5S Class

Total Quality Management
5S
5S - TQM- CSICE-MECH 2017-18 1

WHAT IS 5S?
IN ORDER TO ACHIEVE HIGH LEVELS OF
QUALITY, SAFETY,AND PRODUCTIVITY,
WORKERS MUST HAVE A CONDUCTIVE
WORKING ENVIRONMENT
Developed by the Japanese
Housekeeping System
Helps Create a Better Working Environment
and a Consistently High Quality Process

What is 5S?
An easy definition is: Finding a place for
everything and put everything in its place.
5S is also the foundation for Continual
Improvement (CI) and Lean implementation.
Its the elimination of waste Everywhere while

adding customer value
Its a mindset & commitment to achieve a totally

waste-free operation thats focused on your
customers success achieved by simplifying and
continuously improving all processes

5S stands for 5 initials of the following
Japanese words:
1. Sei-ri (Organization)
2. Sei-ton (Neatness)
3. Sei-so (Cleaning)
4. Sei-ke-tsu (Standardization)
5. Shi-tsu-ke (Self-discipline)
5S ONCSS
3
THE 5S PRINCIPLES
SEIRI Organisation/Sort out
SEITON Orderliness/Systemize
SEISO The Cleaning/Shining
SEIKETSU STANDARDIZE
SHITSUKE - Sustain/Discipline

DISCOVERY OF 5S
Thirty years ago researchers started studying
the secret of success of Japanese manufacturing
companies
5S turned out to be the most impressive "secret"
The factories were so well organized that
abnormal situations were readily apparent
Equipments were so clean and well maintained
that any problem such as a loose bolt or leaking
oil could be easily seen
This passion of cleanliness and orderliness
became a hallmark of Japanese organizations

Seiri = Organization (SORT)
means we remove all items from the workplace that are

not needed for current production (parts, tools,
equipment, etc).
Industrial definition: To distinguish between necessary things
and unnecessary things, and getting rid of what you do not
need.
Dictionary definition: To put things in

order (or organize them) according to
a specific rule or principle.

1. ORGANISATION(SEIRI)
Decide what you need

Remove unnecessary clutter
All tools, gauges, materials, classified and
then stored
Remove items which are broken, unusable
or only occasionally used
Key Words:
1. Classification management (Necessary &
unnecessary things)
2. Red tag movement
3. For unnecessary things, find their true
causes.
Why is my desk getting
messy?
Not necessary
Necessary now, but maybe Unnecessary
in the future
Every item on my desk belongs to the gray circle

Do you throw these things away?
It works!
Not necessary It has a value!
now, but maybe Its still new!
in the future
Its usable!
It looks nice!

RED
TAG
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 (RED TAG IT )
STORE IN THE RED TAG AREA

RED
TAG
For wavering items

PLACE THE SUSPECTED ITEMS IN
THE RED TAG AREA FOR ONE WEEK
ALLOW THE STAFF TO REEVALUATE
THE NEEDED ITEMS
AT THE END OF WEEK THOSE WHO
NEED ITEMS SHOULD BE RETURNED

Typical Seiri Activities
1. Eliminate defects and breakage
2. Organize the warehouse
Before 5S - TQM- CSICE-MECH 2017-18

After 13
T. Sugiyama The 5S Approach to Improvement PHP, 1995
Seiton = Neatness - Orderliness - Set in Order
Dictionary definition: Establishing

a neat layout so that you
can always get just as much of what you need when
you need it.
Industrial definition: It is a way of eliminating search.
ONCE YOU HAVE ELIMINATED ALL

THE UNNEEDED ITEMS
NOW TURN TO THE LEFT OVER

ITEMS
Question When you ask someone to bring a hammer,
how long can you wait without getting mad?
How long is your patience?

5 minutes? 2 minutes??
or
5 seconds???
Organise layout of tools and equipment:
1.Designated locations
2.Use tapes and labels
3.Ensure everything is available as it is needed and
at the point of use

30 Second Rule
Workplace Checkpoints:-
1. Positions of aisles and
storage places clearly
marked?
2. Tools classified and stored
by frequency of use?
3. Pallets stacked correctly?
4. Safety equipment easily
accessible?
5. Floors in good condition?

Key Words & Typical Activities
Key Words:
Design an efficient layout (Functional storage)
Eliminate search (Less search)
Everything should have a name.
(A place for everything and everything in its place)
Typical Seiton Activities:

Stripes on files
First in, first out
Easy to read notices

3. SEISO (CLEAN/SHINE)
Create a spotless workplace
Identify and eliminate causes of dirt and grime
remove the need to clean
Sweep, dust, polish and paint
SHINE means we sweep floors, scrub machines, apply a
fresh coat of paint, and then we KEEP it that way. This
way, everything will be in top working condition so that it
may be used when it is needed.
It also means preventive maintenance.
Definition: Eliminating
trash, filth, and foreign
matters for a cleaner workplace. Cleaning as
a form of inspection.
Key Words:
Keep things clean + Inspection

(Caring attitude)
1. Divide areas into zones
2. Define responsibilities for cleaning
3. Tools and equipment must be owned by
an individual
4. Focus on removing the need to clean

Cleanliness is a big business today.
Sanitation engineers
Laundry
Dry cleaner
Janitor
Garbage collector
Pollution control operator
Clean-room designer
One-third (1/3) or one-fourth (1/4) of the total
investment amount is used for cleanliness.

