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APPLYING
5-S TECHNIQUES
FOR
IMPROVED WORK
ENVIRONMENT
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5-Ss are Basic inEstablishing Norms
for EffectivePerformance
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5-S is a KAIZENTechnique to Ensure
IncrementalImprovement
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ForWorkplace
Management
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Why Implement 5-S&
What are the real benefits ?a. Improves Productivity
b. Helps in proper maintenancec. Improves Quality
d. Improves Safetye. Reduces Costs
f. Detects Inconsistency in Workplace
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OTHER REASONS FOR IMPLEMENTING 5-S
Develops a KAIZEN mindset.
Build Teamwork
Establishes Discipline
Negligible Investment
Generates Enthusiasm
Implementation is Easy
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Some Points on 5-S If you cant do 5-S, you cant do other
work. The company thats doing badly is
doing the 5-S badly.
Moving from managing by results tomanaging by causes.
5-Ss are Crime Prevention.
5-Ss are management barometer.
If you can do 5-S, you can do anything.
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Where 5-S isApplicable?
Every Where
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DERIVED FROM THE FIRST LETTERS OF
EIRI
EITON
EISO
EIKETSUHITSUKE
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WHEN DO WE KNOW ABOUT THEM ?
5-Ss are there for a
very long time.
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WHAT ARE THE MEANING OF 5-Ss ?
EIRI
ORGANISE/ SORT
Distinguishing
between necessaryand unnecessary andgetting rid of what is
not needed.
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WHAT ARE THE MEANING OF 5-Ss ?
EITON
SYSTEMATISE/NEATNESS/LAYOUT
Establishing a neatlayout such that onecan always get as
much of what isneeded, whenneeded.
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WHAT ARE THE MEANING OF 5-Ss ?
EISO
CLEANING/ SHINE
Eliminate trash, filth
and foreign matter tohave a cleanerworkplace. Cleaning
as a form ofinspection.
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WHAT ARE THE MEANING OF 5-Ss ?
EIKETSU
STANDARDISATION &VISUALISATION
Keeping
everythingorganized neat
and clean.
Standards tomaintain.
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WHAT ARE THE MEANING OF 5-Ss ?
HITSUKE
DISCIPLINE/SUSTAIN
Doing the rightthing as a
routine matter.
G S
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General Scenario in Bangladesh
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General Scenario in Bangladesh
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General Scenario in Bangladesh
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General Scenario in Bangladesh
G l S i i B l d h
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General Scenario in Bangladesh
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SEIRI
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SEIRI (Organise)Objective: To reduce or eliminate workplace clutter
thereby reducing space requirements, stock levels,
and reducing working capital. Thereby improving
productivity
Classify everything around you Separately store according to the classification
Discard all obsolete and unwanted things
Fix rules for disposal
Implement preventive 5S
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Understanding SEIRI (Reorganise)
ORGANISE/REORGANIZE THE WORKPLACE
There should be only items necessary toperform work at the workplace.
Dispose/remove all unnecessary items.
Ensure that unnecessary do not enter theworkplace.
Understanding SEIRI (Reorganise)
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Understanding SEIRI (Reorganise)
AS A PREVENTIVE MEASURE IDENTIFY HOW
UNNECESSARY ITEMS ENTERS TO THE WORKPLACE:
Organise procurement & stores.IDENTIFY THE EXCESS QUANTITIES
FOR THIS IT IS NECESSARY TO DECIDE WHAT IS
NECESSARY & UNNECESSARY IN A WORKPLACE:
So suggest them.
How to do SEIRI ?
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How to do SEIRI ?
1. Decide the scope of operation (what
workplaces, areas) and target to beachieved.
