1

Necessity of 5S
Productivity
improvement
Quality assurance
Cost reduction
Job satisfaction
Deadline
observation

Happy workplace

Secure production
volume

Workplace improvement

SHITSUKE

SEIRI
SEITON

SEISO

SEIKETSU
2

The 5 Words
5S is a method that
uses five Japanese
words which start with
the letter S

5S
5 Steps to a Better Workplace

Why 5 S?
The Purpose of 5S is to promote a

safe and efficient work

environment

Not just a cleaning campaign, 5S is

a way to set a new standard that we

all agree on and help us get the
discipline we need to maintain it.

By Implementing the 5S
Opportunity to improve the own

workplace
Team involvement & Problem
solving opportunities appears.

5S gives visible and Motivating

Results
First step in the implementation of

Lean Manufacturing, TPM an Kaizen.

5

Reasons to implement 5S
Improved Safety
No items on the floor
Therefore fewer slips or falls
Safety device in their right

places
Less dust

Reasons to implement 5S
Improved Safety
Fewer break downs
Fewer strange errors from

electronic systems
Less wear from dust or grit in
moving parts

Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
A clean & well functioning

workplace
Fix the unsafe & cluttered work
stations

Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Leakages such as oil will easily

be spotted
Using less floor space may
reduce energy consumption

Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
Easy to do it right than wrong
Safety guards placed properly
Less clutter, fewer visual

distractions& easy access to

tools and materials

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Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
When you do 5S , you inspect the

same

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Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
No searching
Effective tools at the right place

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Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
No searching
Higher morale
Through teamwork and visible

results
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Reasons to implement 5S
Improved Safety
Fewer break downs
Better work Environment
Less Environmental Impact
Few human errors
May find problems earlier
No searching
Higher morale
Goodwill
Helpfulness to create an
impression.
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The 5 phases in 5S

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Step 1 - Sorting
Sorting is a team activity

that will be carried out by

the production an d
maintenance personnel
together
Sorting has two purposes
Remove unnecessary

objects
Reduce waste

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Remove unnecessary
Objects
Go through the whole plant
Look for
Materials
Behind or under

machines
Rejects
Forgotten materials

17

Remove unnecessary
Objects
Go through the whole plant
Look for
Materials
Tools
Not in use
Worn out or broken
Custom-made tools

(made of steel
wire/tape/etc-Replace by
real tools

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Remove unnecessary
Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
Broken
Surplus Inventory
Spare parts for machines

no longer in use

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Remove unnecessary
Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
Out-of-date
Documentation
Instructions
Binders
Manuals

20

Remove unnecessary
Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
Out-of-date
Documentation
Bulletin board
Outdated notices
Irrelevant information

21

Remove unnecessary
Objects
Go through the whole plant
Look for
Materials
Tools
Spare parts
Out-of-date Documentation
Bulletin board
Other stuff
Outdated computer

hardware
Packing Material
Outdated protective

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Remove unnecessary
Objects
?
Look at each object
Ask yourself, Do we need it

at all?
If not Discard it or sell it

Ask yourself, Will we need it

soon?
If not Put it in proper

storage eg:- spare parts, etc.

Is it working , but..
Too difficult to use
In correct design
Too time consuming to use

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Remove unnecessary
Objects
?
Each item to be discarded or
corrected is marked with a
red tag

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Waste elimination
The second purpose of

sorting is to reduce waste

and generate ideas for
improvements
We will try to identify every
thing that is hindering us
from working safely and
efficiently

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Waste elimination
Try to identify every thing

that is hindering us from

working safely and efficiently
Work instrutions
Do we have them?
Are they up-to-date?
Are they in use? If not why

not?

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Waste elimination
Try to identify every thing

that is hindering us from

working safely and efficiently
Work instructions
Safety
What measures should we

take to eliminate the risk of

fire and accidents?
Remove clutter
Improve unsafe electrical

installations
Replace broken safety
devices

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Waste elimination
Try to identify every thing

that is hindering us from

working safely and efficiently
Work instructions
Safety
Environment
What measures do we need

to minimize or prevent
damage to the environment?

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Waste elimination
Try to identify every thing that

is hindering us from working

safely and efficiently
Work instructions
Safety
Environment
Tools and equipment
Anything missing ?
Anything not working properly

?
Anything in need of
improvement?

