
SHITSUKE DISCIPLINE

3. NEED FOR 5-S
• There can be no TQM without 5-s
• A dirty factory can not produce
quality products.
• If housekeeping is weak in a plant,
no further quality diagnosis is
required to know that it produces
poor quality products.

4. NEED FOR 5-S
• An orderly mind alone can create
well- ordered surroundings.
• Conversely, an orderly
environment promotes an orderly
mind
• Clutter hides problems. A neat
work place promotes easy
discovery of abnormalities.

5. WHY 5-S
5-S Contributes to 1. Safety
2. Quality
3. Productivity
5- S Facilitates 4. Visual Control

6. WHY 5-S
Safety
If Clearing and arranging are done
well then the work place has more
space. There is less clutter.
Work preparation is easier,
efficiency is raised, things do not
get lost and the general
atmosphere is more pleasant.
These conditions promote safety.

7. Also, accidents often occur
because of tripping over something
on the floor where it is not supposed
to be something falling down a
cupboard because it is kept
improperly or in the wrong place.

8. Our hands or clothing getting
caught in something which is out of
place.
A hazardous chemical is spilled
or touched because of wrong
location or missing labels.
Orderliness promotes safety
whether at home, office, shop floor
or on the road.

9. Why 5-S
Quality
* A clean and orderly work place is a
pre-requisite for making good
products.
* If a factory has poor housekeeping,
no further analysis is required to
know it has quality problems.

10. Poor 5S causes poor quality in
many ways:
1. Use of wrong parts or materials-
especially if they look similar.
2. Mix-up of rejects and good ones
in stores, causing rejects to be
issued to the shop.
3. Rejects getting mixed in the shop
it self, or going to the next line for
further processing and even to

11. Poor 5S causes poor quality in
many ways:
4. Some process getting missed
altogether examples: parts waiting
for heat treatment getting mixed
up with parts already heat treated.
5. Dusty parts or materials getting
used to the detriment of
performance or impression of the
customer

12. 6. Shelf-life expired materials may
get used.
7. Searching for things takes time
away from quality improvement
Poor 5S causes poor quality in
many ways:

13. Poor 5S causes poor quality in
many ways:
8. Machines wear out faster if they
are not free of dust and this
reduces their accuracy and
variability causing defectives.
9. An Attitude is generated which
say that orderliness, discipline
are not important hence quality
also not important.

14. Why 5-S
Productivity
To improve productivity, it is vital to
provide a clean, cheerful and well
organized environment in order that
everyone can work efficiently.

15. Productivity is very much a function
of morale.
Good morale is promoted when
people can feel proud about the way
they maintain their workplace.
Why 5-S
Productivity

16. 5-S promotes productivity in
many ways
1. Time spent in searching for things
(parts, tools or paper) is eliminated.

17. 2. Production loss due to a part or a
material or tool or anything else
which is supposed to be available
but can not be traced is eliminated.
5-S promotes productivity in
many ways

18. 5-S promotes productivity in
many ways
3. Production loss due to use of wrong
materials, mix-ups of materials and
other such defectives are eliminated.
4. Machines break down more often
when they work in dusty conditions.

19. 5-S promotes productivity in
many ways
5. The act of thorough cleaning of
machines often highlights things that
need attention. Without such cleaning,
timely attention may not be given
causing breakdowns

20. 5-S promotes productivity in
many ways
6. Lack of punctuality affects the
productivity of all members of a
workplace even if only one person
is late.

21. 5-S promotes productivity in
many ways
7. Abnormalities which cause
production stoppages can
be spotted easily
example: a bin without
enough materials on the shop
floor, or a pile-up of rejection
bins

22. Why 5-S
Visual Control:
The job of a manager is to so organized
his plant so that the slightest abnormality
becomes visible immediately.
The most effective system of daily
checking or control is the visual one 5S
makes visual control possible and hence
improves the quality of management.

23. 5-S promotes productivity in
many ways
Where house-keeping is poor, it is hard
to separate the normal from the
abnormal.
Where things are lying all over the
place how does one spot anything
unusual ?

24. 5-S promotes productivity in
many ways
On the other hand where good 5S is
practiced, a manager may get to know
the situation by mere observation.
For example: “Line X seems to be
having higher defectives to day”.

25. 5-S promotes productivity in
many ways
“Why is line A carrying an extra trolley
of in-process goods?
They must have lost production last
night.”
“There seems to be a breakdown in the
middle of a process. There is a pile-up
out there.”

26. 5-S promotes productivity in
many ways
“This line is not balanced. There is no
even flow of materials.”
Managers must learn to spot
abnormalities so that they can take
actions quickly.
Abnormalities must be made strikingly
visible. That can be done only if the
normal is define d and visibly enforced.

