5S Training Module

DEEPJYOTI SERVICES
Training module
on
Implementation &
Monitoring
of
5S
( Work Place Improvement )
DEEPJYOTI SERVICES
Contents :-
1. What is 5 S ?
2. Implementation methodology.
3. Holding Gains
4. Review and measure.
DEEPJYOTI SERVICES
What is 5S
?
5S?
Housekeeping
DEEPJYOTI SERVICES
5S
Housekeeping
OR
L
Improvement ProcessK
DEEPJYOTI SERVICES
5S
Improvement
Process
DEEPJYOTI SERVICES
5S
=
Work Place
Improvement
DEEPJYOTI SERVICES
1
S,
2
S,
3
DEEPJYOTI SERVICES
S,
1 Sorting Out. 5S
2 Systematic Arrangement.
3 Shine Everything.
4 Standardization.
5 Self Discipline.
DEEPJYOTI SERVICES
5 ‘S’ & It’s Benefits
Topic Understanding Actions to be taken Benefits
1 ‘S’ Sorting Out • Segregate Wanted & Un-Wanted things . Space Saving & Improvement
• Remove Un-Wanted ones. in Work Efficiency .
• Decide on frequency of sorting.
2 ‘S’ Systematic • Decide the Place & Arranging in order.

• A place for every thing and every thing in Search Time reduced.
Arrangement it’s place.
3 ‘S’ Shine Everything •Dust Free Equipment / Work Place. •Healthy Work environment
(Cleaning) • Make it easy to Clean. •Abnormalities are Visible
• Make it easy to Inspect Abnormalities. & Corrected.
4 ‘S’ Standardization •Standard Procedure for all activities. Achieving Higher Productivity
•Review of Procedures and Work and Better Quality.
Instructions at a Fixed Interval.
5 ‘S’ Self Discipline • Forming the Habit / Culture. •Habit of doing it Right
• Regular Training & Update. First Time and Every Time .
• Follow the decided things. Total Employees
Involvement.
DEEPJYOTI SERVICES
1Sorting out :
Sort & Out

What to Sort & What to
send Out ( REMOVE ) ?
DEEPJYOTI SERVICES
1Sorting out :
Sorting:
Identify,Segregate
Wanted & Unwanted things
DEEPJYOTI SERVICES
1Sorting out :
out (REMOVE):
RE - MOVE Unwanted things
to
RED TAG AREA
DEEPJYOTI SERVICES
RED TAG AREA
‘Red Tag Area’ is a designated
place at all respective zones
(Production / Non production)
where unwanted things can be
collected temporarily and finally
removed.
DEEPJYOTI SERVICES
1S orting out
RED
TAG AREA
Removal of unwanted things

DEEPJYOTI SERVICES
1Sorting out :
Methodology to Implement
‘1S’
•Divide entire factory( including
Canteen,Offices,Toilets, scrap yards .) into small
Zones.
•Form a Team Leader ( Preferably Senior person of
respective area / Zone) and Team Members ( Group of
4~ 5 people) for every Zone.Ensure the involvement of
all associates.
•Form a committee of senior people( Preferably
DEEPJYOTI SERVICES
Department Heads) who should take a decision for the
disposal of unwanted things / Scrap, out from the
1Sorting out :
ORGANIZATION CHART FOR '5S' TEAM
CEO
Team members
5S' COMITTEE are operators
COORDINATOR
DEPUTY
COORDINATOR
ZONE-1 ZONE-2 ZONE-3 ZONE-4 ZONE-5 ZONE-6 ZONE-7
TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER
TEAM TEAM TEAM TEAM TEAM TEAM TEAM

MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS
DEEPJYOTI SERVICES
Make zones by allocating a reasonable area to each leader
DEEPJYOTI SERVICES
1Sorting out :
Methodology to Implement 1S: (
Contd.…)
•Fix a date and time for Red Tag Campaign & carry out
the audit across all Zones.
•Search & Identify unwanted things and tie them with a
RED TAG.
•Other than product scrap, Red Tagged items should be
moved to respective RED TAG AREA.
•All those items which are finally identified unwanted
ones should be reviewed by the review committee and
decision for disposing off should be taken within a fixed
DEEPJYOTI SERVICES
time( Maximum Time Limit is 15 days).

