Ethiopian TVET System

Training, Teaching and Learning Materials Development

TTLMOFAPPLY 5S PROCEDURES

At the end of this training, the trainee will be able to:-

Lo – 1 Develop understanding of quality system

Lo – 2 Sort needed items from unneeded

Lo – 3 Set workplace in order

Lo – 4 Shine work area

Lo – 5 Standardize activities

Lo – 6 Sustain 5S system
Ethiopian TVET System TTLM Development DBUCNC Department of IT

Lo – 1 Develop understanding of quality system

Quality Assurance (QA)

Quality assurance (QA) is a process-centered approach to ensuring that a company or

organization is providing the best possible products or services. It is related to quality control,
which focuses on the end result, such as testing a sample of items from a batch after production.
Although these terms are sometimes used interchangeably, quality assurance focuses on
enhancing and improving the process that is used to create the end result, rather than focusing on
the result itself. Among the parts of the process that are considered in QA are planning, design,
development, production and service.

Good QA requires good social skills, communication skills, and unilateral thinking and acting on
the QA person's part; it also requires a company willing to embrace people with such an
approach. Good QA requires gathering and implementing semantics from the customer, not just
heartless specifications.

Quality Assurance Plan

 In many cases, it is important that you choose a technician who has earned necessary
professional certification. A pharmaceutical qualityassurance technician, for example,
should have certification from an organization such as the Food and Drug Administration
(FDA) in the United States.

They learn about how different practices affect production. A person who wants to become a
qualityassurance supervisor should plan on working a few years in this kind of position and
learning about how his or her organization structured and which kinds of tools, such as software
and machines, are used in processes.

Quality Assurance Systems

 Deciding on the best courses will depend greatly on what needs to be optimized, which
can be anything from internal tasks to products or customer relationships.
Qualityassurance is an organized way in which systems and procedures are tested and
maintained for the highest possible production and efficiency.

 While similar in scope to a systems analyst, who develops computer systems, a quality
control analyst focuses more on qualityassurance through the testing of systems. His or
her main purpose is to make sure that all computer systems work efficiently and are
functioning properly.

Quality Control and Assurance

1
Ethiopian TVET System TTLM Development DBUCNC Department of IT
 This is especially important for service-oriented companies, because the employees are
the product that they provide to customers. Often, qualitycontrol is confused with
qualityassurance. Though the two are similar, but there are some basic differences.

 Here, the goal is to work within the established order so the company realizes its goals of
turning out quality products, a move that essentially completes the overall task that both
qualityassurance and qualitycontrol are designed to accomplish. One of the reasons
that many people use quality assurance and qualitycontrol interchangeably is that there
is often a great deal of overlap in terms of the personnel that engage in each phase.

Quality Assurance Jobs

 Training department managers to locate and correct potential problems before they occur
is a huge aspect of qualityassurance, not only from a profit standpoint, but also from a
safety standpoint. In some industries, qualityassurance directors also work alongside the
staff to create new products or improve existing ones, meaning that they have to be
extremely organized and very flexible within their daily operations.

The analyst validates the phone staff is friendly and personable during interactions with the
customers. Qualityassurance jobs typically require a strong knowledge of the business
processes of an organization.

5S system

The heart and soul of visual management is 5S. It is systematic approach

to workplace organization and cleaning that will transform a
disorganized workplace into an efficient running machine.
The 5Ss are: listed by English & Japanese language
• Sort (Seiri) – The first step in 5S is to eliminate all the things in
the workspace that are not being used and store them away. If a
tool are material is not used on a daily basis, eliminate it from the
workstation.
• Set in Order(Systematize / Stabilize / Straighten)(Seiton) – The
second step is to arrange the items used on a daily basis so that
they can be easily accessed and quickly stored. Your goal is to
make eliminate any unnecessary movements and actions by the
worker to make his process as efficient as possible.
• Shine/Sweep/Clean (Seiso) – Next is to get everything cleaned
and functioning properly. The goal is to remove all the dirt and the
grime and to keep it that way on daily basis. You want to get it
clean and keep it clean.

