Module 3 5S
Module 3 5S
Module 3 5S
Information
Leadership
Customers
Processes
Planning
Results
People
TQM
5S QC SS LMC QMS
TQM
Approach
TPM
JIT
5S
Strategy
Methodology
• Suggestion
Ground • 5S • QCC/WIT
Scheme
Common Workplace Problems
MODULE 3:
Quality Workplace
Through 5S
MODULE 3:
Quality Workplace
Through 5S
MODULE 3:
Quality Workplace
Through 5S
MODULE 3:
Quality Workplace
Through 5S
Inadequate space
Types of Workplace
MODULE 3:
Quality Workplace
Through 5S
MODULE 3:
Quality Workplace
Through 5S
MODULE 3:
Quality Workplace
Through 5S
Elimination Quality
Work Disciplined
of Loss and
Place Workforce
Waste
Total
Participation
MODULE 3:
5S Concepts,
Principles, and
Application
5S is a systematic approach to:
workplace organization
work simplification
techniques
5S practice:
2. SEISO
SWEEP MODULE 3:
SIMUTIN
3. SEITON 5S Concepts,
SYSTEMATIZE Principles, and
SINUPIN Application
4. SEIKETSU
STANDARDIZE
SIGURUHIN
5. SHITSUKE
SELF-DISCIPLINE
SARILING KUSA
S EIRI, SORT, SURIIN
Take out
unnecessary
and nonworking
items and
dispose. MODULE 3:
5S Concepts,
Principles, and
S EISO, SWEEP, SIMUTIN Application
Clean your
workplace,
always
S EITON, SYSTEMATIZE, SINUPIN
Arrange
necessary items
in systematic
order.
MODULE 3:
5S Concepts,
S EIKETSU, STANDARDIZE, SIGURUHIN Principles, and
Application
MODULE 3:
5S Concepts,
Principles, and
Application
Do things spontaneously
without being told or ordered
Concept, Principles and
Application
5S PILOSOPHY
Productivity comes from the MODULE 3:
elimination of waste.
It is necessary to attack the 5S Concepts,
Principles, and
root cause of a problem, not Application
just the symptoms.
A program to be successful
requires participation of
everyone.
To acknowledge that the
human being is not perfect
Concept, Principles, and
Application
SEIRI (SORT)
MODULE 3:
Waste Elimination
Stratification
Management
Dealing with Causes
Concept, Principles, and
Application
SEIRI (SORT)
MODULE 3:
Not necessary
Necessary Unnecessary
now, but
maybe in the
future
Stratification Needed Action
How to SORT your
Frequently Near point of
workplace
used use
SEIRI (SORT)
MODULE 3:
Success Indicator
5S Concepts,
Principles, and
Application
“Area saved or
percentage of space
available”
SEIRI (SORT)
What is unnecessary?
Items not needed
Needed, over quantity
For future use
Contingency Items
Critically decide the quantity of contingency
items to be retained and criteria for such
items
SEIRI (SORT)
Identifying what is unnecessary
Work in Process (WIP)
Contingency Items
Defective parts
Small items stucked
Supplies such as paper clips, notepads,
pens, pen caps, etc
Items dropped on the floor that are not
picked-up
SEIRI (SORT)
Identifying what is unnecessary
Computer Hard Disk
Floors
Aisles
Work surfaces
Corners near entrance, exits and stairs
Behind and under work benches and equipment
Along interior and exterior walls
Tool boxes that are not sorted
SEIRI (SORT)
Inspection Checklist
Look for unneeded furniture:
Chairs
Desks
Look for unneeded equipment:
Carts
Filing cabinets
Stapler
Benches
Puncher
Cutter
Typewriter
Computer
SEIRI (SORT)
Inspection Checklist
Check walls and boards Look for unneeded
for: supplies:
Lockers Dishes
Storage shelves Trash cans
Floors Personal items
Workbenches Clothes
Mirror
Degree Frequency of use Storage
Things not used for the Throw out
past one year.
LOW
Things not used once in Store at distance OR
the last 6-12 months. keep in store
Things used only once in Store in central place in
the last 2-6 months your zone
MEDIUM
Things used more than Store in central place in
once in a month your zone
USE LESS THAN ONCE A • Store where accessible and easy to find
MONTH
SELDOM USED • Store away, identified
• Discard
USE UNKNOWN • Move to central storage
• Apply to one of the above
SEIRI (SORT)
Dealing with papers
a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information
SEIRI (SORT)
Dealing with papers
4 D Principle
• Do
• Delegate
• Delay
• Dump
SEIRI (SORT)
Red Tagging - Akafuda
Used to identify
unknown or
unneeded items in a
work area.
Addresses issues
such as keep, scrap,
obsolete, defective,
and disposal.
SEIRI (SORT)
Red Tagging - Akafuda
This action tag's is used
to identify
miscellaneous
inventory, tools,
fixtures, office
equipment, files, and
other unknown items.