2. Get Ready.
3. Teach people to recognize what isunnecessary.
4. Quantity & access.
5. Perform management inspection andassessment.
Classification Stratification Management
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Classification - Stratification Management
Things we dont use
Things we dont use but
want to have on hand just
in case
Things we use on & off
Things we use infrequently
Things we use frequently
Discard
Keep as contingency items in
a separate store/record room
Store somewhere far away
Store in the workplace
Keep at the workplace
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Points to remember in classification
Items we do not use
Throw away
Donate
If difficult to get you may still keep
Sell and generate cash
Hazardous waste use appropriate disposal
means Confidential items - shred
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Three techniques to help Classification
The Red Tag Technique
The Yellow Tag Technique
Or use your 5 human senses Look
Listen
Feel
Smell
Taste
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Red Tag Technique
Using a suitable type of red colour disposal notice
1. Train persons in red tagging2. Apply the tags
APPLYING THE RED TAGS
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APPLYING THE RED TAGS
Decide on the standard for red tagging
Committee or Int. Audit
Make the red tags - paper, self adhesive tape, plastic
covers, round seals
Do the tagging during a selected period Mark details
Keep for exchange period
Get final approval for disposal or other action Dispose
Dont delay
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Red Tag Technique -Look at ...
Stocks
Facilities
Locations
Documents Machines
Fittings
Stationery Bank Accounts
Others
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You may discover
Defective items
Dead stock
Sleeping stock Excess materials
Excess spares
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If in doubt throw it out?
Or
Use the yellow Tag technique
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Yellow Tag technique
When you are not sure
On a fixed day label and mark date
If label items are used thereafter remove the
label.
Inspect after 6 months(or 1 year) - Which items
still have labels
If still not sure repeat inspection after one year.
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Advanced SEIRI - Habitual
Make rules for disposal by time or quantity
notices on notice boards, stocks, newspapers, used items,calendars, directories etc.
Reduce stocks
Mark min. and max. stock levels, fixed qty bins for forms,reduce bought out stocks, increase deliveries, reduceinventory by calculating stockminutes
Reduce W-I-P
Purely by implementing SEIRI
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Purely by implementing SEIRI
Many companies have Reduced space requirements
Given up plans for new storage buildings
Reduced the capital expenditure on cabinets etc.
Reduced overdrafts and borrowing
Generated Money in sales of discarded items
Made the factory look better
Made the office more pleasant
SEIRI
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SEIRI
Unnecessary Papers 12 Kg.
Necessary Papers 2.5 Kg.
BENEFITS OF SEIRI
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BENEFITS OF SEIRI
- Saves Floor Space
- Helps to Get Rid of Obsolete Item
- Gives a Clear idea of Material in Stock
- Prevent incidence of Unnecessary Buying
- Better Utilization of Existing Material
Understanding SEITON (Neatness)
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g ( )
Keeping necessary things appropriately
such that - always available.
(A place for everything & everything inplace)
easily available.
All necessary things will have a fixed
determined space to keep known toeverybody.
Understanding SEITON (Neatness)
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In keeping things consider classification
Ensure: Neat Workplace
Efficient Layout
Safe Keeping Eliminate search Efficient utilization of space
As if you can find things blindfolded.
SEITION
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Objectives are :
Reduce search, pick up and transport timeImprove Productivity of time
Reduce Personnel stressImprovequality of work life.
Improve quality of products and services
Prevention of defects. Improve safety
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Understanding SEITON (Neatness)
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g
Ensure:
Everything has a nameand location
Easy to keep
Easy to takeout
FIFO
Park like setting 30 Second retrieval
Understanding SEITON (Neatness)?
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Point to RememberJumble
Things are putevery whichway, whichmeans thatspace is used
inefficientlyand you cannotput as manythere as youshould be ableto.
Orderly
Things are putat right anglesand alongstraight lines.Space is used
most efficiently.Things are allfacing the sameway.
Every curvemeans a likelycollision andbreakage.Every curve is
dangerous.Every curvemeansslowingdown.
Curved
paths
Straight linesare safe lines.
Things movefaster andmoreefficiently.
Straightpaths
Understanding SEITON (Neatness)
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SEITON
should result inReduced or eliminated search time
No mix up
Workplace look neat and invitingNo stress
Can you find anything - a file, a tool, a document,
a particular letter in a file, the correct switch etc.in
just a couple of seconds?