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Waste elimination
Try to identify every thing that

is hindering us from working

safely and efficiently
Work instructions
Safety
Environment
Tools and equipment
Inconvenient work positions
Seat & work s/fs at the right

height
Awkward angles for moving
materials

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Waste elimination
Try to identify every thing that

is hindering us from working

safely and efficiently
Work instructions
Safety
Environment
Tools and equipment
Inconvenient work positions
Deferred maintenance
Temporary repairs/not

properly secured

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Waste elimination
Try to identify every thing that

is hindering us from working

safely and efficiently
Work instructions
Safety
Environment
Tools and equipment
Inconvenient work positions
Deferred maintenance
Improvement Proposals
Review prior suggestions

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Waste elimination
All identified waste items are

marked with an red tag

Machine tagged with errors and improved

suggestions
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5S Sort list
Every tag refers to a 5S Sort list
Think break
Do we have any examples of deferred maintenance
in our plant?

Tag no

Item description

Session
tagged

Dat
e

Tagged
by

Responsib
le

Due
date

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Question yourself Seiri

Do you find items scattered at

your place?
Are any items left in
disorganized way?
Are all item sorted and kept in
designated place?
Are tools and stationeries
properly sorted and stored?

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Step 2 Set in Order

Every tag refers to a 5S Sort list

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Missing letter ?
Every tag refers to a 5S Sort list

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Why-set in order?
The purpose of Seiton set in

order is that everything that

we regularly use should have
a convenient placement
Tools should be kept at the

point of use
No bending to pickup or move
materials
Alter flow paths to improve
efficiency

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Placement

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Efficient layout and color

coding
Make a drawing of the current

situation
Brainstorm to find an optimal
layout
Agree the color code
Mark the location(removable
tapes preferred) of all objects
Move the equipments if
necessary

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Question yourself Seiton?

Are passages and storages

clearly indicated?
Commonly used tools &
stationeries separated from
the seldom used?
Are containers, boxes,
materials and fire
extinguishers stocked up
properly?
Are there grooves, cracks or
bumps on the floor which
hinder work or safely?

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Step 3 Shiny clean

Next step in 5S is to carry out a Shiny clean event

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Shiny clean
To keep your area clean on a

continuing basis
Clean all machines
thorough
Clean all equipments,
fixtures, and tools
Clean the floor, walls,
cabinets, shelves etc.

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Why Seiso?
To prevent the area from

getting dirty in the first

place, so we dont have to
clean it up afterward
A clean workplace is
indicative of a quality
product and process
Dust and dirt cause
potential health hazards
Things to remember : Sweep/Vacuum
Dust / Mop

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Guidelines Seiso?
Divide areas into zones
Define responsibilities for cleaning
Tools and equipment must be owned by an individual
Focus on removing the need to clean

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Question yourself Seiso?

Are machines and equipments

dirty?
Are pipes dirty and corroded?
Are nozzles dirtied by lubricants

and ink?
Are shades, lights, bulbs, and

light reflectors dirty?

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Step 4 Standardized
cleanup
Continue sorting, storing and cleaning to maintain
serene atmosphere at all times

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Why Seiketsu?
Prevents regression back to an unclean/disorganized

environment
Things to remember : Develop schedules, checklists
Periodically evaluate area using 5S Audit sheet
Continually improve neatness

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Phases of Seiketsu?
Clarification of vital points for management Things

to remember : What are the minute defects?

Basic conditions: Cleanliness, refueling, replace tightly

bind fast, dirt, looseness

Operating conditions: pressure, temperature, time,
flow volume, weight, Equipment, jigs and tools, submaterials

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Phases of Seiketsu?
Prepare standards for the conditions
Objectification of judgment standards for normal
versus abnormal
Judgment without using measurement, knowledge,
intuition and knack

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Phases of Seiketsu?
Judgment standards for abnormalities
Inspection methods that can be used by anybody
Methods for actions against abnormalities

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Question yourself
Seiketsu?
Are there sufficient light?
Is there noise/light in your

place causing discomfort?

Do people work at
designated way?
Is there any leakage?

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Step 5 - Shitsuke

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Shitsuke
To maintain discipline, we

need to practice and repeat

until it becomes a way of life

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Shitsuke
Make sure you stick to standard

procedures and make them a habit

Be disciplined to follow rules and
regulations to maintain standards

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Why Shitsuke?
To build housekeeping into every day process
Makes the 7 wastes visible
Gets everyone involved
Things to remember : Training everyone is vital
Involvement from all is necessary
Commitment and discipline toward housekeeping is
essential in taking the first step in being World Class
5 S RATING
0= Poor (Unacceptable)
2= Satisfactory
4= Excellent ( World Class Environment)

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Question yourself
Shitsuke?
If 4S done?
Are regular 5s check

conducted?
Do people involved without
reminder?
Do assemble at time?