Notes disposition related
to identify, return,
scrap, move, or surplus.
SEIRI (SORT)
Red Tagging - Akafuda
Used to identify
any product,
equipment or
inventory that is to
be relocated.
SEIRI (SORT)
Red Tagging - Akafuda
Disposal Tag
Concepts, Principles and Application
Concepts, Principles and Application
Concepts, Principles and Application
Concept, Principles, and
Application
SEISO (SWEEP)
MODULE 3:
SEISO (SWEEP)
MODULE 3:
5S Concepts,
Ensure quality Principles, and
Application
Easy to check abnormality
Prevent machinery and
equipment from deterioration
Keep workplace safe and
easy to work
Concept, Principles, and
Application
SEISO (SWEEP)
Some good Seiso practices
MODULE 3:
Practice 5-10 minutes of Seiso
daily 5S Concepts,
Assign an owner to each Principles, and
Application
machine.
Combine cleaning (Seiso) with
inspection
Repeat sweep-wipe-polish-
check-fix
Organize a Big Cleaning Day
once or twice a year
Concept, Principles, and
Application
SEISO (SWEEP)
MODULE 3:
Success Indicator
5S Concepts,
Principles, and
Application
“Decrease accident
and equipment
downtime”
Concept, Principles, and
Application
SEITON
(SYSTEMATIZE)
MODULE 3:
MODULE 3:
Prevent loss and waste of time
Make it easy to find and pick 5S Concepts,
Principles, and
up necessary items Application
Ensure first-come-first-serve
basis
Make work flow smooth and
easy
Prevent accidents
Stratification Needed Action
SEITON
(SYSTEMATIZE)
MODULE 3:
Success Indicator
5S Concepts,
Principles, and
Application
“Time saved in
searching and
performing the
process”
SEITON
(SYSTEMATIZE)
B10-100 B12-100
B10-150 B12-150
SEITON
(SYSTEMATIZE)
1 2 3 4 5 6 7 8 9 101112
•Seiri wastes
•No horizontal piling
•Nothing on floor
SEITON
(SYSTEMATIZE)
30
Second
Rule
SEITON
(SYSTEMATIZE)
SEIKETSU
(STANDARDIZE)
MODULE 3:
5S Concepts,
“Maintain high standard of Principles, and
Application
housekeeping and workplace
organization at all times”
Key Principles:
Visual management
Standardization
Concept, Principles, and
Application
SEIKETSU
(STANDARDIZE)
MODULE 3:
Maintain cleanliness and
orderliness 5S Concepts,
Principles, and
Prevent mis-operation Application
SEIKETSU
(STANDARDIZE)
MODULE 3:
5S Concepts,
Never STOP in Principles, and
Application
implementing the first 3S’s,
maintain a high standard
of cleanliness and put
everything in writing
SEIKETSU
(STANDARDIZE)
• Visual control • Inspection marks
SEIKETSU
(STANDARDIZE)
MODULE 3:
Success Indicator
5S Concepts,
Principles, and
Application
“Increase in 5S
indicators”
Concept, Principles, and
Application
SHITSUKE
(SELF-
DISCIPLINE) MODULE 3:
5S Concepts,
Principles, and
“Do things spontaneously Application
without being told or ordered”
Key Principles:
Habit formation
Disciplined workplace
Empowerment of workers
Concept, Principles, and
Application
SHITSUKE
(SELF-
DISCIPLINE) MODULE 3:
Implementing 5S
5S
Groundwork
Steps in Implementing 5S
Step 1: Preparation
Step 2: Official announcement
Step 3: Big Clean-up Day
Step 4: Initial Seiri
Step 5: Daily Seiri, Seiton & Seiso
Step 6: Periodic 5S audits
1. Preparation
by Top Management
Visit to 5S model companies
Team Leader
Team Leader
5S Secretariat
DO
• Announcements
• Education
• Akafuda
• Big Seiso
• Seiso-Inspection
• Seiton Campaign
• Special 5S Projects
5S Core Group
ROLES AND RESPONSIBILITIES
CHECK
5S Audit
Documentation of Accomplishments
Review Targets
ACT
Corrective Measures
Revise Plans
Difficulties Encountered
2. Official Announcement
STEP 1 STEP 2
Before After
It is a regular activity within the 5S
program that determines how well 5S
is implemented or practiced in an
organization with reference to a set of
Quality Workplace Standards (QWS).
Turn PDCA (Plan, Do, Check, Act)
Analyze the results of actual implementation
of 5S in the workplace
Provide support and guidance to the members
of each work station to ensure the smooth and
effective implementation of 5S activities while
at the same time encouraging them to
maintain good practices
Dissemination of good practices
Sample of 5S Checklist
Sample of 5S Checklist
Begin with the
end in mind...
Stephen R. Covey
The Seven Habits of
Highly-Effective People