5S - BASIC TRAINING

What is 5S
and
why do
we want to
do it?

Mihir Dodiya
What is 5S ?
 Seiri – Sort (housekeeping)
 Seiton – Systematic Arrangement
(workplace organization)
 Seiso – Shine (Cleanup)
 Seiketsu – Standardize
 Shitsuke – Sustain (Self Discipline)

Mihir Dodiya
 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.
Mihir Dodiya
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
Mihir Dodiya
Some New Words
Lean Manufacturing-concepts that seek continuous
improvement by removing waste in processes
Some Japanese words one need to know:
Kaizen-(pronounced “kai zen”) – Continual improvement
Muda-(pronounced “moo da”) - waste
Gemba-(pronounced “gim ba”) – workplace
Kanban-(pronounced “kon bon”) - Pull type inventory
control system. Items are only produced to meet customer
needs. The request to produce more is signaled from an
upstream operation and/or customer orders.
Mihir Dodiya
KAIZEN: What it is?
1) Process Improvement
2) Observation
3) Use of New Paradigms
4) Short Time
5) Zero Investment
6) Human Development & Empowerment
7) Profits & Savings - Plenty

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 KAIZEN

KAI ZEN

ALWAYS GOOD
CONTINUAL IMPROVEMENT
CHANGE FOR THE BETTER

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 KAIZEN IS A JOURNEY FROM:

EVENT TO CAUSE
RESULT TO PROCESS
GROSS TO MICRO
ENFORMENT OF TO INDUCEMENT
CHANGE OF CHANGE

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 KAIZEN IS CONTINUAL IMPROVEMENT

TIME
TIME

CONTINUOUS CONTINUAL
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 KAIZEN: KNOW THE REALITY
THROUGH YOUR SENSE

OBSERVATION INTELLIGENCE

PHYSICAL EFFORT

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PARADIGM OF HIGH PRODUCTIVITY & QUALITY

KAIZEN AT GEMBA

GEMBA: PLACE OF WORK

GEMBA is where . . .
➢Value is added
➢Actual work is done to meet customer
requirement
➢Problems are solved
➢Staff is responsible for providing support,
not for giving instruction
Mihir Dodiya
1. 5S Principles 12

◼ Elimination of waste
◼ Every body is involved,
Co-operative effort
◼ Attack root cause
◼ Human being is not infallible

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2. Objectives 13

◼ Improve housekeeping
◼ Make every individual
responsible for housekeeping
◼ Beautify by simple means
◼ Productivity improvement
by saving time, space etc.
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The ‘S’ Japanese Word What is involved Objective

Segregate necessary from

unnecessary
SEIRI Remove what is not Saving and
1S
(Sorting Out) required recovering Space
Decide on frequency of
sorting
SEITON Arranging in order
Minimizing search
2S (Systematic Place for everything, time
Arrangement) Everything in its place
Inspecting for
Cleaning the work place/
SEISO problems
3S equipment
(spic and Span) Taking corrective
Attaining the warning bell
actions faster
SEIKETSU Achieving higher
Working Methodology
4S (Standardizatio productivity and
(Procedures & WI) better quality
n)
SHITSUKE Forming the habit in form Doing it right at First
5S
(Self Discipline) of Training and Discipline Time
Mihir Dodiya
SEIRI = Sorting 16

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

Mihir Dodiya
SEIRI = Sorting 17

Japanese Meaning :
The Japanese meaning of “Seiri” is
to straighten and contain.

- Get rid of waste and put it in order according to rules

 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
 1S – SEIRI : SORTING

Sort for . . . 1 ‘ S’
✓ Not Needed at All
✓ Needed but not Now
WANTED UNWANTED
✓ Needed but not here
✓ Needed but not so much Quantity

Mihir Dodiya
Seiri = Sorting What is unnecessary
20

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
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 Organization
21

Frequency of use Storage Method

*Things you have not used Throw them out
LOW
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

Mihir Dodiya
Seiri = Sorting Identifying unnecessary
22

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..
Seiri = Sorting Identifying unnecessary
23

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..
Mihir Dodiya
Seiri = Sorting Identifying unnecessary
24

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..
Seiri = Sorting Identifying unnecessary
25

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
Seiri = Sorting Improvement methods
26

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.
Seiri = Sorting Dealing with papers
27

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
28

How to Reduce Papers

on Your Table ?

4 D Principle

DO
DELEGATE
DELAY
DUMP
 2 ‘S’
Seiton : Systematic Arrangement

PLACE FOR EVERYTHING,

EVERYTHING IN ITS PLACE

Arranging things in systematic way

 2 ‘ S’ - SEITON

2 ‘S’ – In our body there is a fixed place for every organ.

SEITION = Systematic Arrangement 31

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
SEITION = Systematic Arrangement 32

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
Seiton = Systematic Arrangement
33

How to achieve Systematic Arrangement ?

