Documente Academic
Documente Profesional
Documente Cultură
5S
g
n
i
d
a
Spre ide
w
d
l
r
o
W
SUPER
IS FOR EVERYONE
Revised 1998 - 07
PART
KAIZEN
Kaizen
versus
Innovation
Kaizen
Innovation
Effect
Pace
Small steps
Big steps
Timeframe
Intermittent
Change
Approach
Group efforts
Involvement
Everybody
Selected few
Mode
Know-how
Conventional know-how
Technological breakthrough
Requirement
Little investment
Large investment
Orientation
People
Technology
Evaluation
KAIZEN
INCREMENTAL BUT CONTINUOUS PROGRESS
INNOVATION
DRAMATIC BUT
INTERMITTENT
PROGRESS
THE IDEAL
A C TU
A L I TY
INNOVATION
NDARD
A
T
S
W
NE
KAIZEN
MAINTENANCE
INNOVATION
5S
KSS
QCC
QC Circle
TQC
TPM
JIT
Just-In-Time Production
TPM
Overlapping Areas
between
Kaizen Programs
TQC
JIT
QCC
5S
Toward Excellence
KSS
PARTICIPATIVE MANAGEMENT
A Suggested Sequence of
Implementing Kaizen Programs
TQC
TQC
QCC
QCC
Start
Start Here
Here
TPM
TPM
KSS
JI
T
JIT
What is 5S?
O
PART 2
Understanding
the Philosophy
and Power of
SUPER
5S
5S
Super 5S is a Company-wide
Participation Program for Kaizen
O
Super 5S is a company-wide
participation program
involving everyone in the
organization.
It is a very effective approach
for motivating people, and
improving productivity and
the work environment .
5S?
high in Productivity
consistent in Quality
Cost-effective
accurate in Delivery
high in Morale
5S?
Developing Kaizen-minded
people at workplace.
Building good teamwork
through participation.
Developing managers and
supervisors for practical
leadership.
Improving infrastructures for
introduction of advanced Kaizen
technologies.
5S?
O
O
5S?
5S?
5S is a set of five
Japanese words. Each
word starts with a sound
of se or shi.
They are Se-i-ri, Se-i-to-n,
Se-i-so, Se-i-ke-tsu, and
Shi-tsu-ke.
5S?
Seiton
Shitsuke
Seiketsu
Seiso
Seiton
Shitsuke
Seiketsu
Seiso
Seiton
Shitsuke
Seiketsu
Seiso
Seiton
Shitsuke
Seiketsu
Seiso
Seiton
Shitsuke
Seiketsu
Seiso
Shitsuke
Seiketsu
Seiso
PART 3
Step by Step
Implementation of a
SUPER
5S
Program
Step 1: Preparations
Step 2: The CEOs Official Announcement
Step 3: Big Cleaning by All Colleagues
Step 4: Initial Seiri
Step 5: Daily Seiri, Seiton and Seiso
Step 6: Periodic 5S Audits
FROM
SUPER S PROGRAMS
PHASE
MONTH
Preparations
* Understanding philosophy and benefits of Super 5S by CEO
* CEOs visit to Super 5S model companies
* CEOs commitment to Super 5S implementation
* Organize Super 5S Working Committee
* Appoint Super 5S facilitators
* Train Super 5S facilitators and practitioners
CEOs Official Announcement
* CEO officially announces implementation of Super 5S for 2 years
* CEO explains objectives of Super 5S program to all colleagues
* Publicize Super 5S organization and assignments by area
* Promote Super 5S with banners, posters and newsletters
* Organize basic Super 5S training programs for all colleagues
Big Cleaning by All Colleagues
* Organize a full-day of Big Cleaning Day twice a year
* Organize small groups who are responsible for assignments in divided
areas of the companys premises.
