WHAT IS 5S ?

 5S IS A JAPANESE CONCEPT OF
HOUSEKEEPING.
 5S STANDS FOR FIVE JAPANESE
WORDS .
1. SEIRI MEANING SORT
2. SEITON MEANING SET IN ORDER
3. SEISO MEANING SHINE
4. SEIKETSU MEANING STANDARDISE
5. SHITSUKE MEANING SUSTAIN
5 PILLARS of 5S

 SORT
 SET IN ORDER
 SHINE
 STANDARDISE
 SUSTAIN
What is Housekeeping?
 Housekeeping is a term which implies
that everything should be in its place
& there should be a place for
everything.
 Why 5S?

 Customers needs constantly change.

 Companies compete to meet these needs.
 To survive, your company must stay
competitive.
 To Stay competitive we have to improve in
products & quality & lower costs.
 The five pillar system is a good starting
point for all improvement programs.
Benefits of 5S ( For employees)
 Provides an opportunity to organise your
workplace.
 Makes your work place more pleasant to
work in.
 Makes your job more satisfying.
 Removes obstacles & frustrations in your
work.
 Helps you know what you are expected to
do & when & where you are expected to
do it.
 Makes it easier to communicate with
everyone you work with.
 Benefits of 5S
( For the Organisation)

 Zero changeovers brings product

diversification.
 Zero defects bring higher quality.
 Zero wastes lowers costs.
 Zero delays provide reliable deliveries.
 Zero injuries promotes safety.
 Zero breakdown brings better equipment
availability
 Zero complaints brings greater confidence
& trust.
 Definition of “SORT.”

 Sort means that you remove all items

from the workplace that are not
needed for production.
Why Sort is important?
 Effective use of space , time ,money ,
energy & other resources.
 Reduces problems & annoyances in
workflow.
 communication between workers is
improved.
 Product quality increases.
 Productivity is enhanced.
Problems avoided by implementing
SORT.
 The factory becomes increasingly crowded &
hard to work in.
 Lockers, shelves & cabinets for storage of
unneeded items act as barriers of communication
between employees.
 Time is wasted in searching for parts & tools.
 Unneeded inventory & machinery are costly to
maintain.
 Excess stocks in hand hides other types of stock
in production.
 Unneeded items and equipment make it hard to
improve the process.
 Steps involved in
implementing “SORT” in your
workplace
 Launching a red tag project.
 Identifying red tag targets.
 Setting red tag criteria.
 Making red tags.
 Attaching red tags.
 Evaluating red tags.
 Document results of red tagging.
1. Launching a red tag project.
Red tagging is simply a method of identifying
unneeded items , evaluating their usefulness
& dealing with them appropriately.
Red color tags are used for red tagging as it
catches people’s attention easily.

Launching a red tag team involves:

1. Organising a red tag team
2. Organising a time & schedule for red tagging
3. Creating a local red tag holding area.
4. Planning for disposal of red tagged items.
2. Identify red tag targets.
This basically involves:
1.The specific types of items to
evaluate. eg; In manufacturing area
targets can be unused raw materials,
finished components, finished
products, tools , machines etc.
2.The physical; areas where red
tagging will take place.
 3.Set red tag criteria.
This is the most difficult part in the red
tagging exercise is to distinguish what is
needed from what is not.

The following factors determine whether a

item is needed or not:
 The usefulness of the item to perform the
work in hand.
 The frequency with which the item is
needed.
 The quantity of item needed to perform the
work.
 4. Making Red Tags.
Red tags should be designed keeping in
mind the requirements of the organisation.
Some of the information on red tags may
be as follows:
* Category of item
* Item name & manufacturing number
* Quantity
* Reason for red tagging
* Department responsible for red tagging.
* Value of red tagged item
* Date of red tagging
 5. Attaching Red Tags.
The best way to do red tagging is to do the
whole target area quickly- in a day or two.
Following are some of the unneeded items
in the workplace that require red tagging:
 Defective & excess quantity of small parts &
inventory.
 Outdated / broken jigs & dyes.
 Worn out bits.
 Outdated / broken tools & inspection gears.
 Old rags
 Electrical equipment with broken cords.
 Outdated signs / posters / notices & memos.
Places where unneeded
items accumulate
 Rooms & areas not designated for any
particular purpose.
 Corners next to entrances or exits.
 Along interior or exterior walls , next to
partitions & behind pillars.
 Under desks & shelves & in desks &
cabinet drawers.
 On unused management & production
schedule boards.
 In tool boxes that are not clearly sorted.
6. Evaluate Red Tagged Items.
After red tagging process is over , the following
criteria is used to evaluate what to do with red
tagged items.
 Keep the item where it is.
 Move the item to a new location in the work area.
 Store the item away from the work area.
 Dispose the item.
 Throw away the item.
 Sell the item.
 Return the item to the vendor.
 Lend it out.
 Distribute the item to different department in the
company.
 Send it to the central red tag holding area.
7. Document the result of red
tagging

As each company has its own needs of

documenting , it needs to design its own
system of logging& tracking necessary
information as red tagging takes place.

