5S Methodology

Work Environment - (5S)

1S - SEIRI - SEGREGATION
2S - SEITON - SYSTEMATIC
ARRANGEMENT
3S - SEISO - SPICK & SPAN
4S - SEIKETSU - STANDARDISING
5S - SHITSUKE - SELF DISCIPLINE

A SOURCE OF PRIDE
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Customer
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SEIRI
SEITON
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SSS
What are 5S ?
5S stands for five good housekeeping
principles.
5S becomes a base for continuous
improvement.
5S principles are very effective
systematic approach for improving our
work environment and total quality.
5S are participation programme.
5S is based on the belief that every
individual can contribute to improve
his/her workplace where he / she
spends one third of his / her life.
Objectives of - 5S
Objectives of - 5S
Creating a neat and clean workplace.
Systematize day to day working.
Improve work efficiency.
Standardize work practices.
Improve work discipline.
Improve productivity.
Improve quality.
What do we get from practicing 5S activities ?????
What do we get from practicing 5S activities ?????
1. All working area in proper
order.
2. Create more vital working
atmosphere.
3. Cheerful / good mood.
4. Safe environment.
5. Higher work efficiency.
6. Create work effectiveness.
7. Take Pride.
1. Increase production efficiency.
2. Reduce unnecessary work.
3. Low production cost.
4. More space and storage are obtained.
5. World class company is expected.
6. Obvious factory.
7. Confidence and recognition are obtained.
Employee Organisation
5S5s
SEIRI means to distinguish between what is necessary and what is
unnecessary in accordance with specific rules and principles and get
rid of what you do not need.
Saving things and information
which
one does not need consume
extra space and
create more wok.
SEIRI is excellent way to gain valuable floor space
and eliminate scrap and excess raw material.
Throw away / get rid of
Put for sale
Place in the right location
and identify with tag
Unnecessary things with no value
Unnecessary things with value
Things still used and needed
Acceptable product mixed with
reject
Reject mixed with acceptable one

Lost and Waste

Lose Brand loyalty
Customer does not pay for waste.
What is the criteria to distinguish necessary and unnecessary ?
Clarify standards to judge the necessary things from

the unnecessary.
Segregate the things in compliance with the set

standard.
Extended decision making is prohibited.
Schedule the itinerary checking by promotion

committee members.
Eliminate the space to store unnecessary things in

order to expel such things.
Do not hurry to expand the space.
The goods which cannot be sold are unnecessary.

How to implement SEIRI - 1S ?
Where unnecessary things can be found ?
0
Shelves & Lockers - surplus/broken articles
O
Passageway and corners- useless articles
O
Behind pillars and under stairs- materials, defective
O
Warehouses and sheds- materials/in process articles
O
Walls and bulletin boards- expired notice
O
Behind and also under the machines-broken articles
O
Under the floor and side ditches- scrap
O
Materials and in process articles
O
Outskirts ( Near the wall, fences, and drainage)
Benefits from SEIRI
Eliminate the excess use of space.
Eliminate the excess equipment.
Eliminates the excess use of file

cabinet / shelf.
Eliminates accidents.
Eliminates errors.
Eliminate waste of time
Reduce cost of production.

2S - SEITON - SYSTEMATIC ARRANGEMENT
SEITON means having things in the right place or
right location. It is for the most efficient and
effective retrieval. Make a system which enables
anyone to take out the thing promptly.
A place for everything and
everything on its place
What to do with segregated necessary things ?
How to implement SEITON ?
C
Fix the storage space.
O
Clearly indicate the storage location.
O
Unify the names of thing.
O
Stratify things.
Things which are used once or twice a year ---

to be stored in remote place.
Things which are used about once a month ---

to be placed collectively in the work place.
Things which are used daily --- to be placed

within the work area.
C
Decide how to put things.
O
In relation to quality.
Avoid placing the things which resemble each

other together. Show the difference clearly.
Indicate the storage period.
Use the first in first out method (FIFO).
Distinguish clearly between good and inferior

quality goods.

C
Establish a storage standard.
Being taken away--- Who did it,

when is the return date?
Out of stock--- Is there backup

supply?
Stock replenishment---Who places an

order, to whom and for what quantity.
Way of eliminating the unproductive time
spent in looking for necessary things.
C
Decide how to put things.
O
In relation to efficiency.
Assigned place marking, putting things visibly

in place.
Location --- self numbers
Layout --- minimization of movement.
Ease of removal and storing.

O
In relation to SAFETY
Put heavy weights at lower place.
Prevent overturn and drops.

Benefit from SEITON
Helps to reduce time for finding useful
material .
Create work effectiveness.
Create safe atmosphere.
Easy to inspect and recognize when material
are gone from their location.
3S - SEISO - SPICK AND SPAN
Are floors and machines
cleaned for the sake of
appearance????
SEISO means getting rid of waste, grime and
foreign matter and making things clean. Make a
system which eliminates the cause of dirtiness.
CLEANING AS A FORM OF
INSPECTION.
CLEANING IS A EVERYBODY
BUSINESS.
WHY to do SEISO ?
SEISO ( Cleaning) is a philosophy and commitment to
be responsible for all aspects of the things you use and
to ensure that they are in tip top condition
Dust, dirt, grime, foreign matter etc. are looked upon as
the prime causes for unexpected failure of equipment,
unhygienic environment and even accidents.
Therefore SEISO should be viewed as way to eliminate
these problems one by one.
How proper cleaning to be done?
Following steps to be followed for doing proper
cleaning:
C
Measures against the root of uncleanliness.
O
Investigation of the root of uncleanliness.
O
Measures against the cause of uncleanliness
Prevention of leakage
prevention of scattering
prevention of falling
study of manufacturing method
Correct looseness
O
How to deal with places which cannot be cleaned easily ?
Devise effective means to collect and dispose of dust.
Review of dust collection capacity and method,

cleaning equipment and method of washing.
C
Cleaning of workplace
O
Allotment of areas and equipment to be cleaned
First allot the area by group, then allot a related job

by person.
O
Do Cleaning
Detect abnormal condition while cleaning.

