5S - BASIC TRAINING

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

• Seiri – Sort (housekeeping)

• Seiton – Systematic Arrangement
(workplace organization)
• Seiso – Shine (Cleanup)
• Seiketsu – Standardize
• Shitsuke – Sustain (Self Discipline)
 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.
 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
 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.
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
Aren’t you frustrated in your workplace?

Oh, this position I cannot

makes me tired ! remember
what/how to
next…
Where is that Why I am
document ? making mistakes
I cannot find it ! again and again

Oh time is not Why we cannot

enough to communicate
complete this properly?
work!
 Are you
positive thinker or negative
thinker?

8
Thinking negatively in inside
box and give-up?

9
 Work together and do
something with big positive
attitude?

10
 Even you are positive thinker,
you still need something to make your ideas
realistic
You need tools !

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There are useful tools

5S
approaches

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 What is 5S ?
• 5S is a philosophy and a way of organizing and
managing the workspace and work flow with the
intent to improve efficiency by eliminating waste,
improving flow and reducing process
unreasonableness.

It is for improvement of
working environment
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 What is 5S ?
• 5S activities are to create good working
environment through reduction of “Muri”,
“Mura”, and “Muda”
• It help to have a basis of strong management
of workplace
• What is “Muri”, “Mura”, and “Muda”?
– Muri : overburden, unreasonableness or absurdity
– Mura : unevenness or inconsistency, primarily
with physical matter and the human spiritual
condition
– Muda : activity which is wasteful or doesn’t add
value

Source: [Link]
 5S in Japanese/English
5S is literally five abbreviations of Japanese terms with 5 initials of
S.
Japanese English
S-1 Seiri Sort

S-2 Seiton Set

S-3 Seiso Shine

S-4 Seiketsu Standardize

S-5 Sitsuke Sustain

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 Background on 5S activities

• The word “5S(five S)” was generalized

in 1980’s in manufacturing sector in
Japan, as Toyota Production System
(TPS) became famous in the sector
and “5S activities” were set as one of
the bases of TPS
• Service industry started to used “5S” in
1990’s
 Background:
- National Demonstration Project -
• NDP was designed to test TQM approach
for health care quality and safety
improvement
• NDP was conducted in US (1989-1990)
and Japan (2000-2004)
• Many private hospitals in Asia, Europe,
and US are practicing KAIZEN-TQM
approaches for health care quality,
hospitals management and safety
improvement
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What 5S can do?

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Team work improvement through
everyone’s participation

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Identify Abnormalities

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Identify wastes and reduce the wastes

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 The 7 wastes

Overproduction
Over processing
Inventory

Rework Waiting

Transportation Motion
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Mr. Taiichi Ohno, Former President of Toyota Motors
Improve productivities

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Improve safety

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 If no 5S activities….

Hesitate what to do
Looking for necessary
items

Remember what /
how to do Making mistake
Details of 5S approach

26
5S: Sort-Set-Shine-Standardize-Sustain

S1:
Sort

S5: S2:
Sustain Set

S4: S3:
Standardize Shine
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ALWAYS GOOD
CONTINUAL IMPROVEMENT
CHANGE FOR THE BETTER
 KAIZEN IS A JOURNEY FROM:

EVENT TO CAUSE
RESULT TO PROCESS
GROSS TO MICRO
ENFORMENT OF TO INDUCEMENT
CHANGE OF CHANGE
KAIZEN IS CONTINUAL IMPROVEMENT

TIME TIME
 KAIZEN: KNOW THE REALITY
THROUGH YOUR SENSE

OBSERVATION INTELLIGENCE

PHYSICAL EFFORT

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
 1. 5S Principles

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

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 2. Objectives

◼ 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
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

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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

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 1 ‘S’ - SEIRI

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
Seiri = Sorting What is unnecessary

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

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
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Seiri = Sorting Identifying unnecessary

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..
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Seiri = Sorting Identifying unnecessary

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..
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Seiri = Sorting Identifying unnecessary

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..
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Seiri = Sorting Identifying unnecessary

[Link], Pits, Partitions

• Defective parts
• Protection caps, covers
• Packing material
• Hardware items , small items
• Even tools, tooling
Items dropped on the floor are never picked
[Link] Hard Disk
• Many unwanted, outdated, temporary files pile up

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Seiri = Sorting Improvement methods

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.
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Seiri = Sorting Dealing with papers

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

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Seiri = Sorting Dealing with papers

How to Reduce Papers

on Your Table ?

4 D Principle

DO
DELEGATE
DELAY
DUMP

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 2 ‘S’
Seiton : Systematic Arrangement

Arranging things in systematic way

 2 ‘ S’ - SEITON

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

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

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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

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Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ?

• Decide where things belong

• Decide how things should be put away

• Obey the Put away rules

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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..
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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

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Seiton = Systematic Arrangement

USE :

1 ) Signboards

2) Colour codes

3) Outline markings

4) Labels

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Seiton = Systematic Arrangement

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

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Seiton = Systematic Arrangement

• 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
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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

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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 61
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

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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

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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
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

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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
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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

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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

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Seiso = Cleaning

EXAMPLE : PREPARE CHECKLIST FOR CLEANING

[Link] 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

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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

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Seiso = Cleaning

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.

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Seiso = Cleaning

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.

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Seiso = Cleaning

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.

76
Seiso = Cleaning

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.

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Seiso = Cleaning

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.

78
Seiso = Cleaning

Function wise Cleaning check list of

equipment

Tools, fixtures, gauges, dies,

Tooling measuring instruments, etc.

Equipment Furnaces, rollers, chutes,

Specific CNC machines, etc.

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Before shine after shine
Before shine after shine
 4 ‘S’
Seiketsu
 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
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

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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.
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SEIKETSU = Standardization
Tools used for analysis :

MTTR : Mean Time To Repair \ Recover

MTBF : Mean Time Between Failures

OEE : Overall Equipment Efficiency

86
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

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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

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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

89
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
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Seiketsu = Standardization

Some methods for visual communication

Labels
 Precision management labels
 Inspection labels
 Temperature labels
 Responsibility labels

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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
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Seiketsu = Standardization

Some everyday visual management

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

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Seiketsu = Standardization

Some visual communication signs

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 5 ‘S’
Shitsuke
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
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

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

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

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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

101
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.

102
Shitsuke = Self Discipline Pledge
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

103
 ORGANIZATION
• Departments into areas
• Coordinators at department level
Organization
• Coordinator at each area level
• Training for all
• Audit each area and make action
check list
• Implement actions
• Audit and evaluation on continuous
basis 104
 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