5s Training

5S EDUCATION & TRAINING
GOALS AND OBJECTIVES
 To learn and apply 5S principles to target areas within the

company.
 Identify differences in workplace appearance and
functionality before and after 5S application.
 Perform detailed audit of workplace organization.
 Apply sort, set in order and shine to organize workplaces
 Standardize procedures to maintain and control workplace
organization with visual controls.
 Explain methods to sustain 5S application.
APPLICATION of 5S
The origins of the 5S methodology are in the manufacturing industry, its a
process made popular used by Toyota. However, It has been extended from
manufacturing to other sectors such as Aviation, Health care, Education,
Government etc.
INTRODUCTION
5S is the name of a workplace organization methodology that uses a list of five
systematic Japanese principles namely: Seiri, Seiton, Seiso, Seiketsu and
Shitsuke. 5S principles results in a workplace that is clean, uncluttered, safe, and
well organized to help reduce waste and optimize productivity.
STAGES OF 5S
1. Seiri
2. Seiton
3. Seiso
4. Seiketsu
5. Shitsuke
SEIRI OR SORT
This is the first step in 5S, it refers to the sorting of items in disarray.
This stage requires the team to remove all items that clearly do not belong in the
working area and only leave those that are required for the processes in question.
In this first step, Personnel sort everything in a workspace into what is and what
is not needed.
A technique called “red tagging” is frequently used in which every item not
necessary for a process gets red-tagged.
Below is a set of questions that provide a simple means for evaluating the
requirement of an item i.e.
• Does the item have a function in the area?
• How often is it needed and by whom?
• The Impact of removal?
• Does the item consume too much space?
These items are set aside and evaluated later. Rarely used items are stored
nearby but not at the workstation and disposable items are discarded. The Sort
phase is the first step to making more effective use of space by clearing out
hazardous items and clutter that distracts personnel from doing the job.
Tools which can
Tools which Tools which be used in
are useless are usable future.
SEITON OR SET IN
ORDER
Set, or Set in Order, follows the advice: “A place for everything
and everything in its place.” The team position items based on use,
with frequently needed items kept closer at hand. Every item that
made it through the Sort stage is given storage space. Colour-
coded labels are frequently used to easily identify storage spaces.
The Set in Order phase creates an ergonomic, organized and

uncluttered workspace where employees have what they need close
at hand and know where every item is stored. This creates a less
stressful work environment.
SEISO OR SHINE
 With the clutter gone and storage space organized, it’s time to clean.
After a thorough initial cleaning, Staff clean the station daily. This
maintains the gains made in the Sort and Set phases. Cleaning includes
storage areas, machines, equipment, tools and work surfaces.
 The Shine phase creates a more pleasant environment for employees,

who no longer have to combat dust, dirt and clutter. Cleaning the area
every day also leads to a higher level of employee buy-in for the 5S
method.
SEIKETSU OR STANDARDIZE
 This step involves creating ways to sustain the first three steps.
Employees participate in creation of a set of standards that will
govern maintenance of the workspace going forward. Once this “new
normal” becomes a habit, all old habits will fall away. This may require
oversight and enforcement before becoming a habit.
 The Standardize phase takes the progress and changes in behavior from
the first three steps and makes them the standard procedure.
 Basically it makes it easy for everyone to identify the state of normal

and abnormal conditions.
SHITSUKE OR SUSTAIN
 The final stage is Sustain, which is achieved by developing a sense of self-discipline.
the goal is to adhere to the new rules.
 The Sustain phase often requires;
1. Cultivation of team involvement in the 5S process.

2. Good communication that will eventually lead to employees becoming comfortable
with 5S procedures.
3. Make 5S’s part of daily routine until they become automatic and the accepted way of
doing things.
4. Gain management support.
 This final step often proves the most challenging but ideally serves the whole purpose
of adopting the 5S culture.
KEY BENEFITS OF 5S TOOL
Increased Productivity
• According to global research done by various consultancy firms

worldwide, it has been found that effective implementation of 5S
lean manufacturing resources improves productivity.
• The complete removal of unnecessary items along with efficient

workplace maximization is sufficient to help develop improved
productivity with minimal wastage of time.
• Less time spent searching through unnecessary items means more

time spent working.
Improved Safety
• A clean workplace environment, especially in a manufacturing unit

can result in significant reduction in the number of injuries sustained
by employees.
• Also, the reduction in unnecessary travel through the workspace

environment further minimizes the risk of sustaining injuries by
limiting exposure to hazardous substances elsewhere in the facility.
• This in return functions to increase the moral of employees, as

reduced incidents of injuries convey employer’s concern for worker
safety.
Reduction in Waste

Implementing 5s along with other lean processes and practices such as TIMWOODS to identify and
eliminate waste in the production process.
WASTE IMPACT
T Transport Unnecessarily moving things, resources and materials from
one location to another.
I Inventory Making more than customer demand e.g. of printed materials,
reports.
Unnecessary and excessive movements within workspace.
M Motion
Delays between operations due to parts missing ,waiting for
W Waiting information, approval other processes or people.
Completing task before it is needed, developing outputs that
O Over-production the customer hasn’t requested.
Duplicating, performing unnecessary wasteful steps often
because ``We always do it this way’’
O Over-processing
Failure to produce quality output the first time leading to
D Defects rework or scrapping.
Failure to use skills and capabilities of staff. not listening to
people using their knowledge or learning from past mistakes.
S Skills
Employee Commitment
• Achieving employee commitment is one of the major goals of

implementing 5S lean manufacturing training. this is because the
employees would be largely responsible for using it on the ground.
• 5S emphasizes on employee participation by streamlining their work

and allowing them to provide inputs to make productive changes in
the overall design of the workplace and also to carry out its
maintenance tasks. this encourages employee involvement for long-
term workplace sustainability which in turn enhances their
commitment towards work.
• This improvement also provides benefits of lower absenteeism in the

workplace.
EXAMPLES OF IMPLEMENTING 5S IN THE WORKPLACE
THE END
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5S EDUCATION & TRAINING

GOALS AND OBJECTIVES

 To learn and apply 5S principles to target areas within the

The Set in Order phase creates an ergonomic, organized and

 The Shine phase creates a more pleasant environment for employees,

 Basically it makes it easy for everyone to identify the state of normal

1. Cultivation of team involvement in the 5S process.

• According to global research done by various consultancy firms

• The complete removal of unnecessary items along with efficient

• Less time spent searching through unnecessary items means more

• A clean workplace environment, especially in a manufacturing unit

• Also, the reduction in unnecessary travel through the workspace

• This in return functions to increase the moral of employees, as

• Achieving employee commitment is one of the major goals of

• 5S emphasizes on employee participation by streamlining their work

• This improvement also provides benefits of lower absenteeism in the

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