RED TAG CAMPAIGN
Unused Machines & Parts

DEEPJYOTI SERVICES
REDTAG CAMPAIGN
Unused Material
DEEPJYOTI SERVICES and Parts
RED TAG
CAMPAIGN
Unused Raw Material
due to excess
Inventory.
Created Free Space.
DEEPJYOTI SERVICES
1Sorting out
:•RED TAG :-
A Card containing detailed Section / Area :-
5 S RED TAG
information of unwanted Name of Item : Quantity :
things with a given time Reason :-

limit for further action to be 1. Obsolete 5. Unnecessary
taken. 2. Defective
3. Scrap
6. Mix - up
7. Unidentified
4. Not in place 8. Others
To be used based on Action :-
following questions: 1. Move to Scrap Yard

2. Locate properly
4. Rectify
5. Return to Supplier
•What is required ? 3.Segregate 6. Others
•How much is required ? Target date of disposition:
•When is it required ? Remarks :-
•Where is it required?
DEEPJYOTI SERVICES
RED TAG AREA
Collection of Unwanted Things at Red Tag Area

DEEPJYOTI SERVICES
1Sorting out :
Methodology to Implement 1S:
(Contd..)
•Prevent generation and accumulation of unwanted
things
inside the factory premises.
•Repeat the same exercise at the fixed intervals (Once
in a
month ).
•Monitor the performance zone wise for Space Savings,
DEEPJYOTI SERVICES
Reduction in Inventory, Search Time Reduction, ‘1S’

1Sorting out :
Guidelines for conducting 1S Audit
1. Obsolete :- Parts ( Jigs / tooling ) not required as
the design has become obsolete.
2. Defective :- Parts can’t be used as it is ( need
some correction ).
3. Scrap :- Scrap Items not thrown out .
4. Not in place :- Kept at wrong place.
5. Unnecessary :- Extra / not useful.
DEEPJYOTI SERVICES
1Sorting out :
6. Mix-up :- Mixed parts .. Needs attention .
7. Un-identified :- Nobody’s baby .
8. Items not used for last 6 months.
9. Obsolete documents, not used but still stored for a
long time.
10. Others :- Even what is this part ?… Nobody
knows.
DEEPJYOTI SERVICES
Potential Areas for practicing ‘1S’
SCRAP LITTERED SWARF LITTERED
IN REDTAG AREA ON WORK BENCH
FILING RACK IN
DIS-ARRAY
BIN USED AS A SEAT
DEEPJYOTI SERVICES
Example of ‘1 S ’
Before
Habit of accumulating unwanted things After
DEEPJYOTI SERVICES
Rack Removal
DISPATCH DEPARTMENT
BEFORE AFTER
RACKS TO BE
REMOVED
6x8 feet space released
DEEPJYOTI SERVICES
Before
Example of ‘1S’ - BEFORE
Example of ‘1S’ at Office Area
Source: Madras Engg.

After
DEEPJYOTI SERVICES
Example of ‘1S’at Office Area
DEEPJYOTI SERVICES
Before After
Worst Example of “1 S”
DEEPJYOTI SERVICES
Worst Example of ‘1S’
DEEPJYOTI SERVICES
2S
Systematic
Arrangement
DEEPJYOTI SERVICES
2S (Systematic Arrangement)
Objective
•Place for Every Useful Thing & Every Useful Thing is
on it’s place .
•Arranging them in a Systematic manner.
Result: Reduces Search Time
DEEPJYOTI SERVICES
Benefits of ‘2S’
• Faster retrieval of things, result in Elimination of
Search Time.
•Opportunity to correct the abnormalities faster as

visibility improves by system itself.
•Space Saving by systematic arrangements.
•Efficiency of work improves as things are available
when they are actually needed.
DEEPJYOTI SERVICES
Methodology to Implement ‘2S’

•Check What (Item Identification)?, Where ( Location)?
& How Much ( Quantity)? When ( Time limit)? Before
actually practicing ‘2S’.
•Decide appropriate location for every thing.
•Display identification mark for every location.
•Items stored should have the Identification Mark
including
purpose of storage & its review date.
DEEPJYOTI SERVICES
Methodology to Implement ‘2S’Contd..