* Provide enough cleaning tools and materials
* Implement a company-wide big cleaning for one day
* Big cleaning includes the elimination of unnecessary items and wastes
Initial Seiri
* Establish a Disposal Standard for unnecessary items
* Organize a full-day of Seiri activity twice a year
* Everyone concentrates to identify and stratify unnecessary items for
elimination
* Unnecessary items that cost a lot should be evaluated so as to prevent
the occurrence of such waste
Daily Seiri, Seiton and Seiso
* Seiri: Throw away things that are not needed and not being used
* Seiton: Improve locations and methods for storing things so that
searching time is minimized
* Seiso: Set up a daily cleaning schedule for the creation of a healthy and
comfortable workplace
* Motivate colleagues to come up with creative improvements
Periodic Audits on Super 5S
* Establish a Super 5S evaluation and incentive plan
* Conduct a Super 5S audit regularly by auditors
* Organize a Super 5S inter-departmental competition for upgrading
* Award groups and individuals for their contributions
* Organize study tours to other companies doing Super 5S
* Organize Super 5S inter-company competition to sustain the program
PREPARATION
1 / 1 / 1996
10
TO
31 / 12 / 1997
11
12
10
11
12
MASTER PLAN
O
STEP 1: PREPARATION
MASTER PLAN
O
5S Steering Committee
5S Working Committee
5S Audit Committee
5S Facilitator(s)
Purchasing Manager
5S Activist/Trainer
Production Manager
5S Activist/Trainer
Sales Manager
5S Activist/Trainer
Purchasing Group
Machine Group 1
Sales Group
Machine Group 2
Machine Group 3
Painting Group
Assembly &
Packing Group
Administrative Manager
5S Activist/Trainer
Administrative Group
Material
Storage
Machining 1
Machining 2
Painting
Assembly
and
Packing
Sales
Machining 3
Administration
1F
Material
Storage
Machining 1
Machining 2
1F
Painting
Assembly
and
Packing
Sales
Machining 3
Administration
5S TOOL BOX
Promotion Tools
Implementation Tools
5S Newsletters
Evaluation Tools
5S Guidance Stickers
5S DAY
What is Seiton?
Here is
a need for
Seiton is arranging
necessary items in good
order so they can easily
be selected for use
5S Posters
SEIRI
SEITON
Here is
a need for
SEISO
5S Study Tours
Seiri
Here is
a need for
Seiton
Shitsuke
Seiketsu
Seiso
5S Banners
5S Checklists
5S Inter-Department Competition
Congratulations!
We all Practice 5S
5S Badges
SUPER
5S
Department A
Department B
Department C
Department D
Here is an
Excellent Example
of
5S Practice
Seiri
Sort out
unnecessary items
in the workplace
and
discard them
Seiketsu
Maintain ones
workplace so that
it is productive
and comfortable
by repeating SeiriSeiton-Seiso
Seiton
Shitsuke
5S IS FUNDAMENTAL TO
PRODUCTIVITY IMPROVEMENT
Arrange necessary
items in good order
so they can easily
be selected
for use
Seiso
Clean your
workplace completely
so that there is
no dust on floors,
machines or
equipment
MASTER PLAN
O
O
O
MASTER PLAN
O
O
Which
???
Stratification
Required Action
Items having
some value for sale
Items
Necessary
For
SEITON
Items
Not Necessary
SEIRI
Why
How to
Seiri
MASTER PLAN
O
Seiri: Throw away things that are not needed and not
being used. Use space more economically (space is
money).
Seiton: Improve locations and methods of storing
things so that searching and retrieval time is
minimized (time is money).
Seiso: Continue daily cleaning schedule for the
creation of a healthy and comfortable workplace.
Motivate colleagues to come up with creative
improvements for the workplace.
