Doc. No.- SA/5SP/24, Rev.00 DT.12.10.
2018
5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
WHAT IS THE 5S METHODOLOGY?
The 5S methodology is often summarized by the philosophy of “a place for everything
and everything in its place.”
5S Japanese Words
5S originated as 5 Japanese words:
1. Seiri
2. Seiton
3. Seisou
4. Seiketsu
5. Shitsuke
In English, these 5S words have come to be known as:
• Sort: Eliminate that which is not needed.
• Straighten: Organize what remains after sorting.
• Shine: Clean and inspect the work area.
• Standardize: Write standards for 5S.
• Sustain: Consistently apply the 5S standards.
At their core, 5S activities build the discipline needed for substantial and continuous
improvement by creating (and sustaining) efficient and effective work areas.
WHY IS 5S IMPORTANT IN MANUFACTURING?
While 5S was first developed in the context of the automotive industry, it is now widely
considered an essential element of any lean manufacturing program, regardless of
industry.
Doc. No.- SA/5SP/24, Rev.00 DT.12.10.2018
5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
Embedding 5S as part of daily life within your company means much more than an
improved organization, sustained cleaning routines, and efficient activity flows. By using
the 5S methodology, operators are encouraged to improve their overall work
environment and reduce muda or waste.
Adherence to 5S standards is considered the foundation of Total Productive
Maintenance (TPM) and an integral part of the Toyota Production System (TPS). 5S
also creates a stable platform from which Kaizen activities can be launched.
The bottom line - 5S is a low-investment, high-impact lean manufacturing tool that is
predicated on people. It engages operators in “owning” their workspace and helps to
instill a culture of quality, productivity, and improvement.
WHAT ARE THE BENEFITS OF A 5S PROGRAM?
The key benefits of a 5S program include:
• Creating space within your facility by removing unnecessary tools and equipment
• Reducing waste from unnecessary motion by organizing the workspace
• Reducing down time and improving quality by consistently maintaining equipment
• Engaging operators by granting them more responsibility for their work
environment
• Creating a safer work environment by ensuring it is clean and well -maintained
Now that you have a better understanding of why 5S is important and how it can benefit
your manufacturing operations, let’s learn more about each of the 5S steps.
SORT
What Is Sort?
Doc. No.- SA/5SP/24, Rev.00 DT.12.10.2018
5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
The Sort step separates items in your workspace that you know you need from those
that you do not need or may not need by moving the latter to a “red tag” holding area.
Why Do You Need Sort?
Sort enables you to have a more productive workspace by removing unneeded clutter
(and eliminating distractions). It also is a first step towards opening up space that can
be used for other things.
How Do You Implement Sort?
Separate necessary items (e.g., tools, parts, and materials) from unnecessary items.
We recommend sorting items into four categories:
1. Items needed in this work area. These are items you know that you
regularly use in the context of this work area and thus will stay in this work
area.
2. Items needed in another work area. Essentially, these are misplaced items.
If an item is used in another work area, “sort” it into that area by delivering it
to whomever is responsible for that work area.
3. Items you may need. For items you are unsure about, use the 5S “red tag”
system. Mark such items with red tags, which at a minimum, should include
the name of who tagged the item, why it is thought to no longer be needed, a
proposed review date, and the name of the manager who must approve of
disposal. Move the item to a red tag holding area, which should be organized
by review month to make it easy to manage the area.
4. Items you do not need. These are items that you are 100% confident are not
needed. They should be immediately discarded.
STRAIGHTEN
Doc. No.- SA/5SP/24, Rev.00 DT.12.10.2018
5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
What Is Straighten?
The Straighten step thoroughly organizes the items that remain after sorting, such that
frequently used items are easy to access and every item has a clear and easy -to-find
home.
Why Do You Need to Straighten?
Straighten enables every item to have a specific home where it can be easily found and
to which it can be easily returned. It reduces the waste from excess motion as items are
placed in more ergonomic locations. It is also the second step towards opening up
space that can be used for other things.
How Do You Implement Straighten?
After you’ve sorted items, it’s time to decide how you want to organize them. We
recommend the following methodology:
1. Provide easy access to frequently used items. The key to reducing waste
from excess motion is to place frequently used items within easy reach.
2. Group like items. Group the remaining items into logical categories and
brainstorm the best way to organize and store each of these categories.