O
Establish cleaning rules.
Decide when to do cleaning.

C
Cleaning of equipment
O
Do cleaning by a check sheet.
Wipe out dirt.
Cleaning of clogged filters, pipes etc.
Control of generation of heat and other temp.
Correction of displacement.
O
Teaching of equipment and facilities element
O
General equipment and facilities check point
C
Check point for cleaning.
C
Check points for oil
C
Check points for additional tightening
C
check point for temperature control
C
check point for breakage.
4S - SEIKETSU - STANDARDIZE
What do you mean by
SEIKETSU
Seiketsu means continually and repeatedly
maintain 1S, 2S & 3S standard achieved. Make
a system which enables quick detection of a
disordered condition / state.
It must be made possible for
anyone to see the actual
situation at a glance by means of
the visual control
How to maintain 1S, 2S & 3S ?
Standardization is a condition where the segregation,
Systematic arrangement and Cleaning have been
repeated and maintained. Introduce extensive visual
controls so that abnormalities show up by themselves.
Following steps to be followed to maintain and
promulgate first three S more deeply.
C
Points of visual control
O
Standards for what is good and bad are clear.
O
Abnormal conditions are shown.
C
Tools of visual control
O
Label - lubrication label, accuracy label,
inspection label, label showing the person
incharge, equipment number and category.
O
Limit marking - meter zone, stop line,
assigned place marking, danger alert.
O
Visualization - Status indication, direction
indication, maintenance display board,
Instructions, colour code for pipes, picture of
safety gadgets to be used in the area, direction
sign for emergency points & fire extinguisher,
Caution and operation reminders.
PREVENTS THE 1S, 2S AND 3S

RETURNING TO 0S !!!!!
PROPER AND NICE WORKING AREAS.
STANDARD OPERATIONS AND

PROCEDURES.
CREATE EXCELLENT PHYSICAL AND

MENTAL HEALTHS.
IT MEANS HAVING THE ABILITY TO DO
THINGS THE WAY THEY ARE SUPPOSED
TO BE DONE. THE EMPHASIS IS ON
CREATING A WORKPLACE WITH GOOD
HABITS AND DISCIPLINE.
Doing the right things as routine.
5S - SHITSUKE - SELF- DISCIPLINE
Discipline means to get accustomed to the
operation in compliance with standards. It is the
discipline to honour faithfully the promises agreed
upon by the fellow people.
The purpose of SHITSUKE is to support the
four S ( Segregation, Systematic arrangement,
Spick & Span and Standardizing) as the means to
satisfy such fundamental things.
Keep practicing the activities
through those procedure
until they become habits.
Discipline means thinking about the many problems
that occur day to day and resolving to do better.
People sometimes make the most unbelievable
mistakes because they let their guard down- because
they forget their discipline.
Practice and more practice.
When you assume that something
is easy just because you have
done it thousand of times, that is
when you are most likely
to get it wrong.
How to instill discipline ?
1) Cultivation of habits
Make clear what should be done.
Do it every day with the participation

and practice by every one.
2) Conduct training
Train employees until they become

capable of complying with standard.
Make worker responsible for action and

not for the results.
It is very important to practice and more
practice, because practice reinforces correct
habits.
It is very important to be strict about how things
are done - even the little things.
Disciplined workplace is the most
important thing to ensure
Product Quality

5S Methodology

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5S Methodology

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Work Environment - (5S)

Work Environment - (5S)

Creating a neat and clean workplace.

Systematize day to day working.

Improve work efficiency.

Standardize work practices.

Improve work discipline.

Clarify standards to judge the necessary things from

Segregate the things in compliance with the set

Extended decision making is prohibited.

Schedule the itinerary checking by promotion

Eliminate the space to store unnecessary things in

Do not hurry to expand the space.

The goods which cannot be sold are unnecessary.

Eliminate the excess use of space.

Eliminate the excess equipment.

Eliminates the excess use of file

Eliminate waste of time

Reduce cost of production.

Things which are used once or twice a year ---

Things which are used about once a month ---

Things which are used daily --- to be placed

Avoid placing the things which resemble each

Indicate the storage period.

Use the first in first out method (FIFO).

Distinguish clearly between good and inferior

Being taken away--- Who did it,

Out of stock--- Is there backup

Stock replenishment---Who places an

Assigned place marking, putting things visibly

Location --- self numbers

Layout --- minimization of movement.

Ease of removal and storing.

Put heavy weights at lower place.

Prevent overturn and drops.

study of manufacturing method

Devise effective means to collect and dispose of dust.

Review of dust collection capacity and method,

First allot the area by group, then allot a related job

Detect abnormal condition while cleaning.

Decide when to do cleaning.

Wipe out dirt.

Cleaning of clogged filters, pipes etc.

Control of generation of heat and other temp.

PREVENTS THE 1S, 2S AND 3S

PROPER AND NICE WORKING AREAS.

STANDARD OPERATIONS AND

CREATE EXCELLENT PHYSICAL AND

Make clear what should be done.

Do it every day with the participation

Train employees until they become

Make worker responsible for action and

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