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BENEFITS OF SEITON
Materials Easily Available
Materials Easily Retrievable Lesser Production
Downtime
Machine Breakdowns Handled Fast
Time Taken to Search Minimized
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SEISO (Clean)
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SEISO (Clean)
The objective of this step is to improve health of
machinery and human beings by a process ocleaning that makes checking easier.Create anobsession with cleanliness and to inculcate the
habit of cleaning by self.
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Develop a cleaning culture
Prepare a cleaning responsibility map
Prepare a cleaning responsibility schedule
Have a systematic approach
Have 3 or 5 minute cleaning
Understanding SEISO (Cleaning)
C
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Cleaning means inspection.
Remove dirt, dust, grime and foreign
materials from the work palace. Keep the work place & equipment in a ready
to use condition.
Keep work place clean and tidy.
Cleanliness is -- Primary Maintenance- Primary to Quality
Identify source of dirt and contain at thesource such that the workplace orequipment remain clean and useable.
Understanding SEISO (Cleaning)
Whil l i if d f
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While cleaning remove rectify defects.
Cleaning is a team work.
Cleaning is every bodies job.
Cleaning is a part of routine job.
Cleaning is a frame of mind: attitude
Create a pleasant environment.
Assign individual and collectiveresponsibility in cleaning.
Cl i ibili
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Cleaning responsibility maps
Entire premises divided into zones
Each zone to have a person responsible
including the CEO
Give clear directions on the standards expected
Even if a janitorial service is used their work must
be checked by the zone in charge
Cl i ibilit h d l
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Cleaning responsibility schedule
Divide responsibility for daily tasks to people
Display the schedule
May even give evaluation points
Cleaning in a Scientific Manner
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Cleaning in a Scientific Manner
What to clean?
When to clean?
In which order to clean?
Who is responsible?
How to clean?
What tools to use?
What materials to use?
Storage of cleaning tools
Cleaning is checking - use the 5 senses
The Original Condition policy
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g p y
It is true that machines begin deteriorating fromthe moment they are installed or unpacked.
But every effort must be made to bring the
piece of equipment back to original condition
every day.
Then lifetime will be prolonged and breakdownswill be less.
Cleaning is Checking
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Cleaning is Checking
Clean equipment will facilitate detection ofabnormalities.
Cleaning is not polishing etc to make the piece
of equipment more beautiful it is to look after
its health.
Corrode and paint - perfume without a bath.
GARBAGE BIN STRATEGY
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GARBAGE BIN STRATEGY
Have many garbage bins
Have many waste paper baskets
Locate at regular distances
Have separate bins for different items
Have lids
Teach people to use them
5 Minute Cleaning 5 Minute 5S
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5 Minute Cleaning 5 Minute 5S
Fixed time or ad-hoc time
Bell or alarm or music
Standardised procedure for checking
Everyone must participate
Rigidly applied even when on the phone or having
visitors
Understanding SEISO (Cleaning)
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1. Look for accumulated mucks, clogging rustleakage etc.
2. In case of lubricants is it up to the level ?Look for leakage, filter free clogging,damage, collection tray etc.
3. In case of a bolts: Is it properly tightened ?
Loose parts, vibration, sound, shockabsorber, getting heated etc.
Some Points
Understanding SEISO (Cleaning)
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5. Look at motors, condition of fans, fan-belt
coupling, joints, plugs, chains, pumps etc.6. Look at electrical items, panel conditions
safety lamp, bulb, switches etc.
4. Look into hydraulic tank, oil valves, filter,adjustment.
Understanding SEISO (Cleaning)
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7. 5-S Pledge
- I will not get things dirty.
- I will not spill.
- I will not scatter things around.
- I will clean things right away.
- I will rewrite things that have gotten erased.
- I will tape up things that have come down.
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SEIKETSU
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Standardize all three steps
Standardize procedures
Evaluate using checklist
Implement Good and
Bad stickers
(Standardization & Visual Management)
Understanding SEIKETSU(Standardization & Visual Management)
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( g )
Maintain strict control over Seiri, Seiton,
Seiso activities such that there is nodeviation.
Regularizing the 3-S activities so thatabnormalities show up.
Making deviations obvious with visualcontrol (Sensory alertness and control)
Anybody can spot an abnormality.
