5S Training• WHAT IS 5S Based on Japanese words that begin with ‘S’, the 5S Philosophy focuses

on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.

The 5S pillars:• Sort (Seiri) • Set in Order (Seiton) • Shine (Seiso) • Standardize (Seiketsu) • and Sustain (Shitsuke) • provide a methodology for organizing, cleaning, developing, and

sustaining a productive work environment. This lean method enables operators and workers to reduce waste improve downtime.

5S Training

Japanese Term

English Equivalent Meaning in Japanese Context

Seiri TidinessThrow away all rubbish and unrelated

materials in the workplace

Seiton OrderlinessSet everything in proper place for quick

retrieval and storage

Seiso Cleanliness Clean the workplace; everyone should be a

janitor

Seiketsu StandardizationStandardize the way of maintaining

cleanliness

Shitsuke DisciplinePractice 'Five S' daily - make it a way of life;

this also means 'commitment'

5S Training• 5S Flow diagram

5S Training• Sort / Cleanup

• The first stage of 5S is removing the rubbish and clutter, it also involves cleaning and generally making the area tidy. A common area to implement 5S is in machine shops, this will involve removing broken tools and materials that have not been used for some time. By getting rid of unused items space can be made and items that are used on a regular basis can be found quicker.

• A method of removing unused items is to TAG them. Areas are targeted with a "RED Tag" and dated. if the item is then not used within a defined period they are removed and disposed of.

5S Training• Sort / Cleanup• Clearing the area means organizing the workplace so that it is a more

effective, more efficient place to work.• It involves sorting out what is not needed to perform the required work in

the work area. • If it's not needed, remove it. • Use the 48-Hour Rule• Instead of keeping things around that might get used someday, apply the 48-

hour rule to everything in the work area. • The 48-hour rule says: If it is not going to be used in the work area within

48 hours, it does not belong there. • The steps used to identify what is and is not needed in a work area and

then to clear the work area of the unnecessary items are :• Define what is needed. • Define what is NOT needed. • Disposition the items. • Take action: Sort out (move out) what is not needed and move in what is

needed (and is not there now).

5S Training• Sort / Cleanup• Define what is needed• When considering what is needed in a work area, don't just look at the core

equipment and tools used. Consider the materials, supplies, and even the paperwork.

• This is also a good time to evaluate the proper quantities of items to keep in the work area.

• Defining what is needed in a work area is not something that can be done effectively by one person working alone; use a team representing all that work in the area.

• Define what is NOT needed• After the team has identified what needs to be in the area, focus on all the

other items currently in the work area. • If an item is not needed to make the product, support the operation of the

equipment, or for safety reasons, then it probably should not be kept in the direct work area.

5S Training• Once items that are not needed in the work area are identified, it's time to

disposition them and determine where they should be stored. • Disposition the items• Tag items to be removed; use a standardized set of usage-based guidelines

to disposition items to be removed. • Whenever possible, use data to determine the frequency of use, do not

guess. The less frequently an item is used, the farther from the work area it should be stored

5S Training• Set in Order – Seiton• Organize the work area. Make it easy to find what is needed. • Set In Order (Seiton) is the second of the 5Ss and focuses on efficient and

effective storage methods• You must ask yourself these questions:• What do I need to do my job? • Where should I locate this item?• How many of this item do I really need?

• Strategies for effective Set In Order are: • painting floors,• Outlining work areas and locations, • shadow boards, and modular shelving and cabinets for needed items such

as trash cans, brooms, mop and buckets. Imagine how much time is wasted every day looking for a broom? The broom should have a specific location where all employees can find it.

"A place for everything and everything in its place."

5S Training• Set in Order Example

5S Training• Set in Order• Once you have cleaned the area out you need to ensure that the items left are

kept in the right place. Tools should be located where they are needed and the utilization of shadow boards to store them in set locations. Tools should be ordered in order of use, commonly used items being near to the worker, consideration should be given to reducing bending, stretching and excessive movement. Heavy items should be fitted with wheels, i.e, tool boxes and work benches.

5S Training• Set in Order Example

Before After

5S Training• Set in Order• Once everything has been sorted so we know what needs to stay in the work

area, what needs to go to a storage area, and what needs to be thrown out, we can go to the next step. We need to organize so that everything has a place where it belongs.

• In the Systemize step we arrange and identify everything in a work area for the most efficient and effective retrieval and return to its proper place. Storage areas are also organized, or they do not exist, built.