•Every thing should be cleaned thoroughly before they
are stored at its pre fixed location.
•Location and storage of the items should be easily accessible to all.
•Clear identification and visibility for the location.
•Training and information to all.
•FIFO should be ensured.
DEEPJYOTI SERVICES
Presence of Good ‘2S’

•Availability of pre fixed locations for everything.
•Locations are appropriate (Near to use).
•Presence of identification for every thing.
•Containerization- No touching/ damage between two
parts.
•Accessibility is easy and known to every one.
•Locations for fire extinguishers is adequate.
•Gang ways are clearly marked.
DEEPJYOTI SERVICES
Presence of Good ‘2S’Contd..
•Direction for Respective Departments,Shops,Reception,
Canteen , Visitor Rooms, Meeting Halls . is clearly
marked and displayed.
•Direction for Toilets and Water Coolers is self informative.
•Display boards are available for Safety / Fire Prone Areas.
•Display of Speed Control of the vehicle inside the factory
premises is adequate.
DEEPJYOTI SERVICES
Presence of Good ‘2S’( Contd….)
•Direction for Dispensary is clearly marked & displayed.
•Serial numbers on Fans , Machines, Tube Lights, .are
present & visible.
•Important / emergency Telephone Numbers are displayed
at appropriate locations.
•Instructions for Safety / Quality Standards are clearly
visible.
•Shadow Boards are available at the appropriate locations.
DEEPJYOTI SERVICES
Absence of Good ‘2S’

•No visual identification & display boards are available.
•Files / documents / reports can not be found out as the
concerned person is on leave.
•Tables and drawers are filled with full of papers & files.
•Habit of keeping standards, documents, stationary
. in the personal locations exists.
DEEPJYOTI SERVICES
Absence of Good ‘2S’contd...

•Scarcity of accidents at the work place is available.
•Fire Extinguishers are not available at the desired
locations.
•Visitors are roaming as there are no road maps displayed.
•Frequently asked questions by the visitors are: Excuse me,
Where is toilet?, Where is drinking water? …….
•Difficult to identify between Good & Bad.
DEEPJYOTI SERVICES
2S
Right Things in the Right Place.
DEEPJYOTI SERVICES
2S (Systematic
Arrangements)
Before
Pre-Fixed After
Locations
DEEPJYOTI SERVICES
2S
Pre-Fixed
Locations
DEEPJYOTI SERVICES
‘2 S’
Pre
fixed
location
s
DEEPJYOTI SERVICES
2S
Search
Time
Elimination
Fan &
Electrical
Switches
DEEPJYOTI SERVICES
Identified
2S Shadow Boards
Shadow board means if you take tool / gauge / any displayed
item from the board , shadow of that tool/gauge/ item should
remain on the board (empty place )
… refer next slide
DEEPJYOTI SERVICES
2S Shadow Boards
Only shadows on board .. Empty
board Shadow board with tools
DEEPJYOTI SERVICES
2S
Pre fixed location
DEEPJYOTI SERVICES
2S Example : Broom storage arrangement
DEEPJYOTI SERVICES
2S Fixed Point Photograph Location
DEEPJYOTI SERVICES
2S Fixed Point Photograph display Location
Communicating visually through fixed point photographs

Display boards at fixed place
DEEPJYOTI SERVICES
2S
Pre-Fixed
Locations-
Shadow
Boards for
Gauges
DEEPJYOTI SERVICES
2S Example of ‘2S ’
Before After
Wrong place for wrong Tool Correct Tool on correct place
DEEPJYOTI SERVICES
2S Example of ‘2S ’
Before After
Wrong place for parts
DEEPJYOTI SERVICES
2S

‘2S’ in Office
Can you see at a glance
whether files are out of place
? Elimination of
 Can you detect disorder from
a distance ? search time
Before After
DEEPJYOTI SERVICES
2S Example of ‘2S’ at office
area
DEEPJYOTI SERVICES
2S See through , see without touching / opening
Example: Transparent Storage Cupboards
DEEPJYOTI SERVICES
2 S Example of ‘2S’ at office area
Before After
DEEPJYOTI SERVICES
2S Identity at empty place
You know who has taken the file

DEEPJYOTI SERVICES
‘2 S’
Place for Parts under

DEEPJYOTI SERVICES
investigation.
‘2 S’
TOOL STORAGE
AT CORRECT
LOCATION
DEEPJYOTI SERVICES
2S
COCONUT TO CAR PARKING
BEFORE AFTER
DEEPJYOTI SERVICES
Solutions are available even for complicated things

2S
BEFORE AFTER
DEEPJYOTI SERVICES
2S
BEFORE AFTER
DEEPJYOTI SERVICES
2S
BEFORE AFTER
No touching between two

parts
DEEPJYOTI SERVICES
2S Visual Aids
No Fire Don’t Dange Use Vehicle

Smokin Touch r Helmet
g
Direction Dispensary
ATTENTION
240/440 V
DANGER
Fire Hose Fire Electricity

Extinguisher
DEEPJYOTI SERVICES
3 S (CLEANLINESS)
Shine
Everything
DEEPJYOTI SERVICES
3 S (Shine everything )
means……
1.Six side cleaning for all.

