The “5S” Philosophy

A better
Work Environment for
Everyone
TOPICS

5S PHILOSOPHY

WHY 5S

5S OBJECTIVES

PURPOSE OF 5S

ELEMENTS OF 5S

SORTING

SYSTEMATIC ARRANGEMENT

SPIC AND SPAN

STANDARDISATION

SELF DISCIPLINE

5S PHILOSOPHY BENEFITS

By G. Lakshmi Narayanan [email protected]

The
The “5S”
“5S” Philosophy
Philosophy
Based on Japanese words that begin with S, the 5S
Philosophy focuses on effective work place organization
and standardized work procedures. 5S simplifies your work
environment, reduces waste and non-value activity while
improving quality efficiency and safety.

IfIf you’re
you’re going
going to
to do
do it,
it, do
do itit RIGHT!
RIGHT!

By G. Lakshmi Narayanan [email protected]

5S Objectives

What we want from 5S activity ?
Problems cannot be clearly seen when the work place is
unorganized.
Cleaning and organizing the workplace helps the team to
uncover problems.
Making problems visible is the first step of improvement.

By G. Lakshmi Narayanan [email protected]

PURPOSE OF 5S

TO KEEP OUR WORK PLACE CLEAN

PROVIDES NICE ENVIRONMENT TO WORK

INCREASE OUR PRODUCTIVITY

SAVES TIME (MAINLY SEARCHING TIME)

REDUCE THE COST

PROVIDES SAFTEY

CREATES JOY WHILE WORKING

ELIMINATION OF ALL TYPES OF WASTE

By G. Lakshmi Narayanan [email protected]

 ELEMENTS OF 5S
1. SEIRI SORTING OUT
NO UNNECESSARY ITEMS
2. SEITON SYSTEMATIC ARRANGEMENT
PREFIXED LOCATION FOR
PREFIXED QUANTITY BEFORE &
AFTER USE
3. SEISO SPIC AND SPAN
EASY TO CLEAN
4. SEIKETSU STANDARDIZATION
STANDARDS
SELF DISCIPLINE
5. SHITSUKE

By G. Lakshmi Narayanan [email protected]

Sort – (Seiri)

The first S focuses on eliminating unnecessary items from

the workplace.

By G. Lakshmi Narayanan [email protected]

Sort
Sort –– (Seiri)
(Seiri)
Sorting frees up valuable floor space and eliminates such
things as broken tools, obsolete jigs and fixtures, scrap
and excess raw material.
The Sort process also helps prevent the ‘hoarder’ job
mentality (“I might need it”).

By G. Lakshmi Narayanan [email protected]

SORTING (Step 1)

• Segregating necessary from unnecessary

• Discarding what is not required
• Deciding on a frequency of sorting

Objective : Save and recover space.

By G. Lakshmi Narayanan [email protected]

Priority Frequency of Use How to use

Throw away, Store

Less than once per
Low away from the
year, Once per year<
workplace

At least 2/6 months,

Store together but
Average Once per month, Once
offline
per week

Locate at the
High Once Per Day
workplace

By G. Lakshmi Narayanan [email protected]

Sort
Sort –– (Seiri)
(Seiri)
An effective visual method to identify these unneeded items is
called red tagging. A red tag is placed on all items not required to
complete your job. These items are then moved to a central
holding area. This process is for evaluation of the red tag items.
Occasionally used items are moved to a more organized storage
location outside of the work area while unneeded items are
discarded.

By G. Lakshmi Narayanan [email protected]

Sort
Sort –– (Seiri)
(Seiri)

RED TAG!

If you don’t use it,

remove it!