Required Action
SEITON
Items
frequently used
Items
Necessary
Items
sometimes used
Can be placed
farther away
SEIRI
Items
not used at all
but must be kept
Must be stored
separately with
clear identification
O
O
How to
Seiton
SEITON
SEITON
SUPER
SUPER
FIFO
LIFO
Random Access
SEITON
SEITON
SUPER
SUPER
Before 5S activity
Reserved seats
Matching names
SEITON
SEITON
SUPER
SUPER
A1
A2
A3
A4
A5
A6
A7
A1
A2
A3
A4
A5
A6
A7
B1
B2
B3
B4
B5
B6
B7
B1
B2
B3
B4
B5
B6
B7
C1
C2
C3
C4
C5
C6
C7
C1
C2
C3
C4
C5
C6
C7
Reserved seats
Matching names
SEITON
SEITON
SUPER
SUPER
PD20
PD21
PD22
PD20
PD21
PD22
PD30
PD31
PD32
PD30
PD31
PD32
SEITON
SEITON
Transparent / no cover
Stock level indicators
SUPER
SUPER
B10-100
B12-100
B10-150
B12-150
SEITON
SEITON
SUPER
SUPER
1 2 3 4 5 6 7 8 9 101112
Seiri wastes
No horizontal piling
Nothing on floor
SEITON
SEITON
SUPER
SUPER
Quick retrieval
No horizontal piling
Vertical holders
B20S
B25S
B30S
B35S
B40S
B50S
SEITON
SEITON
SUPER
SUPER
10
11
12
10 11
12
10 11 12
SEITON
SEITON
SUPER
SUPER
Matching labels
Color identification
Matching labels
Open/Close separation
SEITON
SEITON
SUPER
SUPER
CLOSED
OPEN
1
*
2
2*
3
*
4
*
5
5
*
1
1*
2
*
3
3*
4
4*
5
*
6
6*
7
*
8
8*
9
*
10
*
6
*
7
7
*
8
*
9
9
*
10
10
*
11
*
11
12
*
12
13
*
14
*
15
*
15
11
*
12
*
13
*
13
14
*
14
15
*
16
*
17
*
18
18
*
19
*
20
20
*
16
*
16
17
*
17
18
*
19
19
*
20
*
Matching labels
Color identification
SEITON
SEITON
SUPER
SUPER
OFF
OFF
OFF
OFF
SEITON
SEITON
SUPER
SUPER
CL10-40
CL15-20
CL20-20
BL20-50
BL20-20
BL30-20
BLH20-40
BLH20-20
BLH25-20
Cast Materials
CL10-40
SEITON
SEITON
SUPER
SUPER
CL15-20
CL20-20
BL20-50
Kanban
Parking place
Safety sign
BL20-20
BL30-20
BLH20-40
BLH20-20
Cart No. 5
BLH25-20
Cart No. 5
Safety First
SEITON
SEITON
SUPER
SUPER
Before 5S - unsafe
No height control
SEITON
SEITON
SUPER
SUPER
No lifting by hands
Sliding or rolling
SEITON
SEITON
SUPER
SUPER
POTABLE
WATER
0
Kg
75
Color labeling for invisible
substances
Indication of flow direction
25
50
SEITON
SEITON
SUPER
SUPER
COLD
HOT
COLD
HOT
Clean
me !
How to
Seiso
SEISO
SEISO
SUPER
SUPER
5S
How to
Seiketsu
Be a good listener.
O
O
How to
Shitsuke
JANUARY
STEP 2
5S IMPROVEMENT RECORDS
WORKPLACE
STEP 1
LOCATION NO.
DATE
01/04/95
COMMENTS
STEP 2
DATE
COMMENTS
Very messy.
RATING
RATING
88
10/04/95
STEP 3
DATE
STEP 4
COMMENTS
COMMENTS
RATING
RATING
DATE
5S IMPROVEMENT RECORDS
WORKPLACE
STEP 1
LOCATION NO.
DATE
STEP 2
DATE
STEP 3
DATE
STEP 4
COMMENTS
COMMENTS
COMMENTS
COMMENTS
RATING
RATING
RATING
RATING
WORKPLACE
STEP 1
DATE
LOCATION NO.
DATE
STEP 2
DATE
STEP 3
DATE
STEP 4
COMMENTS
COMMENTS
COMMENTS
COMMENTS
RATING
RATING
RATING
RATING
DATE
MASTER PLAN
PART 4
5S
5S Activities
SUPER
1. Objectives
Proposed competitions are aimed at improving the organizations total
productivity through everyones participation in the Super 5S program.
Qualification for Participation
Any department which is implementing 5S on a certain level is eligible
for participation.
3. Competition Period
Each competition will be organized for a period of 6 months, two times
a year on a continuing basis.
4. Auditing Team
An auditing team appointed by the Super 5S Steering Committee will
visit each competing department and evaluate its Super 5S activities at
the end of each competition period.