• In the work area, commonly used tools should be readily available. Here is where labeling comes in: storage areas, cabinets and shelves should be properly labeled. Without labeling it is easy to forget what goes where. Even when you have someone who knows the proper locations, labeling makes it more likely that tools and materials will be returned to where they belong.

5S Training• Set in Order• Paint floors to make it easier to spot dirt, waste materials and dropped parts and

tools. Outline areas on the floor to identify work areas, storage areas, finished product areas, etc. Then make signs to identify those areas. Put shadows on tool boards, making it easy to quickly see where each tool belongs. Make it easy for both experienced employees AND new employees to immediately know where they are and where everything belongs.

• To the same when organizing existing storage areas and building new storage areas.

• In an office, provide bookshelves for frequently used manuals, books and catalogs. Labels the shelves and books so that they are easy to identify and return to their proper place.

The objective when you are Systemizing is to have a place for everything

and have everything in it's place, with everything properly identified and labeled.

5S Training• Shine - Get Everything Cleaned Up• Getting everything cleaned up just not mean just the first time. It means to get

cleaned up and establish standards and procedures for keeping everything clean. Once you have everything sorted and organized, if you just let it go back to being disorganized, you have accomplished nothing. So regular cleaning is required - that's why this step is called "shine".

• Regular, usually daily, cleaning is needed or everything will return to the way it was. This could also be thought of as inspecting. While cleaning it's easy to inspect the machines, tools, equipment and supplies you work with. This will help you stop problems, wear and maintenance needs before they become serious.

• Regular cleaning and inspection makes it easy to spot lubricant leaks, equipment misalignment, breakage, missing tools and low levels of supplies. Problems can be identified and fixed when they are small. If these minor problems are not addressed while small, they could lead to equipment failure, unplanned outages or long - unproductive - waits while new supplies are delivered. This advantage alone can quickly pay back the cost of implementing a Five-S System.

5S Training• Take Steps to Prevent Backsliding – Standardize• At this point we have our work areas and facility cleaned up and organized.

The next step is to put systems in place to ensure that what has been accomplished remains in effect. In this step we establish standardized procedures and practices, and make them into habits.

• One of the hardest steps is avoiding backsliding into old work habits. It's easy and comfortable to slip back into what you've been doing for years. Habits are hard to change. But that is also the good news. Once new habits are established, they will tend to continue into the future. But first, we need to change the old habits.

5S Training• Continue training and maintaining the standards. - Sustain• This is by far the most difficult S to implement and achieve. Human nature is to

resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things. Sustain focuses on defining a new status quo and standard of work place organization.

• Once your Five-S System is set up, don't walk away and assume nothing will change. Things don't work that way. Don't expect that you can clean up, get things organized and labeled, and ask people to clean and inspect their areas every day -- and then have everything continue to happen without any follow-up. You'll need to establish a formal system for monitoring and evaluating the results of your Five-S System. That's why this final step is called "sustain".

• Once your Five-S System is operating, you'll be reaping the benefits such as: improved safety, better productivity, improved quality, etc. Think of this step as sustaining these benefits

5S Training

Straight Line not Followed

5S Training

Straight Line Followed

5S Training

Yellow line followed correctlyYellow line not followed correctly

5S Objective• Standardization (Seiketsu)The objective of standardization is to consolidate the first 3 S’s by establishingstandard procedures. This activity is carried out to determine the best work practicesand find ways of ensuring that everyone carries out an individual activity the same‘best’ way.• Discipline (Shitsuke)The objective of discipline is to sustain improvements and make furtherimprovements by encouraging effective use of the ‘Check-Act-Plan-Do’ cycles. This isachieved through strict adherence to current improvements and the development of anenvironment for future improvements.

5S in Life• Sort 1. What do I have? 2. Why do I have it? 3. How can I use it better?• Set in Order 1. What do I need? 2. Where should I locate it? 3. How many do I

really need?• Shine 1. Clean up, de clutter 2. Repair, polish, improve 3. Appreciate and enjoy• Standards 1. Learn from masters, understand precedent 2. Use best practices,

correct as appropriate 3. Advance the body of knowledge• Sustain 1. Institutionalize good habits; eliminate bad habits 2. Build discipline,

work harder on what is important 3. Fast, pray, meditate, deepen commitment

CONCLUSION

LET US ALL STRIVE TO MAINTAIN

5S

IN OUR OFFICIAL & PERSONAL LIFE