Seiri

Seiton
Seiso
Seiketsu
Shitsuke

Case Study: Renata Engineering Plastics (India)

Business Performance

Quality Improvement

Customer complaints: reduced

Revenues: Increase by 150%
by 75%
Productivity: Increase by 300%
Product defect: reduced by 68%
Production costs: reduce by
On-time delivery: increase by
40%
20%
Rate of rejects reduced by 40%
Changeover time: reduced by
50%
Social Domain
Accident rate in 2002: 0
Training hours; External
training of 125hrs/ year

Environmental Management

Energy consumption: reduced

Water: 100% recycle

Reference: A case study recorded by UNIDO in 2002 (REAP 5S Guide)

Case Study: Metalman (India)

Business Performance
Sales Revenues and gross
margins: Increased
Productivity: Increase by 18%
Value added per employee:
Increased by 150%

Social Domain
Accident rate in 2003: 0
Absenteism; reduced by
>50%

Quality Improvement
Customer complaints: reduced
by 85%
Product defect: reduced by 91%
Rate of rejects reduced by 40%
Tool Change time: reduced by
28%
Environmental Management
Electricity: 260 units per month
Water: Save 24,000 liters/month

Reference: A case study recorded by UNIDO in Feb 2003 (REAP 5S Guide)

1. 5S Principles
Elimination of waste

Every body is involved,

Co-operative effort
Attack root cause
Human being is not
infallible

2. Objectives
Improve housekeeping
Make every individual
responsible for housekeeping
Beautify by simple means
Productivity improvement by
saving time, space etc.

3. 5Ss
Seiri
Seiton
Seiso

- Sorting
- Systematic arrangement
- Cleaning
Inspection while cleaning

Seiketsu - Standardization
Shitsuke - Self Discipline

5S
If we do not do 5S, we cant do any
other work efficiently. They are
features which are common to all
places and are the indicators of
how well an organization is
functioning.

RESISTANCE TO 5S

Its an additional burden. Too busy to do 5S activities.

Why clean it? It will get dirty again.
We cannot change the existing setup.
More work pressure No time for these things
It will take too much time we just want to go on with
work.
My employees will never maintain it.
We are smallwe do not have the resources for major
changes.
We already did this a couple of years ago.
Were productive enough the way we are working right
now.
How does that go along with CSR?

BENEFITS OF PRACTISING 5S
More efficient use of resources (technology/equipment,
people and time)
Improved access to tools, supplies, equipment and
information
Improve workplace safety

How to get started with 5S?

Form a cross-functional team
Management &Staff

Choose Target Area for implementation

Department/ Section/ Process

Tag items being held

Items shouldnt be at its place

Items wrongly placed

SEIRI = Sorting Just in Case to

Just-in-Time

Meaning Distinguish between necessary and

unnecessary items and eliminate the unnecessary items

Activity: Establish a criteria for eliminating

unwanted items. - Eliminate unwanted items either by
disposing them or by relocating them.

Success Area saved or percentage of space available

Indicator

SEIRI = Sorting Fight with

habits

SEIRI = Sorting 3 Categories

- Item Required
X Item Not Required

Undecided
Move to Red Tag Holding Area

Seiri = Sorting

What is unnecessary

1. Item is not needed

2. Item is needed however quantity in stock is more
than what is needed for consumption in near
future
3. Item is needed but once in a blue-moon
4. Contingency Parts
Critically decide the quantity of contingency
parts to be retained and criteria for such parts

Organizing
Frequency of use

LOW

Storage Method

*Things you have not used Throw them out

in the past one year
*Things you have used once Store at distance OR
in the last 6-12 months
Keep in store
*Things you have used only Store it in central place
once in the last 2-6 months in your zone
*Things used more than once Store it in central place
a month
in your zone

HIGH

*Things used once a week

Store near the workplace
*Things used daily or hourly Store near the workplace

Seiri = Sorting

Identifying unnecessary

1. Parts & Work in Process (WIP)

Things fallen back behind the machine or rolled under it
Broken / some items inside the machine
Things under the racks/ platform
Extra WIP
Stock of rejected items
Items accumulated over period for rework
Material awaiting disposal decision
Material brought for some trial, still lying even after trial
Small qty of material no longer in use

Contd..

Seiri = Sorting

Identifying unnecessary

2. Tools, Toolings, Measuring devices

Old jigs, tools not in use are lying
Modified tools, tooling for trial, are lying after trial
Worn out items like bushes, liners, toggles etc. lying
Broken tools, bits, etc. may be lying
Measuring equipment not required for the operation
being performed, is lying
3. Contingency Parts
Many times storage place for contingency parts become
a last refuge for broken parts, surplus items and things
nobody is likely to use
Contd..

Seiri = Sorting

Identifying unnecessary

4. Shelves and Lockers

Shelves and lockers tends to collect things that nobody
ever uses, like surplus, broken items, used tea-cups etc.
5. Passages and Corners
WIP material waiting for decision or dispatch
Dust, material not required seem to gather in corner
6. Besides Pillars and under the stairs
These places tends to collect junk, spittoon etc.
7. Walls and Bulletin Boards
Old out dated notices which have lost their relevance
Posters or bulletins on wall
Dust, remains of torn notices, cell tape pieces Contd..