Visualization demonstrate alertness. Making the rules easy to follow.
Understanding SEIKETSU(Standardization & Visual Management)
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(Standardization & Visual Management)
Tools and methods for visual control -
- displays to help people avoid makingoperating errors
- danger alerts- indications of where things should be put
- equipment designations
- cautions and operating reminders
- preventive maintenance displays
- instructions
Understanding SEIKETSU(Standardization & Visual Management)
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( g )
Standards on Right and Wrong-
- Make them easy to see from distance.- Put the displays on the things they are for.
- Make them so that anyone can tell what isright and what is wrong.
- Make them so that anybody can use themeasily and conveniently.
- Make them so that anybody can follow them
and make the necessary corrections easily.- Make them so that using them makes the
workplace brighter and more orderly.
The purpose of standardization is to make
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The purpose of standardization is to makesure that the entire organisation followsthe same procedures the same rules, thesame names, same sizes, shapes, andcolours etc..
Standardization may even be extended toother areas.
Understanding SEIKETSU(Standardization & Visual Management)
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(Sta da d at o & sua a age e t)
Visual Management -- levels.
- Precision Management level.
- Temperature Levels.
- Other relevant Levels.
- Okay Mark.
- Standard Inspection.
Understanding SEIKETSU(Standardization & Visual Management)
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- Lub. Oil.
- Inspection Levels.
- Zone Levels.
- Responsibility Levels.
- Position Mark.
(Standardization & Visual Management)
Floor painting strategyW ki
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Working areas - green
Aisles - orange
Rest areas - blue
Warehouses - Gray
Types of lines and sizes
Avoid right angles
Door opening lines
Storage space lines
Traffic flow direction lines
Safety signs
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Safety signs
Dont do signs
Must do signs
Warning signs - Tiger patterns Safe way signs
Different colours
Prominently displayed
Fix item
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Fix item
Item identification
Shelf indication
Should be flexible
Position Marks
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Position Marks
Waste paper baskets
Garbage bins
Tables and chairs
Cupboards and other furniture
Inspection points
Wire Management
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g
Off the ground
Neat and straight
Colour coded
Storage of registers and files File index displayed
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File index displayed
Colour code
Oblique lines
Easy to see, easy to get and easy to return
Identification strips on registers and books
Homes for registers and books Index labels (A, B, C)
Tags for important pages
Owner
Review period
Summary pages
Next location
Understanding SEIKETSU(Standardization & Visual Management)
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Ensure
Safety
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5-m Gi c~e 5-m Gi ci
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5-m Gi c~e
5-m Gi ci
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5-m Gi c~e 5-m Gi ci
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SHITSUKE(TRAIN & DISCIPLINE TO
CULTIVATE SELF DISCIPLINE )
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CU S SC )
Make everyone committed to the programme
Motivate through competitions
Enforce discipline to inculcate self discipline Have a 5S Patrol Team
Rule observance campaigns
Games
Encourage preventive 5S
Understanding SHITSUKE( Discipline )
- Discipline as a way of cleaning
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- Discipline as a way of cleaninghabits.
- Doing the right thing as a matter of course.
- Following upon standardization & checklists.
- Practice until you can do it unfailingly.
- Rule Observance Campaign.
Important considerations in 5S
Silver bullet improvements or gradualist approach
Management must start 5S first If you can do
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Management must start 5S first. If you can do
5Ss you can do anything
5S is a barometer that tells you how well a
company is managed.
Implementation of 5S will indicate total
participation
5S will make the factory a sales tool.
5S to cleanse the heart
THE THREE TYPES OF WORKPLACES
3rd Class workplace
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3rd Class workplace
Where everyone messes the place and there is no one toclean up
2nd Class workplace
Where people mess up the place and office helpers,cleaners, janitorial services or servants clean up the place
1st Class workplace
Where everyone is disciplined and does not mess up andall participate in cleaning
3 PHASESOF
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IMPLEMENTATION
Active 5S Habitual 5S Preventive 5S
THE 5S CYCLE
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SHITSUKE
SEITONSEIRI
SEISOSEIKETSU
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