2
Ethiopian TVET System TTLM Development DBUCNC Department of IT

• Standardize/Sanitize (Seiketsu) – The fourth step is to develop a

routine for sorting, setting and shining. Standardize creates a
system of tasks and procedures that will ensure that the principles
of 5S are performed on a daily basis.
• Sustain/Self-discipline (Shitsuke) – In the last step, you want to
create a culture that will follow the steps on a daily basis. The
chief objective of sustain is to give your staff the commitment and
motivation to follow each step, day in and day out.

What is 5S?

5S is a systematized approach to:

* organize work areas
* keep rules and standards
* maintain discipline

5S utilizes:
* workplace organization
* work simplification techniques
5S practice:
* develops positive attitude among workers cultivates an environment of efficiency,
effectiveness and economy

3
Ethiopian TVET System TTLM Development DBUCNC Department of IT
What can you gain from 5S?
Practicing 5S brings benefit not only to thecompany’s business but also to the people who
practice it.
• 5S makes your workplace more pleasant
• 5S makes you work more efficiently
• 5S improves your safety
What can a company gain from 5S?

P 5S increases PRODUCTIVITY.
Q 5S improves QUALITY.
C 5S reduces COST.
D 5S makes DELIVERY on time.
S 5S improves SAFETY.
M 5S improves MORALE.

Why 5S brings such benefits?

• 5S improves CREATIVITY of people.

• 5S improves COMMUNICATION among people.
• 5S improves HUMAN RELATIONS among people.
• 5S improves TEAMWORK among people.
• 5S improves CAMARADERIE among people.
• 5S gives VITALITY to people.
5S in WORK STATIONS

VISIBLE RESULTS:
• Decrease in the number of accidents and close calls
• Proper storage
• Improved productivity
• Greater people involvement in improvement activities
• Better use of floor space
• Early detection of problems
• High product quality
• Decreases delay
• Low employee turnover
• Low machine breakdown rates
• Detection system
• Zero breakdown
INVISIBLE RESULTS:
• Happier employees with high morale.
• Happier customers.
5S PHILOSOPHY

 Productivity comes from the elimination of waste

 It is necessary to attack the root cause of a problem, not just the symptoms
 Participation of everybody is required

4
Ethiopian TVET System TTLM Development DBUCNC Department of IT

Lo – 2 Sort needed items from unneeded

SEIRE (SORT)

Sorting is a step that involves selecting what you need to complete the job and removing
everything else from your work area.
 Taking out and disposing unnecessary items.
 Sort/classify the items that you “need” from the items that you “want or not
needed”.
 Dispose the items that you do not need and regroup the items that you need..
Clearly distinguish needed (frequently used) items from unneeded items and eliminate the later.

PROCESS/PROCEDURE:

Step 1: - Look around your workplace with your colleagues.

- Decide and identify which items are unnecessary for you.
- Dispose of unnecessary items.
Step 2: - If you and your colleagues cannot decide if an item is unnecessary, place a Disposal
Notice on the item, indicate the date and set the item aside.

Step 3: - After a certain period, check if the item is still needed or not.
- If no one needs the item after 3 months, it only means that the item is no longer
needed hence, dispose the item right away.
NOTE:
• It is recommended that this approach be used company-wide, involving people
from different departments.
• Never keep anything which is unnecessary to your work.
• While looking around for unnecessary items in your workplace, look at every
nook and corner like when you are looking for cockroaches.

5
Ethiopian TVET System TTLM Development DBUCNC Department of IT

Lo – 3 Set workplace in order

SEITON (SYSTEMATIZE / SET IN ORDER / STRAIGHTEN)

This step customizes your workstation and surrounding area to meet your work area needs.
Arrange remaining items so they are easy to select, use, and to return to their proper location.
 Arrangement / organization of necessary items in good order for use.
Keep needed items in correct place and sequence of use to allow easy and quick retrieval.
PROCESS/PROCEDURE:
Step 1: - Make sure that all unnecessary items are eliminatedfrom your workplace.
- Decide where you can place necessary items.
- Take into consideration the flow of your work.
- Take into account the movement of carts or even people passing your desk from this
point of view to ensure safe and efficient operation.
Step 2: - Place frequently needed items close to the user to minimize effort and time wastage.
- Things that are not used often could be placesslightly farther away.
- Make a plan on these principles and locate/storethings accordingly.