2. Refurbishing everything
3. Make things easy to clean
DEEPJYOTI SERVICES
Six sides of Equipment/Work Place are:
•Top & Bottom side
•Front & Rear side
•Right & Left side
DEEPJYOTI SERVICES
Objectives and Benefits of
Practicing ‘3S’
•Provides dust free environment.
•Creates safe & healthy work place.
•Ensures higher quality of work & products.
•Increases the efficiency & life of equipment .
•Improves Visibility to identify abnormalities.
DEEPJYOTI SERVICES
Presence of Good ‘3S’
•Every thing is dust free (All six sides).
•Visibility is clear, no darkness.
•Clean and safe work place.
•No leakage of oil on the machine/ floor ( Wet to Dry).
•No abnormal sounds / vibrations at the work place.
DEEPJYOTI SERVICES
Absence of Good ‘3S’
•Poor condition of Canteen & Toilets.
•Work place & offices are dark.Windows are badly dusty & dirty that does
not allow sun light to enter even on a sunny day.
•Tube-lights/ bulbs have a layer of dust-allowing less light.
•Walkways on the shop-floor are dark, generally having a coat of muck piled
on it.
DEEPJYOTI SERVICES
Absence of Good ‘3S’contd..
•Puddles of oil & water cause slipping & injury.
•Machines are so dirty & oily that it is hard to know their
original color.
•Oil & air-pressure gauges are hard to read as they are
coated with dirt.
DEEPJYOTI SERVICES
Absence of Good ‘3S’contd..
•Workmen’s dress/ uniforms and shoes are dirty.
•People with soiled clothes,working in dirty environment
tend to have low morale.
•Surroundings are with full of garbage, no greenery seen.
•Higher defectives are produced due to uncleaned
machines .
•Machines tend to have frequent breakdowns due to dust
& dirt.
DEEPJYOTI SERVICES
Methodology to implement ‘3S’
•Divide entire work place into small zones.
•Define the responsibility of person ( Area wise).
•Prepare a check list containing following information:
•Check Items.
•Tools to be used.
•Frequency of inspection.
•Person In charge name.
DEEPJYOTI SERVICES
Methodology to implement
‘3S’contd….
•Check list along with the photograph of the person in
charge
should be displayed at the respective work place.
•Status of ‘3S’ should be recorded in the check sheet,
abnormalities if found should be recorded and
corrected.
•Actual status of ‘3S’ should be audited by a team of
senior
people on weekly basis.(GENBA visit by CEO)
DEEPJYOTI SERVICES
Methodology to implement
‘3S’contd….
•Shine everything by thorough cleaning from Roof
to floor.
•Office: - Clean top & below of the tables, cupboards
& filing racks.
•Shop floor :-Clean machines, equipment,walls,fans.
•Canteen, toilets, and outskirts of the company.
DEEPJYOTI SERVICES
Preventive measures to maintain
‘3S’
• Use of dust collecting covers or devices to prevent
possible dirt generation or reduce the amount of dirt.
• Investigating the causes of dirtiness and implement a
plan to eliminate the sources of dirt.
DEEPJYOTI SERVICES
Preventive measures to maintain ‘3S’
contd.. clean their own equipment and working area
•Operators
and perform basic preventive maintenance( Habit of
self cleaning) .
•Keep everything clean for a constant state of
readiness.
•At the end of the shift ,work place should be cleaned
as
good as it was seen in the morning. (Fresh Look).
DEEPJYOTI SERVICES
List of Tools used for cleaning
Brooms
• Used for Preliminary Sweeping of dust, chips on the Floor.
Mops
• Used for wiping Floors,Table Top, Shelves .
Dusting Cloths/ Rags