• Decide where things belong

• Decide how things should be put away

• Obey the Put away rules

Seiton = Systematic Arrangement
34

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..
Seiton = Systematic Arrangement
35

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
Seiton = Systematic Arrangement
36

USE :

1 ) Signboards

2) Colour codes

3) Outline markings

4) Labels
Seiton = Systematic Arrangement
37

Usage • Store frequently used material

Frequency near the workplace and less
frequently at some distance

Weight & • Heavy material should be

Shape of the stored at lower levels/layers
Place directly on the material
Material handling device for ease of
handling
Functional Storage
Seiton = Systematic Arrangement
38

• Same category of material

Category
may be stored in one location.
e.g, Allen Screws, Oil Seals
• All items required for an
Operation operation may be stored in
Wise one location.
e.g, Allen key, spanner etc
hand tools required for
setting m/c
Functional Storage
Seiton = Systematic Arrangement
39

• 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
40

• 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
Seiton = Systematic Arrangement
41

• Blades, Dies, Other important consumable

- 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
42

• 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
Before sort after sort
Before sort after sort
 3 ‘S’
Seiso : Cleaning

KIKEN KITSUI KITENOI

(DANGER) (PROBLEM) (DIRT)

Clean the surroundings !

 3 ‘ S’ - SEISO

3 ‘S’ – We keep our body clean everyday by having bath

and cutting nails etc
SEISO = Cleaning 47

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
SEISO = Cleaning 48

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
Seiso = Cleaning
49

• Here cleaning means more than just keep

things clean. Cleaning should be viewed a
form of Visual Inspection

• Preventive measures should be taken to ta

problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be ident
and it should be eliminated
Seiso = Cleaning
50

5 Minutes Every day for cleaning

• Devote 5 minutes everyday for cleaning y

work area

• Participation of everyone is required

• Attack hard to clean places regularly

Seiso = Cleaning
51

EXAMPLE : PREPARE CHECKLIST FOR CLEANING

SL.No CHECKLIST TICK

1 Check Floors are clean
2 Check Work areas are clean
3 Check walls are clean
4 Check Pillars and Ceiling are clean
5 Check Windows are clean
6 Check Rooms and Electrical lights are clean
Seiso = Cleaning
52

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
Seiso = Cleaning
53

Cleaning-Inspection points for most

equipment

Grime, clogging, dust balls, rust,

Cleaning
leakage etc.

No oil, Low oil, leakage, filter clogging,

Oils
dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
etc.
Seiso = Cleaning
54

Cleaning-Inspection points for most

equipment

Loose bolts, welding detachment,

Tightening
loose parts, vibration or bumping
noise, friction

Heat Oil tanks, motors, heater, axles, control

panels, washing/ cleaning water,
bearing, wiring etc.
Seiso = Cleaning
55

Cleaning-Inspection points for most

equipment

Breakage, cracks, dent on sliding

Breakage,
parts, handle has come off, broken
Cracks switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.
Seiso = Cleaning
56

Function wise Cleaning check list of

equipment

Compressed Air lines, air valves,

Pneumatics connections, meters, filters,
reservoirs etc.

Hydraulic oil tank, oil valves,

Hydraulics filters, pumps, hoses, gauges,
cylinders etc.
Seiso = Cleaning
57

Function wise Cleaning check list of

equipment

Mach. & Motor fan, fan belt, couplings,

Joints, pulleys, chains, pump
Power Train
bearings etc.

Control panel, lamps, light, switch,

Electrical sensors, wiring, ducts, fuses etc.
Seiso = Cleaning
58

Function wise Cleaning check list of

equipment

Tools, fixtures, gauges, dies,

Tooling
measuring instruments, etc.

Equipment Furnaces, rollers, chutes,

Specific CNC machines, etc.
Before shine after shine
Before shine after shine
 4 ‘S’
Seiketsu

STANDARISATION
 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.
SEIKETSU = Standardization 63

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
SEIKETSU = Standardization 64

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.
SEIKETSU = Standardization 65

Tools used for analysis :

MTTR : Mean Time To Repair \ Recover

MTBF : Mean Time Between Failures

OEE : Overall Equipment Efficiency

Seiketsu = Standardization
66

• 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
67

• 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
68

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
69

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
Seiketsu = Standardization
70

Some methods for visual communication

Labels
 Precision management labels
 Inspection labels
 Temperature labels
 Responsibility labels
Seiketsu = Standardization
71

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
72

Some everyday visual management

examples
 Traffic signal
 Zebra crossing
 In car - Petrol indicator
- Speed indicator
 Direction arrows
 Electric danger sign etc.
Seiketsu = Standardization
73

Some visual communication signs

 5 ‘S’
Shitsuke

SELF DISCIPLINE
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.
 5 ‘ S’ - SHITSUKE

5 ‘S’ – Every human body has its standard process which

they maintain.
SHITSUKE = Self Discipline 77

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
SHITSUKE = Self Discipline 78

Japanese Meaning :
Dictionary meaning is
“learning of the manners”
“having manners, dressing neatly” OR
“training children for good customs”
SHITSUKE = Self Discipline 79

Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.
Shitsuke = Self Discipline
80

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
81

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 82

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
 ORGANIZATION 83

 Departments into areas

Organization
 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
Some 5S Examples

After 5S - Cleaned, organized

and drawers labeled (less time
Before 5S and frustration hunting)
 5S Pictures

Before After
 5S Pictures

Before: Repair After

 5S Pictures

Before After
The Good, Bad and the
Ugly
First the Bad and the Ugly - Life Without 5S
The Good
THANK YOU

Mihir Dodiya