27. 5-S promotes productivity in
many ways
Visual control is promoted by
standardizing 5S and practicing with
use of clear signs, labels, colors and
systems of orderly arrangement.

28. Why 5-S
Visual Control
1. What needs monitoring?
2. How are abnormalities defined?
3. How easy is checking?
4. What actions should be taken?

29. Why 5-S
Visual Control
• The signs must be recognizable at a
glance, under-stand able to everyone.
They should help make the place
visually appealing and less cluttered.

30. Why 5-S
Visual Control
Visual control helps in all areas of 5s-in
storage operations and equipment.
They are also powerful aide in
ensuring quality and safety
(eg. Colors signs on meters)

31. Why 5-S
Visual Control
As part of standardization, a 5S
manual must be prepared.
This manual must have charts and
others visual displays which make their
meaning clear.
Then the manual can be used for
training of employees, new and old.

32. Why 5-S
Visual Control
Without the reinforcement through
visual signs, it is easy not to form
habits of 5S and to backslide.
At the same time putting up poster
and signs only without carrying out a
vigorous programme is hollow and will
yield no results.

33. SEIRI: CLEARING
Take out unnecessary items and
throw them away
Factory floor
• Machine to be scrapped Broken toys
• Rejected materials clothes
• Expired goods Suitcases
• Broken tools, pallets
• Trolleys, old notices
• Scrap heaps outside

34. Take out unnecessary items and throw them away
Office
Used/broken pens
Useless paper
Old diaries
Broken furniture
SEIRI: CLEARING

35. Take out unnecessary items and throw
them away
Home
• Old Clothes
• Broken Toys
• Broken Suitcases
• Useless Tins
SEIRI: CLEARING

36. HOW TO PRACTISE SEIRI
1. Separate the wanted from the
unwanted
NO USE
DISCARD
SEPARATE THE WANTED FROM THE UNWANTED
JUNK & WASTE REPAIRABLE WANTED
REPAIR
TO THE NEXT ‘S’

37. HOW TO PRACTISE SEIRI
2. Throw away the unwanted items
Do not keep them with a vague
idea that the may be needed.
If an item has not been used for a
year, get rid of it.
Be ruthless about throwing
necessary things away.

38. HOW TO PRACTISE SEIRI
3. Classify everything by frequency
of use

39. SEIRI
FREQUENCY OF USE ACTION
1. Not used for the
year
2. Used only once in
last 6-12 months
3.Used only once in
last 2 - 6 months
Throw them away
Store at a
distance
Store at a central
place

40. 4. Used more
than once in a
month
Store at a central
place.
5. Used once a
week or daily
Store near site or
person.
SEIRI

41. 5-S HOUSE KEEPING
SEITON: ARRANGING
Arrange everything in proper
order so
that it can be easily picked up
or use.

42. Factory floor
1.Unlabelled tool crib
2.Cluttered shelves, lockers
3. Stores-no clear location system
4. Things on the floor
SEITON: ARRANGING

43. SEITON: ARRANGING
Office
1.Unlabelled file Cabinet
2.Cluttered drawing
3. Shelves, tables
4. File heaps and Papers all over

44. SEITON: ARRANGING
Home
1. Clutter
2. No orderly Arrangement In
Drawing room or kitchen or
anywhere

45. SEITON:
Consequence of not practicing SEIRI
1. Things are seldom available when
needed. Search squads are all the
time looking for misplaced things.
2. Together with non-practice of
SEIRI, the frustrating effects are:
Items are lost in stores.

46. Consequence of not practicing SEIRI
3. Items-defectives and good ones, or
similar looking materials get mixed up
4. Accidents or near accidents occur due
to clutter.
5. Visual control of the shop floor is not
possible.

47. • Consequence of not practicing
SEIRI
6. Sometimes production is lost
because an item required is
available but can not be found.
In some offices, the consequences can be
even more serious. Critical excise records.
Or tax Records may not be traceable.
This can lead to financial loss/ persecution.

48. The four steps to SEITON
are:
2. Fix Storage place
3. Fix Storage Method
4. Keep storage rules
SEITON
1. Analyze the present situation
2. Fix Storage place
3. Fix Storage Method

49. Analysis
• The Steps involved in retrieving
any item, say a jig are.
a)Get the name correctly.
b)Go to fetch it.
c)Search for it.
d)Take it out.
e)Carry it to the workplace.

50. Analysis
• In Some cases, quantitative
analysis of these steps are
required.
• In the best organized shops, things
are retrieved in seconds

51. SEITON
2. Fix the storage place:
This calls two steps
a) Everything should have a name
b)Consider the storage layout for each
class of items, based on the building
layout
c) 5-S means everything should have an
address.