By G. Lakshmi Narayanan [email protected]

Using red tag campaigns

By G. Lakshmi Narayanan [email protected]

SORT – In RED TAG CAMPAIGN

Raw materials, procured

Types of items Inventory parts, processing parts, in-
process inventory, assembly
parts, semi-finished
products, finished products

Red-tag
targets Machines, equipment, Jigs,
Equipment Tools, cutting bits, gauges,
dies, carts, conveyance tools,
worktables, cabinets, desks,
chairs, supplies

Floors, walkways, operation

Physical areas
areas, well, shelves,
warehouses

Identifying Red-Tag Targets

By G. Lakshmi Narayanan [email protected]

By G. Lakshmi Narayanan [email protected]
 STEP II

SYSTEMATIC ARRANGEMENT

A rational,
orderly and methodical
arrangement of all items we
use, re-work or write off.

By G. Lakshmi Narayanan [email protected]

 A
A Place
Place for
for Everything
Everything
&
&
Everything
Everything in
in its
its Place
Place

By G. Lakshmi Narayanan [email protected]

Set
Set in
in Order
Order –– (Seiton)
(Seiton)
The second S focuses on efficient and effective storage
methods.
You must ask yourself these questions:

1. What do I need to do my job?

2. Where should I locate this item?
3. How many do I need?

By G. Lakshmi Narayanan [email protected]

Set
Set in
in Order
Order –– (Seiton)
(Seiton)
Strategies for effective Set In Order are:
 Painting floors
 Outlining work areas and locations
 Shadow boards
 Modular shelving and cabinets

“A
“A PLACE
PLACE FOR
FOR EVERYTHING
EVERYTHING AND AND
EVERTHING
EVERTHING IN
IN ITS
ITS PLACE”
PLACE”

By G. Lakshmi Narayanan [email protected]

SHADOW BOARDS FOR GAUGES

By G. Lakshmi Narayanan [email protected]

 2S

Before Improvement After Improvement

Workpiece Workpiece
Parts

Parts

Parts
stand
Parts (slanted)
stand

Worktable Worktable
(two-thirds width reduction)

• Worktable was too wide. • Worktable was made smaller

• Parts stand was too far away. (two-thirds width reduction).
• Parts were laid out • Parts were put within closer reach.
horizontally, making • Parts were laid out on a slant,
them hard to see and reach. making them easier to see and
reach.

By G. Lakshmi Narayanan [email protected]

SET IN ORDER

Operator returns tool without having to step back

or look

Tools Kept Close at Hand and Stored in the

Order Used

By G. Lakshmi Narayanan [email protected]

SET IN ORDER

Before Improvement After Improvement

Plastic sheets Workpiece

for packaging

Conveyor Conveyor

• Plastic sheets were kept on • Now plastic sheets are hung

the rack behind the operator. on a hook in front of operator.
• The operator was forced to • The operator does not have to turn
turn around each time he around.
needed a plastic sheet. • Four seconds of motion waste are
• The turning motion required eliminated.
four seconds.

By G. Lakshmi Narayanan [email protected]

 Step III
3S - SPIC & SPAN

Understanding how to prevent things

from getting dirty
and ensuring tip top condition

(Done with the objective of inspecting

for problems and taking faster
corrective actions)

By G. Lakshmi Narayanan [email protected]

Shine
Shine –– (Seiso)
(Seiso)
Once you have eliminated the clutter and junk that has been clogging
your work areas and identified and located the necessary items, the
next step is to thoroughly clean the work area. Daily follow-up cleaning
is necessary in order to sustain this improvement. Workers take pride
in a clean and clutter-free work area and the Shine step will help create
ownership in the equipment and facility.

By G. Lakshmi Narayanan [email protected]

 Shine
Shine –– (Seiso)
(Seiso)
Workers will also begin to notice changes in equipment and facility
location such as air, oil and coolant leaks, repeat contamination
and vibration, broken, fatigue, breakage, and misalignment. These
changes, if left unattended, could lead to equipment failure and
loss of production. Both add up to impact your company’s bottom
line.