• Use dusting cloths for Work Tables, Desks, Chairs, .
• Use wet rags if there is a lot of dirt & dust.
• For polishing or removing oil use dry dust cloths or rags.
DEEPJYOTI SERVICES
Good Example of ‘3S’
Factory Surroundings
DEEPJYOTI SERVICES
Front area and Scrap yard are comparable
31.03.02
FACTORY ENTRANCE SCRAP YARD

DEEPJYOTI SERVICES
Neat & clean Gang ways , painted floor
DEEPJYOTI SERVICES
OVERHEAD PIPES FOR AIR SUPPLY TO
LAYOUT ENSURE BETTER FLEXIBLITY FOR
LAYOUT CHANGES… no pipes on floor
CHANGE
BEFORE AFTER
DEEPJYOTI SERVICES
Example of ‘3S’at Shop Floor
DEEPJYOTI SERVICES
Example of ‘3S’: Shop Floor
DEEPJYOTI SERVICES
Example of ‘3S’: Shop Floor
Before After
DEEPJYOTI SERVICES
3S
Before
Wet to Dry….
Nothing is on the floor
After
DEEPJYOTI SERVICES
Example of Wet to Dry
Machine lifted above the floor…

… easy to clean from 6 sides
DEEPJYOTI SERVICES
Wrong handling of
material.. Falling on
floor DOOR
AFTER
BEFORE
DEEPJYOTI SERVICES
MAXIMUM UTILISATION OF NATURAL LIGHT
Transparent
Sheets
Dark to bright
DEEPJYOTI SERVICES
4S
Standardization
DEEPJYOTI SERVICES
4 S (Standardization)
Objective
• To set standard practices for carrying out routine /
repetitive work in the best known way.
• To ensure that quantity & quality of work is consistent.

• To provide a basis for improvement.
• To provide a basis for daily management / supervision.
DEEPJYOTI SERVICES
Benefits
•Sustains the benefits achieved by implementing 1S, 2S & 3S.
•Avoids Re-occurrence.
•Ensures availability of procedures for every activity.
•Ensures continuity of work .
•Provides systematic approach.
•Provides guidelines for the new people.
DEEPJYOTI SERVICES
What Is To Be Standardised
• Workstation layout, work area layouts.
• Work in Process (WIP).
• Sequence of work.
• Cycle time of work .
• Material and tools used.
• Machines and their process parameters.
• Quality parameters, methods of measurement, reaction plan
and reporting method.
• “ What, Where, When, Who & How ” of work .
DEEPJYOTI SERVICES
Standardization of Colour coding for
Pipe Lines /Containers
Colour Codification Colour Name Description for Application
Green Water
Light Blue Air
Purple Acids
White Oxygen
Brown Flammable Oils /Liquids
Arrows should be marked to indicate the Direction of Flow. (Colour--- Yellow)
And opening / closing positions of valves

DEEPJYOTI SERVICES
4 S (Standardization) EXAMPLES OF COLOUR CODING
AIR LINE LIQUIDS/LUBRICATION LINE
DEEPJYOTI SERVICES
DIRECT LOADING ON LINE
Method of handling finished parts

standardized.
DEEPJYOTI SERVICES
Methodology to practice ‘4S’
•Preparation of S.O.P.( Standard Operating Procedure)
for all the activities to be carried out to maintain 1S,2S,
& 3S.
•Following areas shall be covered while preparing S.O.P.
:
•Machine & Equipment maintenance.
•Manufacturing Processes maintenance.
•Work Place maintenance.
DEEPJYOTI SERVICES
•Quality Standards and Procedures maintenance.

Methodology to practice ‘4S’ contd…
•Preparation of check sheet as per S.O.P. for all the
activities.
•Check sheet shall clearly define the followings:
•Work to be done.
•Tools / method to be used.
•Frequency of work to be done like: daily start up check sheet,
weekly
check sheet, Monthly &Quarterly check sheet .
•Person responsible to carry out and maintain the activity.
•Record of observations/ result for the activity carried out.
DEEPJYOTI SERVICES
Methodology to practice
‘4S’contd...
•Work place cleaning before start of work.
•Utilities maintenance like: Canteen, Toilets,
Garden,Roads,
Fans, Tube Lights .
•Safety Equipment maintenance like: Fire
Extinguishers,
DEEPJYOTI SERVICES
Fire Hoses .
5S
Self
Discipline
DEEPJYOTI SERVICES
5 S (Self Discipline)
Follow the Standards
“Whatever has been decided

must be followed exactly as
per the standard”.
DEEPJYOTI SERVICES
Objective
To bring a cultural change in the
organization…...
…….Achieve
through
‘Total Employee Involvement’.

