5s

1. 5S
THE SECRET TO
JAPANESE
SUCCESSPresentation by : GAURAV KUMAR (FDI)

3. WHAT PROBLEMS DO U COMMONLY
ENCOUNTER AT YOUR WORKPLACE
HIGH ABSENTEEISM
HIGH TURNOVER
DEMOTIVATED EMPLOYEES
DISORDERED/ CLUTTERED ENVIRONMENT
MISTAKES/ERRORS

4. THE SOLUTION TO ALL THESE
PROBLEMS 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
 Reducing useless process.

5. It is for improvement of working
environment
BY ENHANCING
• HOUSEKEEPING TECHNIQUE
• PRODUCTIVITY
• SAFETY

6. • 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
Muri Overburden: give unnecessary stress to our employees and our
processes.
• This is caused by Mura and a host of other failures in our system such
as lack of training, unclear or no defined ways of working, the wrong
tools, etc.
Mura unevenness or inconsistency
Muda • activity which is wasteful or doesn’t add any value
• a physical waste of your time, resources and your money
Ex transportation, motion etc.

15. 1. SORTING (SEIRI)
 Focuses on eliminating unnecessary items from the workplace
 Categorize Equipment, Furniture, Tools in your workplace into
categories:
 Remove items which are broken, unusable or only occasionally
used
• Not needed at all • Needed but not now
• Needed but not here • Needed but in limited quantity

17. EXAMPLE OF SORTING
• Place “RED TAG” for categorization of items to
identify unnecessary items
• Move unnecessary items( broken tools, obsolete jigs
and fixtures, scrap and excess raw material etc.) to
central stored area
• Free up valuable floor space (Space utilization)
• Finding abnormality of equipment and tools (Out of
order, missing parts etc.)

19. RED TAG TECHNIQUE
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
STORE IN THE RED
TAG AREA
RED TAG IT

20. 2. SET (SEITON)
Based on finding efficient and effective storage of necessary items
Apply “Can see, Can take out, and Can return” philosophy
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”
“PLACEFOR EVERYTHING& EVERYTHINGIN ITS PLACE”

23. EXAMPLE OF VISUAL MANAGEMENT

24. 3. SHINE(SEISO)
oCleaning up one’s workplace daily so that there is no dust on
floors, machines or equipment.
oDivide areas into zones
oDefine responsibilities for cleaning
oTools and equipment must be owned by an individual
It will create ownership and build pride in the workers
Cleaning with meaning Cleaning with inspection

26. Example of “Shining” activities
Daily sweeping and mopping of floor, bathroom, corridor etc.
Regular cleaning and maintenance of equipment and tools
Periodical check for changes in equipment and the service
area such as:
 leaks
 vibration
 misalignment
 breakage etc.

27. 4. STANDARDISE (SEIKETSU)
Maintenance an environment where first three S are
implemented in same manner throughout the
organisation.
Give opportunities to employees to take active part in
development of these standards
Regularly audit using checklists and measures of
housekeeping
Real challenge is to keep it clean

29. Example of “Standardize” activities
• Work instructions, Standard Operating Procedures (SOPs)
• Checklist development and regular usage for SOPs
• Mechanism and format development for ordering supplies,
reporting etc
• Colour coding for waste segregation
• Standardized common symbols

31. 5. DISCIPLINE or SUSTAIN
(SHITSUKE)
■ Maintain S1-S4 through discipline, commitment and empowerment
■ Driving force behind all 5S
■ Part of health and safety
■ Involve the whole workforce
 It focuses on defining a new mindset and a standard in workplace

33. EXAMPLE OF “SUSTAIN” ACTIVITIES
• Regular progress reporting
• Refresher training
• Periodical evaluation of 5S activities with proper advices for
continuation and further improvements
• Appreciation, recognition and awarding on good 5S activities
• Reminder using 5S corner, new letters, good practice sheet
etc.

35. Zero changeovers leading to product/ service
diversification
Zero defects leading to higher quality
Zero waste leading to lower cost
Zero delays leading to on time delivery
Zero injuries promoting safety
Zero breakdowns bringing better maintenance

39. Wrap-up
• Positive attitude is very important for implementation
of 5S activities
• It is not “Cleaning Campaign”
• 5S activities are to create good working environment
through reduction of “Muri”(overburden),
“Mura”(unevenness), and “Muda”(waste)
• It is a basis of organization management

40. 1. NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME SPACIOUS