Documentation of results of red tagging also

helps in measuring the improvements &
savings produced as a result of red tagging.
Definition of “SET IN
ORDER.”

This means arranging needed items

so that they are easy to find , use
and put away and anyone can find
them & put them away.
 Why set in order is
important ?
Eliminates many kinds of wastes in
production & clerical activities. These
include searching waste, waste due to
difficulty in using items, Wastes due to
difficulty in returning items.
 Problems avoided by
implementing “ Set in Order.”
 Motion Waste.
 Searching Waste.
 Waste of Human Energy.
 Waste of Excess Inventory.
 Waste of Defective Products.
 Unsafe Working Conditions.
 Definition of
Standardisation

Standardisation means creating a

consistent way of doing tasks &
procedures.
Implementation of Set in
order
 Step one: Deciding Appropriate Locations
A 5S map is a tool to evaluate current
locations of parts & equipment & decide the
best locations.
Using the 5S map basically involves
creating 2 types of maps:
- A before map
- An after map.
Implementation of Set in order

 Step Two: Identifying Locations:

Once the locations have been decided , we need a
way to identify these locations so that everyone
will know what goes where & how much of each
items belongs in each location. The following
strategies are used for deciding what where &
how many.
 The Signboard strategy
 Color coding strategy
 Painting strategy
 Outlining Strategy
The Signboard Strategy

The signboard strategy uses signboard to

identify What , Where & How many?
The three main types of signboard are:
 Location Indicators : These show where the
items go.
 Item Indicators: This shows what specific
items go in each places.
 Amount Indicators: These show how many
of each items belongs there.
Color Coding Strategy
 Color coding can be used to show
which parts, tools , jigs, and dies are
to be used for which purpose.
e.g; if certain parts are to be used for
making a particular product they can
all be color coded with the same
color & even stored in the same
location.
 Painting Strategy

 The Painting Strategy is a method for

identifying locations on floors &
walkways.
eg; Painting strategy is used to create
divider line that mark off the factory’s
walking area.
 Outlining Strategy
 Outlining strategy is a good way to
show which jigs & tools are stored
where.
 Outlining simply means drawing
outlines of jigs & tools in their proper
storage positions. When you want to
return a tool the outline simply
provides an indication of where it
belongs.
Definition of “SHINE”

Shine means that we keep everything

swept & clean. It lays emphasis on
removal of dirt, grime & dust from
the workplace.
Why Shine is Important?

 To turn the workplace into clean, bright

place where everyone will enjoy working
in.
 To keep everything in top condition so
that when someone needs to use
something it is ready to be used.
Problems avoided by
implementing Shine
 Defects are less obvious in dark, messy
factories.
 Puddles of oil & water can cause accidents.
 Dirty windows prevents sufficient lights into
the workplace leading to poor morale.
 Lack of preventive maintenance of machines
leads to frequent breakdowns & accidents.
 Cuttings / shavings can blow into peoples
eyes and cause injuries.
 Dirt / filth in the work environment can cause
low morale.
 Implementing Shine in your
work place.

 Step 1: Determine Shine targets.

 Step 2: Determine Shine assignments.
 Step 3: Determine Shine methods
 Step 4: Prepare Tools
 Step 5: Start to Shine
Step 1: Determine Shine
Targets.
Shine targets are grouped into 3 categories.
 Warehouse items - These include raw materials,
procured sub contracted parts, parts made in-house,
assembly components, semi finished & finished
products.
 Equipment - These includes machines , tools dyes,
spare equipment, furniture etc.
 Space- this refers to floors passages, pillar windows,
rooms, lights , ceilings, shelves etc.
Step 2: Determine Shine
assignments
Workplace cleanliness is the responsibility
of everyone who works there.
For determining shine targets we divide the
factory into shine areas and assign specific
areas to individuals. The shine areas can be
shown on a 5S map.
A 5S schedule showing who is responsible
for cleaning which areas on which days &
times of the the days should also be posted
in the workplace.
Step 3: Determine Shine Methods.