5. Super 5S Evaluation Forms
One of the following Super 5S Evaluation Forms will be used by the
auditors according to the function of the participating departments:
7. Awarding
With better results and psychological effects in mind, the
implementing organization should work out an awarding method that
can encourage, but not discourage, the participating colleagues and
departments toward intended objectives.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
FOCUS
are they conveniently located and labeled for easy retrieval?
are they conveniently located for easy handling?
are they conveniently located and labeled for easy retrieval?
are they clearly labeled for separation from good items?
are they clean, safe, well-maintained and convenient to operate?
are they laid out in a tidy, safe and convenient manner?
are they conveniently labeled and placed at designated locations?
are they conveniently labeled and placed at designated locations?
are they clean and conveniently placed at designated locations?
are they dust-free, tidy and conveniently labeled for items stored?
are they well-maintained and placed at designated locations?
are they clean, tidy, safe and well-maintained?
are they clean and organized inside and outside?
are they up-to-date, easy to retrieve and at convenient locations?
are they dust-free, tidy, safe and well-maintained?
are they dust-free, tidy, safe and well-maintained?
are they adequate for efficient operation?
are they clean and do they present a good image?
are they conveniently located for use and well-maintained?
are they adequate and cleaned regularly?
are they clean, tidy and well-maintained?
are they clean, tidy and well-maintained?
are they clean, tidy, safe and do they present a good image?
are they clean, tidy, safe and do they present a good image?
TOTAL SCORE (a)
ADJUSTED SCORE = (a) / (b) x 10
BONUS SCORE FOR SUPER 5S PRACTICE
FINAL SCORE
ITEM
materials / parts
work-in-process
finished products
defective / rejects
machines / equipment
wiring / piping
dies / tools / jigs
spare parts / lubricants
containers / pallets
racks / shelves / cabinets
carts / wagons / forklifts
lifts / conveyers / cranes
desks / tables / chairs
forms / files / records
floors / passages / stairways
walls / windows / ceiling
lighting / ventilation
working wears / shoes
safety devices
fire extinguishers / fire exits
cleaning tools / waste baskets
canteens / toilets / lockers
external areas / gardens
security guards / car parks
NO. OF ITEMS EVALUATED (b):
AUDITOR:
DEPARTMENT:
DATE:
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
SCORE
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
20 15 10 5 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
DEPARTMENT:
FOCUS
are they tidy and conveniently organized?
are they clean and labeled for the easy retrieval of things needed?
are they clean and systematically organized?
are they tidy and conveniently stored for retrieval?
are they clean and well-maintained?
are they clean and well-maintained?
are they clean and well-maintained?
are they clean and well-maintained?
are they clean and well-maintained?
are they clean and well-maintained?
Is it tidy, safe and conveniently laid out for operation?
are they adequate for efficient operation?
are they dust-free and well-maintained?
are they adequate and well-maintained?
are they adequate and clear of obstacles in case of emergencies?
are they adequate and well-maintained?
are they clean and do they present a good image?
are clean and well-maintained?
ITEM
desks / tables / chairs
cabinets / shelves
documents / files
forms / office supplies
telephones
facsimiles
typewriters / word-processors
computers / monitors
printers
copying machines
electric wiring
lighting / ventilation
floors / walls / windows / ceiling
fire extinguishers
emergency exits
safety devices
working clothes / shoes
waste baskets
AUDITOR:
DATE:
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
SCORE
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
8 6 4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
20 15 10 5 0
DEPARTMENT
ORGANIZATION:
DATE OF AUDIT
DATE:
ADJUSTED PT.
SUPER 5S PT.
TOTAL PT.
RANKING
AUDITOR
SEIRI
SEITON
SEITON
SEISO
SEIRI
SEITON
SEITON
SEISO
SEIRI
SEITON
SEITON
SEISO
SEIRI
SEITON
SEITON
SEISO
SEIRI
SEITON
SEITON
SEISO
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
Here is an
Excellent Example
of
5S
Practice
T
A
R
G
E
T
S
A
C
TI
O
N
S
STEP 1
STEP 2
STEP 3
STEP 4
Seiri 1
Seiri 2
Seiri 3
Seiri 4
Seiton 1
Seiton 2
Seiton 3
Seiton 4
Seiso 1
Seiso 2
Seiso 3
Seiso 4
Seiketsu 1
Seiketsu 2
Seiketsu 3
Seiketsu 4
Shitsuke 1
Shitsuke 2
Shitsuke 3
Shitsuke 4
Keep only
necessary
items
Do not put
anything on
the floor
Assign items
a place
.