Seiri = Sorting

Identifying unnecessary

8.Floor, Pits, Partitions

Defective parts
Protection caps, shoe covers
Packing material, stickers, barcodes, cut-leads
Hardware items, small items, runners, plastic granules
Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
Many unwanted, outdated, temporary files pile up
Old dated mails still remaining in inbox and sent items
Deleted mails not being purged when closed
Recycle bin not emptied

Seiri = Sorting

TAGGING

Seiri = Sorting

TAGGING
continued

Type of
Items Duration of
Tag
Use
No Red Tag Used at every 2
Leave the item in its place or search
days
for even more convenient location

Red TagType A
Red TagType B

Used about once a

week
Used about once a
month

Remove it from the direct workplace

but store it close to the work area
Store it somewhere accessible in the
facility

Red TagType C

Used about once a

year or less
frequently

Consider storing it outside or moving

it off-site

Red TagType D

No longer needed

Remove: sell, return, donate or

discard

Seiri = Sorting

Improvement methods

1. Flow Process Chart (Procedural Analysis)

Drawing a process flow chart for the system
eg. How to make and use category wise grouping

2. Operational Analysis
Preparing the sequence of operations for system
eg. How to perform Seiri (sorting)
3. Check List
A check sheet is used to decide what sort of main system
and sub system are necessary.

Seiri = Sorting

Dealing with papers

How to reduce papers

on your table ?
1. Make a single pile of papers
2. Go through them and sort in
following categories
a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information

Seiri = Sorting

Dealing with papers

How to reduce papers on

your table ?
4 D Principle
DO
DELEGATE
DELAY
DUMP

SEITION = Systematic Arrangement

Meaning

To determine type of storage and layout that

will ensure easy accessibility for everyone .

Activity

- Functional storage
- Creating place for everything and putting
everything in its place

Success - Time saved in searching (30 sec to locate an item)

Indicator - Time saved in material handling

SEITION = Systematic Arrangement

The main target areas for Seri-Seiton improvement are :
Tool-setting and preparation operations, line balancing and
process planning, parts supply to assembly line, peak time
problems etc.

Improvement Methods
Kit Method / Assembly box method / Outside tool setting
Cassettisation / Parallel operations / Changes in assignment
method

Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ?

Decide where things belong

Decide how things should be put away

Obey the Put away rules

Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ?

Decide where things belong
Standardize Nomenclature
Determine an analytical method of storage

Decide how things should be put away

Name & locations to everything.

Label both item and location
Store material functionally
Prevent mistakes with coding by shapes
& color
contd..

Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ?

Decide how things should be put away
Follow first in first out rule
If two identical items are to be located,
then store them separately, color code them.

Obey the rules

Put the things back to their location after
their use

Seiton = Systematic Arrangement

USE :

1 ) Signboards
2) Color codes
3) Outline markings
4) Labels

Seiton = Systematic Arrangement

Functional

Storage

Seiton = Systematic Arrangement

Usage
Store frequently used material
Frequency near the workplace and less
frequently at some distance
Heavy material should be stored
Weight &
Shape of the at lower levels/layers
Place directly on the material
Material
handling device for ease of
handling

Functional Storage

Seiton = Systematic Arrangement

Category

Same category of material may

be stored in one location.

Eg. Fasteners, Seals ,
resistors
Operation All items required for an
operation may be stored in one
Wise
location.
Eg. Allen key, spanner etc hand
tools required for setting m/c

Functional Storage

Seiton = Systematic Arrangement

Outlining and Placement Marks

Mark boundaries of dept., aisles, Machines
- Follow straight line, right angle rule
- Nothing shall be kept outside the boundaries

Stands and shelves

Keep only required number of stands and shelves

- Standardize height, size
- Provide casters where necessary so that it can be
moved

Seiton = Systematic Arrangement

Wires and Ducts

Color code
- When there are multiple connections - bundle the
wires, label them and make sure that they are in
straight line /right angle and firmly anchored

Machine-tools & Tools

Put the tools in the order you need them

- Location of the tool should be such that it can be
put away with one hand
- Try to eliminate some hand tools by permanently
attaching it to the bolt head

Seiton = Systematic Arrangement

Blades, Dies, Other important consumables
Store them in the protected place
- Maintain these things regularly by applying rust
preventive, oiling etc.

