KULDEEP MATHURM.B.A.

JIWAJI UNIVERSITY GWALIOR

5S Methodology for Well Organized Work Place

Learning Objectives

What 5S is.How 5S relates to Manufacturing.Why we do 5S.How we do 5S.The benefits of doing 5S.

What is 5S?

A process designed to organize, clean and standardize the workplace, and instill the discipline required to keep it that way.

The Five Pillars

Organization / Sorting / (Seiri)

Orderliness / Standardizing / (Seiton)

Cleanliness / Sweeping / (Seiso)

Standardized Cleanup / (Seiketsu)

Discipline / Self-discipline / (Shitsuke)

Sorting/Organization (Seiri)Separates the necessary from the unnecessary

and then cleans everything remaining. I. Tagging Technique:No Tag = necessary itemColored Tag = unnecessary item or not sureII. Place tagged items in a designated

holding place.allow all area workers on each shift the

opportunity to look at the itemsallow maintenance and other depts. The

opportunity to check for their belongings

Sorting/ Organization (Seiri)

III. Disposition of tagged items

after one week in holding place, tagged items should be:

-disposed of if determined unnecessary

-kept if determined necessary

get rid of colored tagged items that are determined to be unnecessary

Sorting/ Organization (Seiri)IV. Initial Cleaningclean all items remaining

-workbenches-tools-floors-equipment

develop cleaning schedule-assign responsibility-follow up on assignments

Simplifying/ Orderliness (Seiton)

Simplifying creates a home, with visual tools, for all items, and arranges them in line with the physical flow of the work.

I. Arrange workplace in line with flow of work

a. 1. Present Map - shows the current workplace arrangement

b. 2. Future Map -shows a new and improved workplace arrangement

How to Use Present Map1. Use a print out or draw the current workplace

outline (walls, doors, etc...) on a large sheet of white paper with a black marker.

solid lines= permanentdotted lines= non-permanent2. Draw in items such as trash cans, desks,

toolboxes, lockers, benches and lunch tables.draw items to scaledraw them in their exact locationBe sure to include every item! 3. Mark the flow of work through the workplace by

drawing red arrows.

How to Use a Future Map

1. Draw the workplace outline again on a clean sheet of white paper.

2. Draw in items such as trash cans, benches, lunch tables, a second time placing them in locations that improve the workflow.

3. Test the arrangement by drawing the flow with red arrows.

Visual Tools1. Border- sets boundaries, areas

2. Home address- tells what item belongs inside the border

3. Label- tells what the item is and where it belongs

Sweeping/ Cleanliness (Seiso)Sweeping is the continuous upkeep and

control of work area identifies problems and unacceptable conditions.

I. Visual Sweeping

a) safety - traffic lanes clear, hazardous material marked

b) waste - overflowing trashcan, excess supplies on workbench

c) cleanliness - tools in designated spots on shadow board, floors clean

Sweeping/ Cleanliness (Seiso)

II. Physical Sweeping

a) safety - report unsafe conditions, clean up spills on floor

b) waste - empty trash can, remove excess supplies from area

c) cleanliness - sweep floor, place tools on shadow board

Standardized Clean up (Seiketsu)Standardizing defines how tasks should be done and

explains the best way to perform them.

I. 5S Agreements - document the procedures and guidelines for sorting, simplifying and sweeping

>visual controls guidelines

>item quantity requirements

-document the schedule in which they are to be completed and reviewed

>housekeeping standards

>workplace arrangement methods

Standardized Clean up (Seiketsu)

II. Work Processes

-document all steps in each process at the workplace

-document operating procedures and directives

-document all job aids (user guides, reference materials, trouble shooting guides)

Self Discipline/ Discipline (Shitsuke)Ensures that all 5S policies are followed in daily

work, and leads the way for continuous quality efforts.

1. Team - establish a plan for the work area teambe specificassign responsibilities

2. Individual - establish a personal plan for yourselfbe realisticrevise and update as you proceed

Why do we do 5STo improve safety in the workplace.

To improve the physical flow of work through the workplace.

To organize the work area and make the job easier.

To do preventative maintenance.

Benefits of 5SImproved safety

A clean, orderly workplace

Improved efficiency

Increased employee morale

Standardized work methods

Will There be ResistanceWhat’s so great about organization and orderliness?Why clean when it just gets dirty again?Implementing organization and orderliness will not

boost outputWe already implemented organization and

orderlinessWe did the five pillars years agoWe’re too busy to spend time on organization and

orderlinessWhy do we need to implement the five pillars