DEEPJYOTI SERVICES
Methodology to Implement ‘5S’
•‘Practice makes the person perfect’,Ensure that
practices
set are followed exactly as per standard.
•Motivate people to get involved in the improvement
process.
•Form the teams at all levels.
•CEO to interact personally with all teams by meeting
at GENBA.
DEEPJYOTI SERVICES
Methodology to Implement ‘5S’contd..
•Training / retraining to all employees for continuous
improvement.
•Effective communication through Sun Rise Meeting .
•Prepare check list for carrying out audits for ‘5S’.
•Audit shall be conducted at a regular interval (
1/week)
•Score of audit ( Zone wise and separate for all 5S )
shall be
monitored and displayed at the respective areas.
DEEPJYOTI SERVICES
Methodology to Implement ‘5S’contd..
•Abnormalities found should be analyzed for the root
cause
and actions are taken to prevent reoccurrence.
•Good and Bad areas( Zones) should be identified and
displayed .
•Reward distribution for the best area ( month wise).
•Zone wise competition should be created for healthy
environment.
DEEPJYOTI SERVICES
Holding Gains
•Progress monitoring through Audit Scores.

•Improving ownership by Allocating Areas.
•Using Red Tag Campaigns.
• Visual communication through Fixed Point
Photography.
•Continuous Training to all employees.
•Periodic Audits at all levels.
•Motivation to employees through Recognition.
•Encouraging house-keeping projects through Total
Employee Involvement (TEI).
DEEPJYOTI SERVICES
Review and measure
• Start reviews for implementation status ( GENBA ).
• Audit all Zones / Areas for 5 S( GENBA ).
• Auditors should be the Zonal leaders.
• Frequency of the Audit …. Weekly .
• Measure each Zone’s performance by Audit scores.
(Target for 1 S , 2 S and 3 S is min. 75 % )
• Least score out of all zones would be Company’s final
score.
• Display Audit scores ( Radar Chart ) and Before - After
photographs .
DEEPJYOTI SERVICES
Audit Checklist
ZONE NO. ZONAL MGR.
5 S Audit Sheet - Shop floor LEVELS
S.N. 1S Sorting Out (SEIRI) Score 0 5 10 15 20
1 Floor Cleanliness - free from dust, oil, mud etc 20

2 General Cleanliness inside factory - Walls, pillars, pipelines are clean without scaling, paint peeling marks, strains etc. 20
3 Cleanliness of containers/pallets - free from dust, oil. Container/pallet in painted condition and free from damages. 20
4 Cleanliness of parts - free from dust, oil (dry condition) 20
5 Cleanliness of Jigs, Fixtures - free from dust, oil 20
6 Unused/Excess material removed to separate place, away from work area 20
7 No mix up of parts in pallets, containers, trays etc 20
TOTAL FOR 1S 140
1S SCORE = ( TOTAL s core X 100 /140)
S.N. 2S Systematic arrangement (SEITON) Out of 0 5 10 15 20
1 Gangway - Marking is clear and no material in the Gangway. 20

2 Use of right pallet / container, trays etc. 20
3 Right pallets, containers, trays etc in right location 20
4 Right component in right containers/pallets etc 20
5 Only calibrated jigs/fixtures are used 20
6 Fire Extinguisher are in fixed location 20
7 Proper shadow board for tools. 20
8 Proper storage of housekeeping tools. ( Broom, Brush , Small Shovel , Tool for cleaning at Heights ) 20
TOTAL FOR 2S 160
2S SCORE =( TOTAL s core X 100 /160)
S.N. 3S Shine Every thing (SEISO) Out of 0 5 10 15 20
1 Component parts not touching each other in containers, trays etc. 20

2 Containers, Trolleys are OK & clean 20
3 Material movement facilities are neat & clean 20
4 Plant and Equipment available in clean condition - all sides 20
5 Preventive maintenance schedule available and effective 20
6 Chip/Swarf collection and disposable system available. 20
TOTAL FOR 3S 120
3S SCORE = ( TOTAL s core X 100 /120))
S.N. 4S Standardization(Seiketsu) Out of 0 5 10 15 20
1 Retrieval of tools, document is easy ( ask for documents , related tools ) 20