WIP- Work In Process

Designate a place for each component/part

- Decide on how much quantity to be stored
- Ensure that there is no damage to good part
during transit, they do not get rusty and they are
not mislabeled

Seiton = Systematic Arrangement

Oils & Lubricants

Reduce number of oils used (Standardize)

- Color code for oil

- Safety aspects - fire prevention, pollution,
leak, spillage

Instrumentation & Measuring Devices

Label them, show direction of flow

SEISO = Cleaning
Meaning

Cleaning trash, filth, dust and other foreign

matter. Cleaning as a form of Inspection

Activity

- Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning inspection

Success
Indicator

- Reduction in machine down time

- Reduction in no. of accidents

Seiso = Cleaning

Here cleaning means more than just keeping

things clean. Cleaning should be viewed as a
form of Visual Inspection
Preventive measures should be taken to tackle
problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated

Seiso = Cleaning

Various Minor Defects

= Trash
= Dirt
=Knocking
= Loose parts = Leaks
=Scattering
=Skips
=Curvature
=Abrasion
=Rust
=Scratches
=Eccentricity
=Lurching
=Abnormal
=Vibration
Movements
=Abnormal
=Heat
=Abnormal
Sounds
smells
=Faded color =Hisses
- Cracks

Seiso = Cleaning

5 Minutes Every day for cleaning

Devote 5 minutes everyday for cleaning your
work area
Participation of everyone is required

Attack hard to clean places regularly

Seiso = Cleaning

Cleaning-Inspection points for most

equipment
Grime, clogging, dust balls, rust,
Cleaning leakage etc.

Oils

No oil, Low oil, leakage, filter clogging,

dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
etc.

Seiso = Cleaning

Cleaning-Inspection points for most

equipment
Tightening
Heat

Loose bolts, welding detachment,

loose parts, vibration or bumping
noise, friction

Oil tanks, motors, heater, axles, control

panels, washing/ cleaning water,
bearing, wiring etc.

Seiso = Cleaning

Cleaning-Inspection points for most

equipment
Breakage,
Cracks

Breakage, cracks, dent on sliding

parts, handle has come off, broken
switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.

Seiso = Cleaning

Function wise Cleaning check list of

equipment
Pneumatics

Compressed Air lines, air valves,

connections, meters, filters,
reservoirs etc.

Hydraulics

Hydraulic oil tank, oil valves,

filters, pumps, hoses, gauges,
cylinders etc.

Seiso = Cleaning

Function wise Cleaning check list of

equipment
Mech &
Power Train
Electrical

Motor fan, fan belt, couplings,

Joints, pulleys, chains, pump
bearings etc.

Control panel, lamps, light, switch,

sensors, wiring, ducts, fuses etc.

Seiso = Cleaning

Function wise Cleaning check list of

equipment
Toolings
Equipment
Specific

Tools, fixtures, gauges, dies,

measuring instruments, etc.

Furnaces, rollers, chutes,

CNC machines, etc.

SEIKETSU = Standardization
Meaning

Setting up standards / Norms for a neat, clean,

workplace and details of how to maintain the
norm (Procedure)

Activity

- Innovative visual management

- Color coding
- Early detection of problem and early action

Success
Indicator

Increase in 5S indicator

Seiketsu = Standardization
Regularizing 5S activities so that
abnormalities are revealed
Make it easy for everyone to identify
the state of normal or abnormal
condition
For maintaining previous 3S, deploy
visual management

Seiketsu = Standardization
It has been estimated by scientific
study that 60% of all human activities
starts with sight
5S is easy to do once.It is consistency
that is difficult. That is why Visual
Management is so important, so that
everybody will know that there is
some problem.

Visual Management

Seiketsu = Standardization
What visual control communicates ?
It grabs one or more of our senses in
order to

Alert us to an abnormality
Help us recover quickly
Promote adherence and prevention
Enable successful self management

Seiketsu = Standardization
Some methods for visual communication

Color coding
Use of Labels
Danger alerts
Indication where things should be put
Directional arrows/ marks
Transparent covers
Performance indicators

Seiketsu = Standardization
Some methods for visual communication
Labels
Precision management labels
Inspection labels
Temperature labels
Responsibility photos

Seiketsu = Standardization
Points to remember in making visual
control tools
1. Make them easy to see from
distance
2. Put the display on the things
3. Everyone can tell what is right and
what is wrong
4. Anybody can follow them and make
necessary corrections easily
5. Work place should look brighter &
orderly

Seiketsu = Standardization
Some everyday visual management
examples
Traffic signal
Zebra crossing
In car - Petrol indicator
- Speed indicator
Direction arrows
Electric danger sign
Toilet

Seiketsu = Standardization
Some visual communication signs

SHITSUKE = Self Discipline

Meaning

Every one sticks to the rule and makes it a habit

Activity

- Participation of everyone in developing good

habits
- Regular audits and aiming for higher level

Success
Indicator

High employee morale

Involvement of all people

SHITSUKE = Self Discipline

Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.

Shitsuke = Self Discipline

We need everyone to maintain 5S

guidelines.

To maintain DISCIPLINE, we need

to practice and repeat until it
becomes a way of life.
Discipline is the Core of 5S

Shitsuke = Self Discipline

Discipline means making a steady

habit of properly maintaining
correct procedure.

Time and effort involved in

establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.

Shitsuke = Self Discipline

Pledge

It shall be my constant effort to

maintain my workplace in good
order by
Assigning a place for everything
& keeping everything in its place
Sorting out unwanted material
periodically & discarding them
Keeping my work area neat &
clean everyday

Before 5S

Before 5S

Before 5S

Machine building Bay

Heat Treatment Area

Heat Treatment Area

Machine Shop

End of the
presentation &
Beginning of 5S
activities.