Make needed
items
accessible
Reduce
searching
time
Reduce
walking
distances
In each
section clean
one machine
well
Increase the
number of
clean
machines
Increase the
number of
clean
machines
Create a
clean
workplace
Create a
comfortable
workplace
Create a
healthy and
safe
workplace
Create a
highly
productive
workplace
Discard
unnecessary
items more
often
Use wagons
to transport
items
-
Draw lines to
separate
passageways
for people
Reduce
excess
inventory
-
Arrange
items by type
and size
-
Remove
obstacles
around
needed items
Use labels to
simplify
retrieval
-
Place
frequently
used items
close by
Select a
machine and
clean it
completely
Use more
convenient
cleaning
tools
Prevent
machines
from getting
dirty
Combine
cleaning
with
inspection
Clean ones
workplace
daily
Set up a
cleaning
schedule
Eliminate
hazards
Introduce
creative
thinking
PASSPORT TO SUCCESSFUL 5S
What is 5S?
Seiri:
Seiton:
Seiso:
checkpoints
The 5S Activity Bulletin Board is wellorganized and data are updated
score
score
10
Tackled - 3
Not Tackled - 1
10
Tackled - 3
Not Tackled - 1
PART 5
A Collection of
Photographs
Illustrating
SUPER
5S Practices
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
65
67
69
71
73
75
77
79
81
83
85
87
89
The End
of the
Presentation
Thank You Very Much
for Your Participation
Kazuo Tsuchiya
T
A
R
G
E
T
S
A
C
TI
O
N
S
STEP 1
STEP 2
STEP 3
STEP 4
Seiri 1
Seiri 2
Seiri 3
Seiri 4
Seiton 1
Seiton 2
Seiton 3
Seiton 4
Seiso 1
Seiso 2
Seiso 3
Seiso 4
Seiketsu 1
Seiketsu 2
Seiketsu 3
Seiketsu 4
Shitsuke 1
Shitsuke 2
Shitsuke 3
Shitsuke 4
Keep only
necessary
items
Do not put
anything on
the floor
Assign items
a
place
.
Make needed
items
accessible
Reduce
searching
time
Reduce
walking
distances
In each
section clean
one machine
well
Increase the
number of
clean
machines
Increase the
number of
clean
machines
Create a
clean
workplace
Create a
comfortable
workplace
Create a
healthy and
safe
workplace
Create a
highly
productive
workplace
Discard
unnecessary
items more
often
Use wagons
to transport
items
-
Draw lines to
separate
passageways
for people
Reduce
excess
inventory
-
Arrange
items by type
and size
-
Remove
obstacles
around
needed items
Use labels to
simplify
retrieval
-
Place
frequently
used items
close by
Select a
machine and
clean it
completely
Use more
convenient
cleaning
tools
Prevent
machines
from getting
dirty
Combine
cleaning
with
inspection
Clean ones
workplace
daily
Set up a
cleaning
schedule
Eliminate
hazards
Introduce
creative
thinking
PASSPORT TO SUCCESSFUL 5S
What is 5S?
Seiri:
Seiton:
Seiso:
checkpoints
The 5S Activity Bulletin Board is wellorganized and data are updated
score
score
10
Tackled - 3
Not Tackled - 1
10
Tackled - 3
Not Tackled - 1
SUPER S PROGRAMS
Preparations
* Understanding philosophy and benefits of Super 5S by CEO
* CEOs visit to Super 5S model companies
* CEOs commitment to Super 5S implementation
* Organize Super 5S Working Committee
* Appoint Super 5S facilitators
* Train Super 5S facilitators and practitioners
PHASE
MONTH
Initial Seiri
* Establish a Disposal Standard for unnecessary items
* Organize a full-day of Seiri activity twice a year
* Everyone concentrates to identify and stratify unnecessary items for
elimination
* Unnecessary items that cost a lot should be evaluated so as to prevent
the occurrence of such waste
PREPARATION
FROM
PENETRATION AND ADVANCEMENT
TO