5S
THE SECRET TO
JAPANESE SUCCESS
WHAT PROBLEMS DO U ENCOUNTER AT
YOUR WORKPLACE
• HIGH ABSENTEEISM
• HIGH TURNOVER
• DEMOTIVATED EMPLOYEES
• DISORDERED/ CLUTTERED
ENVIRONMENT
• MISTAKES/ERRORS
THE SOLUTION TO ALL THESE
PROBLEMS IS
5S
5S
HOUSEKEEPING TECHNIQUE
PRODUCTIVITY AND SAFETY
ENHANCEMENT TECHNIQUE
IDEA BEHIND 5S
• IN ORDER TO ACHIEVE HIGH LEVELS
OF QUALITY, SAFETY,AND
PRODUCTIVITY, WORKERS MUST
HAVE A CONDUCIVE WORKING
ENVIRONMENT
WHAT IS 5S?
• Developed by the Japanese
• Housekeeping System
• Helps Create a Better Working
Environment and a Consistently High
Quality Process
THE 5S PRINCIPLES
• SEIRI – Organisation/Sort out
• SEITON – Orderliness/Systemize
• SEISO – The Cleaning/Shining
• SEIKETSU – STANDARDIZE
• SHITSUKE - Sustain/Discipline
DISCOVERY OF 5S
• Thirty years ago researchers started
studying the secret of success of Japanese
manufacturing companies
• 5S turned out to be the most impressive
"secret"
• The factories were so well organized that
abnormal situations were readily apparent
DISCOVERY OF 5S
• Equipments were so clean and well
maintained that any problem such as
a loose bolt or leaking oil could be
easily seen
• This passion of cleanliness and
orderliness became a hallmark of
Japanese organizations
ADVANTAGES OF 5S
• If tools and materials are conveniently
located in uncluttered work areas
• Operators spend less time looking for
items
• This leads to higher workstation efficiency,
a fundamental goal in mass production
ADVANTAGES OF 5S
• A clean and tidy workplace leads to
greater well being and increased
motivation
• Company image improves
ADVANTAGES OF 5S
• Health and Safety is ensured
• Machine maintenance
• Quality
• Productivity
• Lean Manufacturing
ADVANTAGES OF 5S
• RESULTS IN A PLACE EASIER TO MANAGE
• SMOOTH WORKING NO OBSTRUCTION
• NO DEVIATION, NO PROBLEMS
• B/C EVERYONE KNOWS WHERE THE
THINGS ARE SPPOSEDF TO BE
ADVANTAGES OF 5S
• TIME SAVING
• QUICK RETRIEVAL
• ACCIDENTS & MISTAKES MINIMIZED
• INCREASES SPACE
• CREATES WORKPLACE OWNERSHIP
ADVANTAGES OF 5S
• FOUNDATION OF ALL QC TOOLS
• CONTINUOUS QUALITY
IMPROVEMENT
• LEAN MANUFACTURING
• KINDERGARTEN OF QUALITY TOOLS
& TECHNIQUES
ADVANTAGES OF 5S
• VISUAL MANAGEMENT SYSTEM
• VISUAL CONTROL TO SEE THE
ABNORMALITIES
• SIMPLE SIGNALS THAT PROVIDE AN
UNDERSTANDING OF THE
CONDITION( NORMAL/ ABNORMAL)
• A LOOK AT THE PROCESS REVEALS ITS
DIRECTION (RIGHT/WRONG)
Lean Production
• The latest incarnation of JIT
• Based on Toyota Production System.
• Waste elimination
• Widely used in automotive
manufacturing & other repetitive mfg.
It’s the elimination of waste Everywhere –
while adding customer value…
It’s a mindset & commitment to
achieve a totally waste-free
operation that’s focused on your
customer’s success… achieved
by simplifying and continuously
improving all processes
From the operations perspective
Lean production cuts costs &
inventories rapidly to free cash,
which is critical
It also supports growth by improving
productivity & quality, reducing lead
times, and freeing huge amounts of
resources.
From the operations perspective
For example, lean production frees
office and plant space and increases
capacity so companies can
1. Add product lines
2. In-source component production
3. Increase output of existing products
without acquiring new facilities.
KINERGARTEN OF ALL THE QC
TOOLS
• 5S IS THE STARTING POINT OF ALL
THE QC TOOLS
• COULD BE SAID AS THE PRE-
REQUISITE OF ALL QC TOOLS
METHODOLOGY
OF 5S
1. ORGANISATION(SEIRI)
• Decide what you need
• Remove unnecessary clutter
• All tools, gauges, materials, classified and
then stored
• Remove items which are broken, unusable
or only occasionally used
RED
RED TAG TECHNIQUE TAG
• GIVE STAFF RED LABELS
• ASK STAFF TO GO THROUGH EVERY
ITEM IN THE WORK PLACE
• ASK IF NEEDED & THOSE THAT ARE
NEEDED,IN WHAT QUANTITY
• NOT NEEDED RED TAG IT
• STORE IN THE RED TAG AREA
RED
TAG
For wavering items
• PLACE THE SUSPECTED ITEMS IN THE
RED TAG AREA FOR ONE WEEK
• ALLOW THE STAFF TO REEVALUATE
THE NEEDED ITEMS
• AT THE END OF WEEK THOSE WHO
NEED ITEMS SHOULD BE RETURNED
ORGANISATION
PRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once per Throw away
year Store away
Once per year from the
workplace
Avg. Once per month Store together
Once per week but offline
High Once Per Day Locate at the
workplace
2. ORDERLINESS(SEITON)
• ONCE YOU HAVE ELIMINATED ALL
THE UNNEEDED ITEMS
• NOW TURN TO THE LEFT OVER ITEMS
ORDERLINESS(SEITON)
Organise layout of tools and
equipment
– Designated locations
– Use tapes and labels
– Ensure everything is available
as it is needed and at the
“point of use”
ORDERLINESS(SEITON)
Workplace Checkpoints:-
• Positions of aisles and storage places
clearly marked?
• Tools classified and stored by frequency
of use?
• Pallets stacked correctly?
• Safety equipment easily accessible?
• Floors in good condition?
3. SEISO (CLEAN/SHINE)
• Create a spotless workplace
• Identify and eliminate causes of dirt
and grime – remove the need to
clean
• Sweep, dust, polish and paint
SEISO (CLEAN/SHINE)
• Divide areas into zones
• Define responsibilities for cleaning
• Tools and equipment must be owned by an
individual
• Focus on removing the need to clean
4. SEIKETSU (STANDARDISE)
• Generate a maintenance system for the
first three
• Develop procedures, schedules, practices
• Continue to assess the use and disposal of
items
• Regularly audit using checklists and
measures of housekeeping
• Real challenge is to keep it clean
5. SHITSUKE (SUSTAIN / DISCIPLINE)
• Means inoculate courtesy & good habits
• Driving force behind all 5S
• Deming’s point number 1: Constancy of
purpose
• Make it a way of life
• Part of health and safety
• Involve the whole workforce*
• Develop and keep good habits
LITMUS TEST FOR 5S
• 30 SECOND RULE
• ONE MUST LOCATE THE ITEM WITH IN 30
SECOND IF 5S IS PROPERLY IMPLEMENTED
• ALSO APPLIES TO THE ELECTRONIC RECORDS
RETRIEVAL
WHAT U HAVE COME ACROSS
AT THE END OF DAY
Followings can be harnessed form the 5S
1. NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
Cont.
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME SPACIOUS