Placement of Materials/Equipment Based on Frequency of Use

Priority Frequency of Use How to Store

Low Less than once a year Throw away
Once a year or so Store in distant place
Once every 2-6 months
Average Once a month Store together some-
Once a week where in the office
High Once a day Carry or keep at
Once an hour your workplace

6
 Ethiopian TVET System TTLM Development DBUCNC Department of IT
STEP 3: - It is necessary to make sure that everyone in your workplace knows where things are
kept for efficient use.
- Make a list of things with their locations.
- Label each drawer and cabinet to show what is kept inside.
STEP 4: - Apply the same principles as in Step 3.
- Indicate the places where fire extinguishers arelocated as well as passages for carts.
- Place warning signs for safety precautions.

NOTE:
Three Rules for Storage Space
• Get rid of all unnecessary items
• Decide proper storage layout/classification
• Standardize names
Arrange necessary items in good order
 prevent loss and waste of time
 easy to find and pick up necessary items
 ensure first-come-first-served basis
 make production flow smooth and work easy
SEITON PRACTICES
 Don’t place goods in frontage along passages
 Store goods for first-in-first-out retrieval
 Everything must have its location
 Label items and their location systematically, mark everything
 Separate special tools from common ones
 Frequently used items nearer to the user
 Make things visible to reduce searching time, organize by color
 Keep space for safety equipment and evacuation passages clear

Things used Place as close

constantly as possible

Thing Things used

s Place a little
occasionally
need Further away
ed
Seldom
used, Enclose in a separate,
but still designated place
Classificati needed
on
No potential Immediate disposal
use

Thing 7
s Potentially Consider where
not useful useful and move
need or valuable
Ethiopian TVET System TTLM Development DBUCNC Department of IT

Lo – 4 Shine work area

SEISO (SHINE / SWEEP)

This step is powerful because its purpose is to find the reason why things become dirty.
Emphasis is on the removal of dust, dirt and grime to reveal the source and eliminate it.
 Cleaning of the workplace, including tools and equipment
Clean it so that defects are so easy to spot and eliminate.

PROCESS/PROCEDURE:

Step 1: - Determine the subject of clean up (what to clean)

e.g, location (storage, shelves, etc.), equipment,space (passageway, room, etc.)
Step 2: - Assign persons responsible for cleanup (who, where).
Step 3: - Determine the method of clean up (how to do it).
- Target the ff areas for cleaning (storage, equipment and surroundings)
- Draw up a cleaning responsibility map
- Create a cleaning schedule.
Step 4: - Implement cleaning.
Step 5: - Make a daily 5-minute cleaning habit before going home (Keep it simple and easy to
understand.)
NOTE:

• Do not wait until things get dirty.

• Clean your workplace; machines and equipment, tools and furniture regularly.
• Put aside 3-minute of seiso per day.
• Be responsible for your own work area.
• Never throw anything and make it your habit.
• Cleaning is also checking.
Clean your workplace completely

8
Ethiopian TVET System TTLM Development DBUCNC Department of IT
 keep environmental condition as clean as the level necessary for the products
 prevent deterioration of machinery and equipment and make checking of
abnormalities easy
 Keep workplace safe and work easy
SEISO PRACTICES
 Big Seiso ( Clean-Up Day )
 3-5 minute cleaning daily
 Assign owner to each machine
 Combine cleaning with inspection
 Make daily maintenance points clear by providing visible instructions
 Prevent causes of dust and dirt

Lo – 5 Standardize activities

SEIKETSU (SANITIZE / STANDARDIZE)

This step creates a work area free of checklists; if good standards are put in place it will be easier
to maintain and continue improving.
 Maintaining the workplace in high standard of housekeeping and organization.
Set easy-to-follow standards and develop a structure to support the three first (S’s) pillars.

PROCESS/PROCEDURE:

Step 1: - Establish standards for maintaining compliancewith 3S.

- Remember the 3 “NO” principles:
 No unnecessary items
 No mess
 No dirt
Step 2: - Make a schedule for cleaning your workplace.
Step 3: - Interdepartmental competition and cooperation is avery effective means of sustaining
andenhancingpeople’s interest in 5S
Maintain a high standard of housekeeping and workplace organization at all times.

