TRAINING MANUAL

5S

SUNNY ENGINEERS
  5 S is a Japanese Concept of organizing spaces so work can
be performed efficiently, effectively and safely.
 Basically one has to ensure that “There is a place for
everything and Everything in its place”.

BASIC  This has to be maintained every time and everyday.

(SUSTAINED)
INTRODUCTION
THE
MEANING OF
5S
1 S- SEIRI-SORT

 Siri means the sorting of all items and removing unnecessary items from the location.
Goals:
 Reduce time loss looking for an item by reducing the number of items.
 Reduce the chance of distraction by unnecessary items.
 Simplify inspection.
 Increase the amount of available, useful space.
 Increase safety by eliminating obstacles.
Implementation:
 Check all items in a location and evaluate whether or not their presence at the location is useful or necessary.
 Remove unnecessary items as soon as possible. Place those that cannot be removed immediately in a 'red tag area' so
that they are easy to remove later on.
 Keep the working floor clear of materials except for those that are in use to production.
2 S SEITON- SET IN ORDER

 Seiton is putting all necessary items in the optimal place for fulfilling their function in the workplace.
Goal:
 Make the workflow smooth and easy.
Implementation:
 Arrange work stations in such a way that all tooling / equipment is in close proximity, in an easy to reach spot and
in a logical order adapted to the work performed. Place components according to their uses, with the frequently
used components being nearest to the workplace.
 Arrange all necessary items so that they can be easily selected for use. Make it easy to find and pick up necessary
items.
 Assign fixed locations for items. Use clear labels, marks or hints so that items are easy to return to the correct
location and so that it is easy to spot missing items.
3 S SEISO-SHINE

 Seiso is sweeping or cleaning and inspecting the workplace, tools and machinery on a regular basis.
Goals:
 Improves the production process efficiency and safety, reduces waste, prevents errors and defects.
 Keep the workplace safe and easy to work in.
 Keep the workplace clean and pleasing to work in.
 When in place, anyone not familiar to the environment must be able to detect any problems within 50 feet in 5 sec.
Implementation:
 Clean the workplace and equipment on a daily basis, or at another appropriate (high frequency) cleaning interval.
 Inspect the workplace and equipment while cleaning.
4 S SEIKETSU-STANDARDISE

 Seiketsu is to standardize the processes used to sort, order and clean the workplace.
Goal:
 Establish procedures and schedules to ensure the repetition of the first three ‘S’ practices.
Implementation:
 Develop a work structure that will support the new practices and make it part of the daily routine.
 Ensure everyone knows their responsibilities of performing the sorting, organizing and cleaning.
 Use photos and visual controls to help keep everything as it should be.
 Review the status of 5S implementation regularly using audit checklists.
5 S SHITSUKE-SELF DISCIPLINE
 Shitsuke or sustain the developed processes by self-discipline of the workers.
Also translates as "do without being told".
Goal:
 Ensure that the 5S approach is followed.
Implementation:
 Organize training sessions.
 Perform regular audits to ensure that all defined standards are being implemented and followed.
 Implement improvements whenever possible. Worker inputs can be very valuable for identifying improvements.
 When issues arise, identify their cause and implement the changes necessary to avoid recurrence.
DO’S & DON’TS
DO’S & DON’TS

 Sunny Engineers was founded in the year 2000 to cater exclusively to the job work needs of M/S Gabriel India
Ltd.
 It is operating from its current location since 2009.
 Caters to 8 domestic and 5 overseas clients in Auto, Home Security, Water Treatment activities.
 85% of the business is from exports.
 We are ISO 9001:2015 Certified.
DO’S & DON’TS

 Sunny Engineers was founded in the year 2000 to cater exclusively to the job work needs of M/S Gabriel India
Ltd.
 It is operating from its current location since 2009.
 Caters to 8 domestic and 5 overseas clients in Auto, Home Security, Water Treatment activities.
 85% of the business is from exports.
 We are ISO 9001:2015 Certified.
DO’S & DON’TS

 Sunny Engineers was founded in the year 2000 to cater exclusively to the job work needs of M/S Gabriel India
Ltd.
 It is operating from its current location since 2009.
 Caters to 8 domestic and 5 overseas clients in Auto, Home Security, Water Treatment activities.
 85% of the business is from exports.
 We are ISO 9001:2015 Certified.
DO’S & DON’TS

 Sunny Engineers was founded in the year 2000 to cater exclusively to the job work needs of M/S Gabriel India
Ltd.
 It is operating from its current location since 2009.
 Caters to 8 domestic and 5 overseas clients in Auto, Home Security, Water Treatment activities.
 85% of the business is from exports.
 We are ISO 9001:2015 Certified.
DO’S & DON’TS
DO’S & DON’TS
PRESS MACHINE
  Respect your seniors, colleagues and sub ordinates
 Strong commitment to Safety & Quality
 Honesty

BENCH  Continuous Improvement

GRINDER  Humane treatment

 Work discipline & focus on 5 ’S’
 Commitment and focus on the job at hand
 Self motivated
  Start your day on time, do not be late.
 Plan your current and next day in advance. Follow up accordingly.
 Write down all activities planned or asked to do.
 Put forward all efforts to the task at hand.
 Ask if something is not understood or unknown.
 Focus your energies on the job to do not on irrelevant activities or idle
gossip
 Maintain good relationship with colleagues and work as a Team. Support your
HAND GRINDER 
colleague wherever they are weak.
Have a customer centric focus.
 Keep high focus on Safety, Quality and 5 S.
 Keep your superiors/colleagues informed of the activities you are doing.
 Keep all records updated.
 Plan your next day’s activities before ending for the day.
 Maintain proper attire, personal hygiene, and proper behaviour with all
people.
 Commitment to the task at hand is most important.
  Although Salary is a very important part of any employees’
criteria, it should not be the only one.
The Company Offers
 Salary in line with industry standards.
 Scope for technical learning.
 Scope for learning systematic approach in problem solving.
 Independent charge, ability to experiment.
 Leadership Role.
 Recognition of special efforts through public appreciation.
BENEFITS Besides these benefits company offers
 Leaves adjusted against Extra working (min 2 hours reqd.)
 Tea breaks twice a day and additional tea & snacks for working
more than 2 hours. Dinner or dinner allowance for working
over 9 p.m.
 Conveyance allowance for own vehicle or public transport for
travel outside for company work.