52. SEITON
3. Fix the method of storage
a) Decide between storage by
function or storage by workplace
of process, or a combination

53. SEITON
3. Fix the method of storage
b) Select or design the appropriate
storage method. Here is where
creativity can be used to help
orderliness and easy retrieval.

54. SEITON
3. Fix the method of storage
c) Do not be restricted by available
standard storage systems.
d) Display names of items and
storage place clearly and
prominently.

55. SEITON
4. Follow the rules
a) It all comes to good daily
management. The best storage
system can work only if it is
maintained that way, everyday.
b) Stock outs must be prevented
and items taken out must be
returned.

56. SEITON
4. Follow the rules
c) Even if an item is used by some
one, it should be made to visually
striking.
d) Storage areas should be clearly
marked and things should be
within yellow and white lines
marked on the floor.

57. Passages Should be kept clear.
There should be no storage in the
wrong places or available open
places on the pretext of keeping
them “temporarily”.

58. SEISO: SWEEPING
Sweep your workplace thoroughly
so that there is no dust anywhere.
Our environment is among the most dusty,
anywhere in the world.
We should therefore take even more trouble
to sweep and mop than they do elsewhere

59. Factor floor
•Dirty machines
•Dust on products, parts, raw
Materials
•Dirty jigs, fixtures,
•Dusty walls, roofs ,Littered Floor,
untidy
•Outside of the factory

60. Office
•Dusty table
•Dirty Office equipments
Type writers,
Computers,
•Dirty windows
•Dust in hidden places etc

61. Home
•Dirty furniture & floor
•Dusty window
•Dusty book shelves
•Dusty floor, cobwebs, fans

62. Consequence of not
practicing SEISO
• Most machines are affected by dust
and dirt. Their performance may go
down, they may wear out faster. The
costs Can be huge.
• Cleaning reveals many potential
equipment problems which may
otherwise get overlooked.

63. Consequence of not
practicing SEISO
• Dust and dirt on products, materials,
packing boxes will almost certainly
affect either their performance quality
and in the least their aesthetic quality.
• A dusty and dirty place is unpleasant
to work in.

64. Washing, with a strong overtone of
keeping things disinfected as well as
free of hazardous Chemicals.
Some authors call this step standardizing.
But Standardizing should be common
to each of the 5-s.
SEIKETSU: CLEANLINESS

65. Factor floor
•Handling hazardous Chemicals
Control of fumes,
•Hazardous, Dust etc.
•Disinfecting personal Hygiene.

66. Office
•Pest control.
•Personal hygiene

67. Home
•Pest control
•Personal hygiene

68. Consequence of not practicing
SEIKETSU
1. Good health and safety require the
practice of Seiketsu (it does not cover all
safety and health aspects but is basic to
it).
2. Hazardous chemicals, dusty chemicals,
fumes etc. can make it a dangerous
place to work in unless controlled

69. Consequence of not practicing
SEIKETSU
3. Washing thoroughly cleans a place
and makes the work place pleasant so
an unwashed work place can become
unpleasant.
4. Personal hygiene is also essential for a
healthy workforce.

70. SHITSUKE: DICIPLINE
Discipline, especially with regard
to safety rules and punctuality

71. 5 S- TQM
K.Vijay Anand
Associate Professor
Electronics and Instrumentation Engineering Dept.
R.M.K Engineering College
kva.eie@rmkec.ac.in

72. SHITSUKE: DICIPLINE
5-S means everything is in its
place.
People must also be in their place,
at the right time, in the right attire,
It is Management’s responsibility
to train people to practice 5-s with
discipline, to acquire the habit and
to keep it.

73. Consequence of not practicing
SHITSUKE
1. If management is not disciplined , then
employees would not be either and the
first 4-S would backslide.
2. Without acquiring the 5-S habits, it is
difficult to maintain good 5-S.

74. Consequence of not practicing
SHITSUKE
3. Lack of shitsuke means not
following standards. Not only 5-S
but all activities relating to safety
and quality will also be affected.

75. 5-s House Keeping
Training on 5S must be with the
aid of visual charts and display.
That is the way to ensure that the
message is understood and stays
clear.
It is also easier to train new or
Transferred employees.
The charts and displays reinforce
the usage continuously and enable us
to form habits/Until 5-S Become a
habit, the battle is not won.

76. 5-S HOUSE KEEPING
IMPORTANCE OF 5S
A Clean workplace is high in P roductivity
A clean workplace produces high Q uality
A clean workplace keeps C ost down

77. A clean workplace ensures
elivery on time
A clean workplace is afe for
people to work
A clean workplace is high in orale
D
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