 Maintain cleanliness and orderliness

 Prevent miss-operation
 Make it easy to find out abnormality
 Standardize good practices
SEIKETSU PRACTICES
 Visual control signs
 Color coding
 Maintenance labels
 Fixed-point photography

9
Ethiopian TVET System TTLM Development DBUCNC Department of IT

Lo – 6 Sustain 5S system

SHITSUKE (SUSTAIN/SELF-DISICPLINE)
Sustaining is the end result of how well we have performed the previous four S’s. In the
sustainability stage, think of ways to eliminate effort in maintaining an area.
 Doing things spontaneously without being told.
Educate people so that 5S expands beyond initial limits and turns into natural standard behavior.

PROCESS/PROCEDURE:
Step 1: - Create reasonable rules.
 Create reasonable rules of behavior in the workplace. Engage everyone concerned
in the creation of rules not just the department heads or supervisors.
 Discuss the rules with everyone concerned. This will result to a feeling of
involvement.
 Show rules and standards clearly and attractively using illustrations, photographs
and color-coding.
Step 2: - Exhibit before and after 5S photos where everyone will see them.
Step 3: - Recognize good practices and good performance.
Train people to follow good housekeeping rules autonomously.
• Enhance autonomous management activities
• Maintain the discipline needed to do a good job
• Upgrade productivity and quality consciousness
 Wash hands after going to the toilet
 Wash hands before and after meals
 Eat and smoke at designated places
 Keep workplace always clean and tidy
 Wear clean uniform and shoes
 Follow safety rules
 Put things back in their proper places
 Work according to standards
 Observe proper office decorum
10
Ethiopian TVET System TTLM Development DBUCNC Department of IT

Self-check
I. Write the correct answer on the blank space.
1. ____________ is a process-centered approach to ensuring that a company or organization is
providing the best possible products or services.
2. _____________typically require a strong knowledge of the business processes of an
organization.
3. Write the 5S in Japanese and English terms.
1. ____________________
2. ____________________
3. ____________________
4. ____________________
5. ____________________
4. What is 5S?
5. 5S is a systematized approach to:
1. _____________________
2. _____________________
3. _____________________
6. What can a company gain from 5S?
P. __________________
Q. __________________
C. ___________________
D. ___________________
S. ___________________
M. ___________________
7. What are the benefits of 5S?
A. _______________
B. _______________
C. ________________
11
Ethiopian TVET System TTLM Development DBUCNC Department of IT
D. ________________
E. ________________
F. ________________
8. __________is a step that involves selecting what you need to complete the job and removing
everything else from your work area.
9. ___________ is Arrangement / organization of necessary items in good order for use.
10. What is the use of arranging necessary items in good order in implementing the 5S?
i. _______________________
ii. _______________________
iii. _______________________
iv. _______________________
11. _______________is powerful because its purpose is to find the reason why things become
dirty.
12. _______________a work area free of checklists; if good standards are put in place it will be
easier to maintain and continue improving.
13. _______________ is the end result of how well we have performed the previous four S’s.

Answer key
1. Quality assurance
2. Qualityassurancejobs
3. 5S:-
1. SEIRE (Sort)
2. SEITON (Systematize / Stabilize / Straighten)
3. SEISO (Sweep / Shine)
4. SEIKETSU (Sanitize / Standardize)
5. SHITSUKE (Self-discipline / Sustain)
4. 5S means good housekeeping and workplace organization
5.
1. organize work areas
2. keep rules and standards
3. maintain discipline
6.
a. P. 5S increases PRODUCTIVITY.
b. Q. 5S improves QUALITY.
c. S. 5S improves SAFETY.
d. D. 5S makes DELIVERY on time.
e. C. 5S reduces COST.
f. M. 5S improves MORALE.
7.
• 5S improves CREATIVITY of people.
• 5S improves COMMUNICATION among people.
• 5S improves HUMAN RELATIONS among people.
• 5S improves TEAMWORK among people.
• 5S improves CAMARADERIE among people.

12
Ethiopian TVET System TTLM Development DBUCNC Department of IT
• 5S gives VITALITY to people.
8. Sorting
9. Systematize
10.
 prevent loss and waste of time
 easy to find and pick up necessary items
 ensure first-come-first-served basis
 make production flow smooth and work easy
11. SEISO (SHINE / SWEEP)
12. SEIKETSU (SANITIZE / STANDARDIZE)
13. Sustaining

13