1.

5S - BASIC TRAINING
2. What is 5S ?
• Seiri – Sort (housekeeping)
• Seiton – Systematic Arrangement (workplace organization)
• Seiso – Shine (Cleanup)
• Seiketsu – Standardize
• Shitsuke – Sustain (Self Discipline)
3. What is 5S ? 5S represents 5 disciplines for maintaining a visual workplace (visual controls and
information systems). These are foundational to Kaizen (continuous improvement) and a
manufacturing strategy based "Lean Manufacturing" (waste removing) concepts. 5S is one of the
activities that will help ensure any company’s survival.
4. 5S
1. Sort - All unneeded tools, parts and supplies are removed from the area
2. Set in Order - A place for everything and everything is in its place
3. Shine - The area is cleaned as the work is performed
4. Standardize - Cleaning and identification methods are consistently applied
5. Sustain - 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or
dangerous conditions
12. 1. 5S Principles • Elimination of waste • Everybody is involved, Co-operative effort • Attack
root cause • Human being is not infallible
13. 2. Objectives • Improve housekeeping • Make every individual responsible for housekeeping
• Beautify by simple means • Productivity improvement by saving time, space etc.
16. SEIRI = Sorting 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
17. SEIRI = Sorting Japanese Meaning : The Japanese meaning of “Seiri” is to straighten and
contain. - Get rid of waste and put it in order according to rules
18. 1 ‘S’ - SEIRI Respiratory System 1 ‘S’ – Our respiratory system sorts oxygen and other gases.
And exhales other gases which are unwanted for our body
19. 1S – SEIRI : SORTING • Sort for . . . • Not Needed at All • Needed but not Now • Needed but
not here • Needed but not so much Quantity 1 ‘ S’ WANTED UNWANTED
20. What is unnecessary Seiri = Sorting 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. Contingency Parts
Critically decide the quantity of contingency parts to be retained and criteria for such parts
21. Organization Frequency of use Storage Method Throw them out *Things you have not used
in the past one year LOW *Things you have used once in the last 6-12 months Store at distance OR
Keep in store *Things you have used only once in the last 2-6 months Store it in central place in your
zone AVERAGE *Things used more than once a month Store it in central place in your zone *Things
used once a week Store near the workplace HIGH *Things used daily or hourly Store near the
workplace
22. Identifying unnecessary Seiri = Sorting • 1. Parts & Work in Process (WIP) • Things fallen
back behind the machine or rolled under it • Broken 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..
23. Identifying unnecessary Seiri = Sorting • 2. Tools, Tooling, 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..
24. Identifying unnecessary Seiri = Sorting • 4. Shelves and Lockers • Shelves and lockers tends
to collect things that nobody • ever uses , like surplus, broken items etc. • 5. Passages and Corners •
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..
25. Identifying unnecessary Seiri = Sorting • 8.Floor, Pits, Partitions • Defective parts •
Protection caps, covers • Packing material • Hardware items , small items • Even tools, tooling • Items
dropped on the floor are never picked • 9.Computer Hard Disk • Many unwanted, outdated, temporary
files pile up
26. Improvement methods Seiri = Sorting 1. Flow Process Chart (Procedural Analysis) Drawing
a process flow chart for the system e.g. How to make and use category wise grouping 2. Operational
Analysis Preparing the sequence of operations for system e.g. 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.
27. Dealing with papers Seiri = Sorting 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
28. Dealing with papers Seiri = Sorting How to Reduce Papers on Your Table ? 4 D Principle DO
DELEGATE DELAY DUMP
29. 2 ‘S’ Seiton : Systematic Arrangement PLACE FOR EVERYTHING, EVERYTHING IN ITS PLACE
Arranging things in systematic way
30. 2 ‘ S’ - SEITON 2 ‘S’ – In our body there is a fixed place for every organ.
31. 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 Indicator - Time saved in material
handling
32. SEITION = Systematic Arrangement Japanese Meaning: Dictionary meaning of Seiton is “to
be correctly prepared” and “to prepare correctly”. In short these means : (a) arrange correctly in
accordance with the correct method of doing activities and (b) make thorough preparations so that
activities can be done even if they occur abruptly
33. Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide
where things belong • Decide how things should be put away • Obey the Put away rules
34. 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 & colour • contd..
35. Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide
how things should be put away • - Follow (FIFO) first in first out rule • - If two identical items are to be
located, • then store them separately, • - colour code them. • Obey the rules • - Put the things back to
their location after • their use
36. Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Colour codes 3) Outline markings
4) Labels
37. Seiton = Systematic Arrangement Usage Frequency • Store frequently used material • near
the workplace and less • frequently at some distance • Heavy material should be • stored at lower
levels/layers • Place directly on the material • handling device for ease of • handling Weight & Shape of
the Material Functional Storage
38. Seiton = Systematic Arrangement • Same category of material • may be stored in one
location. • e.g, Allen Screws, Oil Seals Category • All items required for an • operation may be stored in •
one location. • e.g, Allen key, spanner etc • hand tools required for • setting m/c Operation Wise
Functional Storage
39. 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
40. Seiton = Systematic Arrangement • Wires and Ducts • - Colour 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
41. 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
42. Seiton = Systematic Arrangement • Oils • - Reduce number of oils used (Standardize) • -
Colour code for oil • - Safety aspects - fire prevention, • pollution, leak, spillage • Instrumentation &
Measuring Devices • - Label them, show direction of flow
43. Before sort after sort
44. Before sort after sort
45. 3 ‘S’ Seiso : Cleaning KITSUI KIKEN KITENOI (DANGER) (PROBLEM) (DIRT) Clean the
surroundings !