4. SEIKETSU (STANDARDISE)
Generate a maintenance system for the

first three
Develop procedures, schedules, practices
Continue to assess the use and disposal of
items
Regularly audit using checklists and
measures of housekeeping
Real challenge is to keep it clean

Seiketsu = Standardization
Definition:
SEIRI SEITON
Keeping things organized, neat,
and clean, even in personal and
environment aspects.
SEISO

Seiketsu = Standardization
GAP
Ideal State Current State
1.Define an ideal state

2.Standardize the solution (5S standardization)
Typical Seiketsu Activities
1. Make quality manual
2. Directional markings
3. Color-coded pipes
STANDARDIZATION happens when the first three Ss
are properly implemented and maintained.
It means that racking, paint colors, labeling, operational
layouts are designed in a standard fashion.
Everything will be in place so everyone will know exactly
what they are responsible for; and, exactly when, where,
and, how to do it.
5. SHITSUKE (SUSTAIN / DISCIPLINE)
Means inoculate courtesy & good habits
Driving force behind all 5S
Demings point number 1: Constancy of
purpose
Make it a way of life
Part of health and safety
Involve the whole workforce*
Develop and keep good habits
Shitsuke = Self-discipline
Definition:
Doing the right things
as a matter of course.
We SORT areas. We SET IN ORDER work places. We
SHINE areas. With STANDARDIZATION it is easy to
identify anything out of place.
SUSTAIN is different: It isnt a single separate activity; We
SUSTAIN when we have developed habits of always using
the first 4 Ss together on a daily basis.
Key Words & Typical Activities
1. Habit formation (Make it a habit)

2. Create a disciplined workplace
Typical Shitsuke Activities

1. Wear your safety shoes
2. Exercise time
3. No smoking at workplace
WHAT U HAVE COME ACROSS
Followings can be harnessed form the 5S

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
5 Ss
Sort
Clear out rarely used
Items by Red Tagging
Straighten
Sustain Organize and Label a
Use Regular Management Place for Everything
Audits to Stay Disciplined Eliminate
Waste
Shine
Standardise Clean It
Create Rules to Sustain
the first 3 5S
When Does 5S Happen?
ALL THE TIME!! 5S is a mindset and a
culture. The 5Ss are a part of each
Associates workday. There will also
be CI Events and WPO (WorkPlace
Organization) Events. In an Event,
Associates are taught how to
implement the principles of Continual
Improvement.

How is 5S Implemented?
By the associates! Who has a better idea
to make our jobs easier than us? Our
management is committed to improving
how we work.
We want to work smarter, not harder.
Along the way, support will come from
EVERYONE.
We will teach the 5S process, and together
we will implement it and make it work.

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

ADVANTAGES OF 5S
Health and Safety is ensured
Machine maintenance
Quality
Productivity
Lean Manufacturing
TIME SAVING
QUICK RETRIEVAL
ACCIDENTS & MISTAKES MINIMIZED
INCREASES SPACE
CREATES WORKPLACE OWNERSHIP

ADVANTAGES OF 5S
RESULTS IN A PLACE EASIER TO MANAGE
SMOOTH WORKING NO
OBSTRUCTION
NO DEVIATION, NO PROBLEMS
B/C EVERYONE KNOWS WHERE THE

THINGS ARE SUPPOSED TO BE

ADVANTAGES OF 5S
FOUNDATION OF ALL QC TOOLS
CONTINUOUS QUALITY
IMPROVEMENT
LEAN MANUFACTURING
KINDERGARTEN OF QUALITY TOOLS
& TECHNIQUES

ADVANTAGES OF 5S
VISUAL MANAGEMENT SYSTEM
VISUAL CONTROL TO SEE THE

ABNORMALITIES
SIMPLE SIGNALS THAT PROVIDE AN
UNDERSTANDING OF THE
CONDITION( NORMAL/ ABNORMAL)
A LOOK AT THE PROCESS REVEALS ITS
DIRECTION (RIGHT/WRONG)

5S Class

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Total Quality Management

5S - TQM- CSICE-MECH 2017-18 1

5S - TQM- CSICE-MECH 2017-18 2

Its the elimination of waste Everywhere while

Its a mindset & commitment to achieve a totally

5S - TQM- CSICE-MECH 2017-18 3

5S - TQM- CSICE-MECH 2017-18 5

5S - TQM- CSICE-MECH 2017-18 6

means we remove all items from the workplace that are

Dictionary definition: To put things in

5S - TQM- CSICE-MECH 2017-18 7

Decide what you need

Every item on my desk belongs to the gray circle

5S - TQM- CSICE-MECH 2017-18 10

GIVE STAFF RED LABELS

5S - TQM- CSICE-MECH 2017-18 11

For wavering items

5S - TQM- CSICE-MECH 2017-18 12

Before 5S - TQM- CSICE-MECH 2017-18

Dictionary definition: Establishing

Industrial definition: It is a way of eliminating search.

ONCE YOU HAVE ELIMINATED ALL

NOW TURN TO THE LEFT OVER

How long is your patience?

5S - TQM- CSICE-MECH 2017-18 15

5S - TQM- CSICE-MECH 2017-18 16

Typical Seiton Activities:

5S - TQM- CSICE-MECH 2017-18 17

Keep things clean + Inspection

5S - TQM- CSICE-MECH 2017-18 19

5S - TQM- CSICE-MECH 2017-18 20

Generate a maintenance system for the

5S - TQM- CSICE-MECH 2017-18 21

5S - TQM- CSICE-MECH 2017-18 22

1.Define an ideal state

1. Habit formation (Make it a habit)

Typical Shitsuke Activities

Followings can be harnessed form the 5S

5S - TQM- CSICE-MECH 2017-18 30

5S - TQM- CSICE-MECH 2017-18 31

Operators spend less time looking for items

5S - TQM- CSICE-MECH 2017-18 32

5S - TQM- CSICE-MECH 2017-18 33

B/C EVERYONE KNOWS WHERE THE

5S - TQM- CSICE-MECH 2017-18 34

5S - TQM- CSICE-MECH 2017-18 35

VISUAL CONTROL TO SEE THE

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