Determining Shine methods involves

the following steps:
 Choosing targets & tools: Define what will
be cleaned in each area & what supplies &
targets will be used.
 Performing the five minutes shine: Cleaning
should be practiced daily & should not take
a lot of time.
 Creating standards for shine procedures:
People ought to know effective procedures
of shine so that their time is used efficiently.
 Step 4: Prepare Tools

Here we apply “Set in Order “ to our

cleaning tools storing them in places
where they are easy to find , use &
return.
Step 5 : Start to Shine.
Suggestions about implementing Shine
procedures:
 Ensure that dirt from floor cracks , wall
corners & around pillars are removed.
 Wipe off dirt from walls windows & doors.
 Be through in cleaning dirt, scrap, shavings,
oil, dust , rust, & other foreign matters from all
surfaces.
 Ensure use of cleansing agents when
sweeping is not sufficient to remove dirt.
 Cleanliness / Inspection.
It is important to do certain amount of cleanliness
inspection while implementing shine
activities.Once daily cleaning becomes a habit we
should start incorporating systematic inspection
procedures into our shine procedures.

The cleaning inspection steps are as follows:

 Determine cleaning / Inspection targets.
These are the targets related to shine and
includes- machines, equipment, jigs, dies, cutting
tools & measuring instruments.

 Assign cleanliness / Inspection jobs: Once it has

been determined who will do cleanliness/
inspection jobs it should be displayed for the
concerned people to see.
 Determine cleanliness / inspection methods:
List all inspection items & combine them to make a
inspection checklist.
 Implement cleaning / inspection: While
implementing one should use all the senses to
detect abnormalities. Some tips for diagnosing
abnormalities are given below.
i) Look closely at how the machine works & watch
for slight defects ( e.g; oil leakage, debris
scattering, deformations etc.)
ii) Listen closely for changes in sound the machine
iii) Use your nose to detect burning smell
iv) Touch the machine only where it is safe during
operation & during downtime.
 Correct equipment problem:
All equipment problems should be fixed or
improved.
Definition of “STANDARDISE”

Standardise is the result that exists

when the first three pillars- Sort, Set
in Order, & shine are properly
implemented.
Why Standardise is
important?
 To prevent setbacks in first three
pillars.
 To make implementing them a daily
habit & to make sure that all the three
pillars are maintained in their fully
implemented state.
 Problems avoided by
implementing Standardise
activities.
 Conditions go back to their old undesirable
state even after a company wide 5S
implementation programme.
 At the end of the day piles of unneeded
items lie scattered around.
 Tool storage tanks become disorganised &
must be put back in order.
 Cutting , shavings fall on the floor & are not
swept.
 Implementation of Standardise
 Assign 3S responsibilities: Unless 3S clear
instructions are given Sort, Set in Order & shine
will have little meaning. 3S instructions should be
given to people who deliver goods from suppliers,
delivery sites should be clearly marked. A 5S job
cycle chart listing 5S jobs to be done alongwith
their frequency should be displayed in each area.
 Integrate 3S duties into regular work duties:
If people carry out 3S duties only when they find
things slipping. then 5S implementation has not
taken root. Maintenance must become everyone’s
regular work.
 Check 3S maintenance level: A regular check
should be their to ensure how effective the 3S jobs
are being maintained.
Definition of “SUSTAIN”

Sustain means to make a habit of

properly maintaining correct
procedures.
Why Sustain is important?

 Unless we commit ourselves to sustain

the benefits of 5S activities,
implementation of the first four pillars
quickly falls apart.
 Problems avoided by
Implementing Sustain.
 Unneeded items begin piling up as soon as
sorting is completed.
 Tools & jigs are not returned to their original
place.
 No matter how dirty equipment becomes little
or nothing is done to clean it.
 Dirty machines start to malfunction & produce
defective goods.
 Dark , dirty disorganised workplace lowers
workers morale.
 Management’s role in
Implementation of Sustain.
 Educating all in the factory about 5S
concepts tools & techniques.
 Creating terms for implementation.
 Allowing times for implementation &
creating schedules for work.
 Providing resource for 5S implementation.
 Acknowledging & supporting 5S activities.
 Promoting ongoing 5S efforts.
 Improving the quality & efficiency of work.
 Employees role in
Implementation of 5S.
 Continuing to learn more about 5S.
 Helping to educate others about 5S.
 Being enthusiastic about 5S
implementation.
 Helping to promote 5S implementation
efforts
 Taking initiative to figure out ways to
implement 5S in your work.
 Asking your supervisor / manager for
support you need to implement 5S.
 Tools that helps
sustain 5S efforts.
 5S Posters
 5S Slogans
 5S Newsletter
 5S Pocket Manuals
 5S Months / weeks.