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Action Plan for

Implementing 5S

Awareness programme of 5s for all employees, supervisors,

engineers and managers.

Form steering committee
Application programme on 5S for all Employees
Steering committee periodically evaluates all cells, scores displayed

on the display board

Display posters on house keeping, distribute cards on 5S to all

employees
Annual award for the best cell

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Advantages of 5S
If tools and materials are conveniently located in uncluttered work areas
Operators spend less time looking for items
This leads to higher workstation efficiency, a fundamental goal in mass production
A clean and tidy workplace leads to greater well being and increased motivation
Company image improves
Time saving
Quick retrieval
Accidents & mistakes minimized
Increases space
Creates workplace ownership
Foundation of all qc tools
Continuous quality improvement
Lean manufacturing
Visual management system
Results in a place easier to manage
Smooth working no obstruction

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Checking System

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5S Audit
Three purposes of conducting regular 5S Audit reviews
are:

Review compliance to the 5S standards for your

factory
Note and address non-compliance to fix what is

wrong!
Provide a formal opportunity to suggest

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The Basic Steps

Plan for the audit by dividing the workplace into

various areas, probably the same ones where

different teams conducted the various 5S stages.
Make a checklist for each area, based on the
standards that were set during 5S.
Find out the list of known problems in each area.
From the initial 5S sweep, this may include:
Machines needing repair
Tool racks
Signage on tool racks or cabinets or storage shelves;

warning signs; keep clear markings for corridors; or

instruction pages
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Surplus equipment or materials which were not immediately

During the audit, three key

tasks
ONE
Determine whether known problems have been

addressed:
Does this machine still leak lubricants?
Has the required tool rack been installed in this area? Is it

labeled? Is it full? Are tools still left on workbenches?

Is the warning sign in place so people will not walk under
this crane?
Why is this outdated drill press still in the corner?

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During the audit, three key

tasks
TWO
See that standards are being met:
Are tools left on workbenches?
Is something missing from a tool rack?
Is dirt accumulating somewhere?
Are existing labels still visible and easily read? (This is

especially important for signs that may be obscured by dust,

and for lines painted on floors where they can be scuffed)
Are there new sounds or smells that indicate that gears are
grinding or fluids are leaking?

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During the audit, three key

tasks
THREE
Note what has not yet been standardized this is the

most creative and difficult part, because it may

involve seeing what is missing in an area that seems
tidy:
Why is there no sign over the neat stack of work-in-process

materials on that shelf? (How will the next shift know what is
there, or what should go there?)
Tools that are not yet labeled
Is there a limit to how high those barrels can be stacked?
Why dont we show that information on the sign for that
storage area?
Do we need all those cans of wing nuts in this assembly
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Safety infractions should also

be part of the 5S audit
Are WHMIS (Workplace Hazardous Materials

Information System) labels used properly?

Are fire exits visible and clear? Are the fire
extinguishers charged and inspected on schedule?
Are stairs and ladders safe?
Do we notice unsafe behavior regarding heights and
falls? Climbing a ladder without maintaining three
points of contact? Working on a height without the
required safety tether?
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To follow up on each 5S
audit
Write up a work order to deal with each deficiency
Update the next check list:
Check off what was corrected
Add new deficiencies to be reviewed
Determine the score:
Deduct for each deficiency
Add a point for each correction
Add a point for each suggestion for improvement
If the previous audit had found deficiencies, the goal is
to eradicate them
The ultimate goal is to regularly achieve zero
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outstanding deficiencies

How often should audits be

Performed?
Regular audits lead to the best results:
Weekly self-check audits by teams of workers,
reviewing their own areas
This might be the best way to generate suggestions for

improvements

Monthly audits by the area supervisor

Ensure that the weekly audits catch any problems with
the daily or weekly cleanups
Pay special attention to the less-frequent cleaning
tasks
Try to notice what is missing: new tools that do not yet
have a place in a rack; materials stored neatly but not
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How often should audits be

Performed?

Quarterly audits by the plant manager

Ensure that standards are being met
If there are deficiencies, ask why: try to determine
the root causes
Ensure that resources are allocated to repairs and to
making the long-term improvements
Without audits, it is impossible to ensure compliance.

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5S Audit check sheet

Model
follows

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