2 Andon Lights On Machines Are Available And Effective 20
3 Localized Shadow Boards, Tools Available For Cleaning And Maintenance And Effective 20
4 Easy To See And Inspect Facility Available On Machines And Equipment's 20
5 Pre-Fixed Quantity Per Container / Pallets Is In Practice 20
TOTAL FOR 4S 100
S.N. 5S Self Discipline (Shitsuke) Out of 0 5 10 15 20
1 People are aware for " 5S " requirement and their doing their role ( ask 2-3 people ) 20
2 Availability of operating Standards ( Operation sheet , work instructions ) and are effective 20
3 Activities are done as per schedule ( Audit , Action on NC products etc. ) 20
4 Appropriate legible Visual Control System In Practice ( area names , displays ) 20
TOTAL FOR 5S 80
DEEPJYOTI SERVICES
Best = 100 % marks, Good= 70 % marks, Average= 50 % marks, Below Av.= 30 % Marks, Poor= 10 % Marks, Not done at all= 0 %
Marks.
Radar Chart
1S
SORT OUT •Section
100 •Date
75
50
5S 2S
SELF 25 SYSTEMATIC
DISCIPLINE ARRANGEMENT
0
4S 3S
STANDARDIZATION SHINE
EVERYTHING
•100
•80
Graph
•60
•40
•20
Marks %
Month
DEEPJYOTI SERVICES
5S is not one time activity,
it’s a Continuous
IMPROVEMENT PROCESS .
No TQM,TPM,TPS..LEAN is
possible without 5 S
5S……..a way of life.
DEEPJYOTI SERVICES
Thank you
DEEPJYOTI SERVICES

5S Training Module

Uploaded by

Copyright:

Available Formats

5S Training Module

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

5S Training Module

Uploaded by

Copyright:

Available Formats

DEEPJYOTI SERVICES

2 ‘S’ Systematic • Decide the Place & Arranging in order.

Sort & Out

Removal of unwanted things

ZONE-1 ZONE-2 ZONE-3 ZONE-4 ZONE-5 ZONE-6 ZONE-7

TEAM TEAM TEAM TEAM TEAM TEAM TEAM

time( Maximum Time Limit is 15 days).

Unused Machines & Parts

Created Free Space.

information of unwanted Name of Item : Quantity :

things with a given time Reason :-

To be used based on Action :-

following questions: 1. Move to Scrap Yard

•How much is required ? Target date of disposition:

•When is it required ? Remarks :-

Collection of Unwanted Things at Red Tag Area

Reduction in Inventory, Search Time Reduction, ‘1S’

BIN USED AS A SEAT

Example of ‘1S’ at Office Area

Source: Madras Engg.

Result: Reduces Search Time

•Opportunity to correct the abnormalities faster as

•Space Saving by systematic arrangements.

•Efficiency of work improves as things are available

when they are actually needed.

Methodology to Implement ‘2S’

Methodology to Implement ‘2S’Contd..

Presence of Good ‘2S’

Absence of Good ‘2S’

Absence of Good ‘2S’contd...

Right Things in the Right Place.

Communicating visually through fixed point photographs

Example: Transparent Storage Cupboards

You know who has taken the file

Place for Parts under

Solutions are available even for complicated things

No touching between two

No Fire Don’t Dange Use Vehicle

Fire Hose Fire Electricity

1.Six side cleaning for all.

•Top & Bottom side

•Front & Rear side

•Right & Left side

•Improves Visibility to identify abnormalities.

Dusting Cloths/ Rags

FACTORY ENTRANCE SCRAP YARD

Machine lifted above the floor…

• To ensure that quantity & quality of work is consistent.

• To provide a basis for daily management / supervision.

•Provides guidelines for the new people.

Arrows should be marked to indicate the Direction of Flow. (Colour--- Yellow)

And opening / closing positions of valves

AIR LINE LIQUIDS/LUBRICATION LINE

Method of handling finished parts

•Quality Standards and Procedures maintenance.

“Whatever has been decided

‘Total Employee Involvement’.

•Progress monitoring through Audit Scores.

ZONE NO. ZONAL MGR.

5 S Audit Sheet - Shop floor LEVELS