3. Visualize item homes. For each group, decide on the best way to make it
clear when an item is missing or misplaced. A classic example is creating a
shadow board for tools.
4. Use containers. If it is appropriate for the type of item, consider organizing it
within a container.
5. Unleash the labeler. If an item is too big to put into a container, consider
giving it a frame and putting a label on the item in addition to the frame.
6. Be agile. Your initial straighten pass will likely deliver a significant
improvement - but you are also likely to overlook some potential
improvements. Meet with your team after one week and again after two
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5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
weeks to brainstorm further improvements as part of your initial
implementation.
SHINE
What Is Shine?
The Shine step elevates the work area by thoroughly cleaning and inspecting tools,
equipment, and other items. It also can include routine maintenance on equipment,
which is one of the ways it flows directly into TPM.
Why Do You Need to Shine?
Shine creates a work environment that engages and empowers operators by giving
them more responsibility and agency over their work area. It also helps them to identify
problems before they interfere with production. For example, in a clean work
environment, it is much easier to spot emerging issues such as fluid leaks, material
spills, metal shavings from unexpected wear, hairline cracks in mechanisms, etc.
How Do You Implement Shine?
After you’ve straightened items, it’s time to elevate the work area by cl eaning,
inspecting, and in some cases performing routine maintenance. We recommend the
following:
1. Grab the metaphorical spray bottle. Using appropriate cleaners and
cleaning tools, make the work area sparkle. With every sweep, mop, brush,
wipe, wash, and wax, strive to return your workspace to its former glory. Be
Miyagi.
Doc. No.- SA/5SP/24, Rev.00 DT.12.10.2018
5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
2. Find the source. The guiding principle of this step is “clean to understand.” If
there are any signs of leaks, spills, or unexpected debris, strive to understand
the source. It is likely an early warning of a future problem.
3. Inspect. After cleaning each item, take a moment to look it over and examine
its condition. Does it need updating, maintenance,
• Make sure to follow proper cleaning procedures to prevent damage to equipment.
STANDARDIZE
What Is Standardize?
The Standardize step is a bridge between the first three steps (Sort, Straighten, Shine)
and the last step (Sustain). In this step, your goal is to capture best practices for 5S as
standardized work for your team.
Why Do You Need to Standardize?
Standardize makes 5S repeatable. It transforms 5S from a one-off project to a
reproducible set of activities.
How Do You Implement Standardize?
It’s time to make sure all your hard work continues to pay dividends into the future. Set
expectations for the future with a documented 5S process. To do so, we recommend
that you:
1. Document in pairs. Have one team member walk through each task as
another documents it to ensure nothing important is missed.
Doc. No.- SA/5SP/24, Rev.00 DT.12.10.2018
5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
2. Capture the essence. We are huge proponents of simplicity (and agile).
Capture the essence of each task and no more. Otherwise, your
documentation will very likely not be maintained.
3. Prefer checklists. Checklists feel easy. Short checklists feel even easier. A
great format is to have a name for each task that serves as a quick reminder
and a more detailed description for training.
4. Organize to simplify. Organize your checklists by role, by shift, and by
frequency (daily, weekly, monthly). This will make the 5S process much less
intimidating to your team.
SUSTAIN
What Is Sustain?
The Sustain step assures that 5S is applied on an ongoing basis. It transforms your
standardized 5S processes into regularly completed tasks.
How Do You Implement Sustain?
Once you’ve standardized, it’s time to continually act upon those standards. We
recommend you:
1. Create a schedule. Embed 5S practices as scheduled tasks (by role, shift,
and frequency).
Doc. No.- SA/5SP/24, Rev.00 DT.12.10.2018
5S PROCEDURE Prepared By: -Vinod Kumar
Approved By: -R P Singh
2. Teach through demonstration. Instruct employees on how to conduct 5S
tasks through demonstration and training. Showing employees what is
expected of them will prepare them to enact tasks on their own.
3. Supervise to solo. After initial 5S training for employees, gently supervise
while they continue to form habits. It is easy to make mistakes or fall off the
wagon, so patiently and helpfully offer corrections when necessary.
4. Adapt as necessary. When giving or receiving feedback on tasks, see where
changes can be made to make the tasks easier and more efficient.
Standardized work is intended to be living documentation.