46. 3 ‘ S’ - SEISO 3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc
47. 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 - Reduction in machine down time Indicator - Reduction in
no. of accidents
48. SEISO = Cleaning Japanese Meaning : Dictionary meaning “to clean up” and “getting rid of
dirt and unclean items” While cleaning potential defects such as abrasion, damage, loose parts,
deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection
49. 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
50. 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
51. Seiso = Cleaning EXAMPLE : PREPARE CHECKLIST FOR CLEANING
52. Seiso = Cleaning Seiso Cycle • BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS,
JIGS & FIXTURES. • BEGINNING OF WORK - DO TRIALS AND START UP • DURING OPERATION - CLEAN,
INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES • AFTER COMPLETION OF WORK - DISPOSE OFF
AND GET RID OF UN-NECESSARY THINGS • SEISO IS A PART OF GOOD WORKMANSHIP • SEISO IS AN
IMPORTANT PRE-CURSOR • WITH 5S
53. Seiso = Cleaning Cleaning-Inspection points for most equipment Grime, clogging, dust balls,
rust, leakage etc. Cleaning No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines,
clogged drainage, oil spillage, worn& torn ports etc. Oils
54. Seiso = Cleaning Cleaning-Inspection points for most equipment Loose bolts, welding
detachment, loose parts, vibration or bumping noise, friction Tightening Oil tanks, motors, heater,
axles, control panels, washing/ cleaning water, bearing, wiring etc. Heat
55. Seiso = Cleaning Cleaning-Inspection points for most equipment 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. Breakage, Cracks
56. Seiso = Cleaning Function wise Cleaning check list of equipment Compressed Air lines, air
valves, connections, meters, filters, reservoirs etc. Pneumatics Hydraulic oil tank, oil valves, filters,
pumps, hoses, gauges, cylinders etc. Hydraulics
57. Seiso = Cleaning Function wise Cleaning check list of equipment Motor fan, fan belt,
couplings, Joints, pulleys, chains, pump bearings etc. Mach. & Power Train Electrical Control panel,
lamps, light, switch, sensors, wiring, ducts, fuses etc.
58. Seiso = Cleaning Function wise Cleaning check list of equipment Tools, fixtures, gauges,
dies, measuring instruments, etc. Tooling Equipment Specific Furnaces, rollers, chutes, CNC machines,
etc.
59. Before shine after shine
60. Before shine after shine
61. 4 ‘S’ Seiketsu STANDARISATION
62. 4 ‘ S’ - SEIKETSU 4 ‘S’ – In every human being the structure of fingers are same I.e.
Standardised. If it is not so, then we call it is abnormal.
63. 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 - Colour coding - Early detection of problem and early action Success Increase in 5S
indicator Indicator
64. SEIKETSU = Standardization Japanese Meaning : Dictionary meaning “unsoiled things,
purity and cleanliness” Clean manners , Clean cloths, clean politician It is the proof that 3 S’s are being
faithfully carried out.
65. SEIKETSU = Standardization Tools used for analysis : MTTR : Mean Time To Repair \
Recover MTBF : Mean Time Between Failures OEE : Overall Equipment Efficiency
66. 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
67. 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
68. 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
69. Seiketsu = Standardization • Some methods for visual communication • Colour coding •
Use of Labels • Danger alerts • Indication where things should be put • Directional arrows/ marks •
Transparent covers • Performance indicators
70. Seiketsu = Standardization • Some methods for visual communication • Labels • Precision
management labels • Inspection labels • Temperature labels • Responsibility labels
71. 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
72. Seiketsu = Standardization • Some everyday visual management • examples • Traffic signal
• Zebra crossing • In car - Petrol indicator • - Speed indicator • Direction arrows • Electric danger sign
etc.
73. Seiketsu = Standardization Some visual communication signs
74. 5 ‘S’ Shitsuke SELF DISCIPLINE
75. ENSURE . . . • Procedure & Work Instruction are correct. • Standard are expressed in specific.
• Visual Aids are used. • Train at all levels. • Work ethics for effective management. • Transparent &
Discipline work culture.
76. 5 ‘ S’ - SHITSUKE 5 ‘S’ – Every human body has its standard process which they maintain.
77. 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 High employee morale Indicator Involvement of all people
78. SHITSUKE = Self Discipline Japanese Meaning : Dictionary meaning is “learning of the
manners” “having manners, dressing neatly” OR “training children for good customs”
79. SHITSUKE = Self Discipline Activities : 5S Committee 5S Training 5S Competition / evaluation
5S Month Posters , Literature etc.
80. 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
81. 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.
82. Pledge Shitsuke = Self Discipline • 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
83. ORGANIZATION Organization • Departments into areas • Coordinators at department level •
Coordinator at each area level • Training for all • Audit each area and make action check list •
Implement actions • Audit and evaluation on continuous basis
85. Some 5S Examples After 5S - Cleaned, organized and drawers labeled (less time and
frustration hunting) Before 5S