By G. Lakshmi Narayanan [email protected]

By G. Lakshmi Narayanan [email protected]
 STEP IV
4S - STANDARDIZATION

Standardization is the result that exists when the

first three pillars – sort, Set-in-order and
Shine are properly maintained

– The Place degenerates very quickly if we do

not standardize

– In this stage, we learn about keeping

everything clean by making standards
These are made by the people who work in the area

By G. Lakshmi Narayanan [email protected]

Examples of Visual Control

• Warning lights • Visualize conditions

• Transparent windows • What is where chart
• Colour coding • Who is where chart
• Labels • Inspection Labels
• Position marks • How much of ‘what’ chart
• Okay marks
• Make spaces transparent

By G. Lakshmi Narayanan [email protected]

 Direction Flow

By G. Lakshmi Narayanan [email protected]

Standardize
Standardize –– (Seiketsu)
(Seiketsu)
Once the first three of the 5S’s have been implemented, you should
concentrate on standardizing best practice in your work area. Allow your
employees to participate in the development and documentation of such
standards. They are a valuable but often overlooked source of
information regarding their work.

By G. Lakshmi Narayanan [email protected]

Standardize – (Seiketsu)
Standardize means establishing “Best
Manufacturing Practices, including:
 Workplace Layout and Design
 Materials Handling Analysis
 Clear and Concise Work Instructions
 Well Defined Work Methods
 Safe (Ergonomic) Working Practices
 Cycle Time Reduction
 Training
 Documentation
By G. Lakshmi Narayanan [email protected]
 STANDARDIZATION

Making Sort, Set-in-order and

Shine a Good Habit
These are

1. Fix responsibilities for implementing and

evaluating system.

2. Integrate these responsibilities into routine

work.

3. Check how well the system is working and

sustaining itself.
By G. Lakshmi Narayanan [email protected]
 NECESSARY ITEMS

1. Operator Location 3
2. Machine 9

3. Air Gun
4. Power Supply
1 2
5. Water Line
6. Out Put Bin 6
5
7. Inspection Table
8. Tool Cabinet 4
9. Chip Bin 7 X
10. Dust Bin 8
11. Fire Extinguish 11 10

By G. Lakshmi Narayanan [email protected]

5S – Set Standards, Practice &
Discipline

• Standardizing the 4S practices

• Continuous audit and revision of standards
• Training of concerned in the revised standards
• Abolishing unwanted standards
• Operation Standards, Limit samples, Quality Control
Process Charts etc
• Horizontal deployment of standards
• Quality system manual
• Gauge calibration standards

By G. Lakshmi Narayanan [email protected]

Process of Sustainment
• Daily monitoring through audit scores
• Improving ownership by allocating areas
• Using red tag campaigns
• Communicating visually through fixed point/worse point
photographs
• Structured communication
• Continuous training of all employees
• Periodic audits at all levels
• Motivating through recognition
• Encouraging house-keeping projects through Total
Employee Involvement (TEI)

By G. Lakshmi Narayanan [email protected]

 5S : SELF DISCIPLINE OR SUSTAIN

Here are some of the things that happen in a company when

commitment to the five pillars is not sustained.
1. Unneeded items begin pilling up as soon as sorting is
completed.
2. No matter how well Set in Order is planned and
implemented, tools and jips do not get returned to their
designated places after use.
3. No matter how dirty equipment becomes, little or nothing
is done to clean it.
4. Items are left protruding into walkways, causing people to
trip and get injured.
5. Dirty machines start to malfunction and produce defective
goods.
By G. Lakshmi Narayanan [email protected]
The
The “5S”
“5S” Philosophy
Philosophy BENEFITS
BENEFITS
Once fully implemented, the 5S process can increase moral,
create positive impressions on customers, and increase
efficiency of the organization.

Not only will employees feel better about where they work,
the effect on continuous improvement can lead to
less waste, better quality and shorter lead times.
Any of which will make your organization more profitable
and competitive in the market place

By G. Lakshmi Narayanan [email protected]

 Lakshmi Narayanan has been a great supporter of the
TPM on Line Group and this is one of his excellent
contributions to our purpose of spreading the Lean Culture

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