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METHODOLOGY OF 5S.

5S developed by Hiroyuki Hirano, in Japan.

Hirano provided a structure for improvement programmes.

HISTORY OF 5S

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This methodology encourages workers to improve their

working conditions and helps them to learn to reduce waste, unplanned downtime, and in-process inventory.

The objectives of 5S: To improve productivity of the workers. To improve housekeeping. To improve quality. To improve Health and Safety.

1.

2.

3.

4.

5S is a phrase that refers to workplace organization and It lays the groundwork and develops the discipline

standardization.

INTRODUCTION OF 5S.
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necessary to support the successful implementation of other Lean concepts throughout an organization

5S stands for five words in Japanese that begin with the

letter S and describe the activities of workplace organization and standardization. Conversio Japanese Translation Other* n Seiri Organization Sort Sorting Seiton Neatness Set in Order Simplify Seiso Cleaning Shine Sweep Standardizati Seiketsu Standardize Standardize on Shitsuke Discipline Sustain Self-discipline

5S CHART

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The first step in 5s Tidiness or sort.

SEIRI (SORTING).

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Throw away all rubbish and unrelated materials in the To ensure that everything left in the workplace is related

workplace.

to work. The edit Master subtitle style Click to number of necessary items in the workplace must be

kept to its absolute minimum.

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Seiton (Set in Order)

Definition:
to

set in order or to

put everything

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How to Set in Order (Seiton)

Three factors:
v

planwheresomething should be stored;

(consideration: how often is it used?; is it easy to reach the item?)

v

planhowit should be stored;

(putting a label; special conditions for long-term storage)

v

ensure people follow these rules.

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ased ty by e Incr ctivi e rodu sing th p crea ent de l e sp g a too tim vin ie retr

Cost s saving e becaus ols ost to l do not be o need t ed r e-orde

BENEFITS OF SEITON Easier cleanup

Reduced in tools are juries; st convenie ored in nt and ergonom ic places workers d o le s s bending , lifting, twisting an stretchin d g

Increased productivit y because it is clear when items are indeed unavailabl

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SEISO SHINY CLEAN

Seiso means to clean or shine Maintenance and cleanliness become part of the everyday working routine to increase both workplace safety and longevity of tools and equipment.

2 goals of seiso are : To set the new standard for cleanliness.

To learn how to maintain that level of cleanliness.

BENEFITS OF SEISO

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Setting the standard for future cleanliness. Learning how to do the cleaning. Higher morale, especially if managers participate in the event.

A safer and comfortable work environment. Less downtime to repairs, since equipments will be inspected briefly but regularly and because there will be less dirt clogging the machinery.

Performing the work validates what was planned.

SEIKETSU (STANDARDIZE).
v

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The fourth step of the5Smethod - standardized cleanup.

It derives from the one-timeSeisostep which made the factory shiny clean and set the standard for cleanliness.Seiketsumakes it possible and feasible to live up to that standard.

Standards must be applied to: i) work instructions ii) procedures

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Motivation of Seiketsu

Enables and ensures compliance to the new standards of cleanliness. The benefits include:

Maintaining the higher morale gained duringSeiso -Pride in the workplace -Relapsing into dirty or messy conditions means that the Seiso

effort was wasted

Minimal

investment in time: the goal is 5 minutes per worker per

shift -No big clean-up before a visit from customers or executives

Less

downtime for equipment.

How to Standardize Cleanup (Seiketsu)

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Seiketsu or standardise is about maintaining the improvements and continuously improvement.

Seiketsu is usually achieved through the use of specific audits and checklists, ensuring that what should be where and how things should be done are clearly specified.

These audits should be scored in such a manner as to not be subjective and conducted by someone independent to the area being audited.

Audit results should be clearly displayed, along with corrective actions if necessary

SHITSUKE (SUSTAINING).
v Maintain and review standards that includes instilled discipline, self-discipline, common cultural values, and self-motivated practice to improve. v Once the previous 4S's have been established, they become the new way to operate. v Maintain focus on this new way and do not allow a gradual decline back to the old ways. While thinking about the new way, also be thinking about yet better ways. v When an issue arises such as a suggested improvement, a new way of working, a new tool or a new output requirement, review the first 4 S's and make changes as appropriate.

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Why fail to implement shitsuke?

v

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Lack of discipline (some employees avoid cleaning and straightening at all costs)The checklists were not followed or are not created clearly and to the v The audit was not done consistently point and properly The results of the audit were not communicated and nobody was assigned to fix the problem, with a v The employees were not trained deadline properly in 5S. The employees were not made responsible for 5S. They are not owners of the operation v Recognition and rewards were not in
v

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Contoh Aplikasi Sistem 5S

5S Riverside Medical ORGANIZAT Center Bilik stor bahan : ION Masalah: Sukar untuk mancari barang dan memerlukan banyak ruang Aplikasi: Sort: bahan stor disusun dan disenaraikan ProMedica Click to edit Master subtitle style Laboratories Set- in- Order: label tingkat dan rak. Sustain: Bahan diletakkan kembali mengikut label. Faedah: Pekerja boleh mencari bahan kurang dari 30 saat.

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CONCLUSION.
v

5S is a phrase that refers to workplace organization and standardization.

5S consists of Seiri, Seiton, Seiso, Seiketsu and Shitsuke.

5S can improve productivity of the workers, housekeeping, and quality.

It also can improve Health and Safety.