5S is the base for all the TPM activities.A proper implementation of 5S is required to improve the efficiency . The goal of 5S is to create a work environment that is clean and well-organized.Problems can not be clearly seen when the workplace is unorganized.

. The below 5S road map in Excel for PepsiCO plant can be used throughout 5S activities to clarify boundaries, assign responsibilities, and divide tasks into bite-size pieces.

What ? Where? Team

Leader Team Members P-D-C-A

Oct- 15Wk04

Nov - 15Wk 01 to

03

Nov - 15Wk 04 &

Dec-15 (Wk01 to

02)

Oct - 15Wk 01 &

02

Oct- 15Wk 03 &

04

Nov 15Wk 01 -

03

Nov 15Wk 04

Dec 15Wk 01 -

04

Jan 15Wk 01 -

04

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

'5-S' Road map - SIPA (PET )To do Who ? When?

Remarks Why ?

S4 S5

1 ] Preparation for implementing 5S 2 ] Motiating people for change

Zero defect

S0 S1 S2 S2 S3 S4 S4 S5

S0 S1 S2 S2

1 ] Develop criteria for need/want to release 30% place

Zero inventory/

More space

1 ] PEEP: Place for everything & everything in its place

Zero waiting

S3 S4

S0 = Enablers [Motivate people for 5-S

implementation]Na

me

S3

SIPA

DIM

AC

Palle

tizer

S0

S0

S3 = Shine (Seiso) [Ensure spic & span

cleanliness with inspection]

SIPA

CSD

PE

T BM

SIPA

Fi

ller/R

inse

r/Cap

per

SIPA

Lab

eller

/S

leeve

r

S2 = Set in Order(Seiton) [Do systematic

arrangement for all needed items]

S1 = Sort(Seiri) [Sort out what is needed

and what is not]

Zero breakdown

S0 S0 S1 S2 S2 S3 S4 S4 S5

1 ] CLITA: Deploy Clean-Lubricate-Inspect-Tighten-Adjust 2 ]

S4 S4 S5S5 = Sustain (Shitsuke) [Self -

discipline at workplace]

1 ] Through continuous education, training, display of results & PDCA improvement cycles

Zero changeove

r/setup

S4 = Standardise (Seiketsu)

[Create a highly standardised workplace]

1 ] SOPs Developed & Displayed 2 ]

Zero accidents

S0 S0 S1 S2 S2

To implement the first S the Red-Tag process is commonly employed. The Red-Tag strategy helps to identify unwanted items and determine their usefulness. For the implementation of first S, the work area is classified and the list of wants and wastes are identified.

Requisites Area Who Status Remark

TM

TM

TM

TM

TM X

TM X

TM X

TM X

X

X

X

X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

Scrap Disposal

Listing Wants in an Area after eliminating waste

ACTION PLAN FOR "S1" Seiri

Sorting out what is required & dipose unwanted ()

Work Area

Classification in work areas

Audit / Visual Inspection of wants / wastes

TL

Waste identification checklist provides a way to classify the items and removing unnecessary items in the work place.

GembaWork AreaTM

Freq. Rare Never Good Worst Yes No Yes No Yes No

Waste Remark

(S1) Waste Identification Checklist

Process / Equipment / Item in areaUsage Condition Repairable

Usage outside

area

Better Substitute

avl

Once the first S has been successfully implemented, what is left should be arranged so that there is ease of use and storage.

ACTION PLAN FOR "S2" Seiton

Systematic Arrangement of wanted ()

Requisites Area Who Status Remark

Organising wants in an area in terms of usage / value / importance to process / life cycle

TM X

TM X

TM X

TM X

Identifying amenities / infrastructure / tools required for correct organisation (P tags)

TM X

TM X

TM X

TM X

Organising in compliance with PEEP & Identifying missing / abnormal item or structure

TM X

TM X

TM X

TM X

GembaWork AreaTM

Process / Equipment / Item in area Usage Value Qty (Nos)Critical to process

Total Pref. No

0

0

0

0

0

0

0

0

0

0

0

0

(S2) Systematic arrangement checklist

Scores can be 1/ 3/ 5 for low / Med / High categories repectively & Pref.no will be in descending order of total score

Item with pref. no "1" should always be the easiest accesible and further on

In case of consumables qty. to be re-ordered when inventory level for Highitems reaches 25 % / 50 % levels

Arrangement to comply PEEP concept so that any missing / misplaced item can be identified by visual inspection

List down amenities / tools / structure for correct arrangement. When identified can be purchased or can be picked up from scrap

The third S is to thoroughly clean the work area. Daily follow-up cleaning is absolutely necessary to maintain a clutter-free workplace and a desirable environment. SHINE speaks for itself. Everyone enjoys working in a clean environment which raises morale and increases productivity.

Requisites Area Who Status Remark

TL / TM X

TL / TM X

TL / TM X

TL / TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

ACTION PLAN FOR "S3" Seiso

Systematic Arrangement of wanted ()

External / Internal man power arrangement for through cleaning

Through cleaning done & scrap disposed safely

All Items / Process / Equipments easly identifiable / accesible / safe

Once the 3S are in place, the next step is to concentrate on standardising best practises.The plan must include the creation of procedures and simple daily checklists which are to be visibly displayed at every workplace.

ACTION PLAN FOR "S4" Seiketsu

Systematic Arrangement of wanted ()

Requisites Area Who Status Remark

Daily Inspection / Reporting abnormalities

TM X

TM X

TM X

TM X

Action for deviation / 5S awareness session or training

TM X

TM X

TM X

TM X

The fifth S is to make it a habit of maintaining the momentum of the previous four S to ensure sustainability of the system.

ACTION PLAN FOR "S5" Shitsuke

Systematic Arrangement of wanted ()

Requisites Area Who Status Remark

Monthly / Qtrly. "5S" audit by Internal / External accesor

TL / Auditor X

TL / Auditor X

TL / Auditor X

TL / Auditor X

Action for deviation / findings / document learnings

TL / TM X

TL / TM X

TL / TM X

TL / TM X

5S awareness session / training for continual improvement / Visits

TL / TM X

TL / TM X

TL / TM X

TL / TM X

Gains in terms of value, life cycle, availability to be published

TL X

TL X

TL X

TL X

SEIRI 8

SEITON 8

SEISO 7

SEIKTSU 6SHITSUKE

7

1SCheck Item

DescriptionScore

0 1 2 3 4

SE

IRI

Materials / partsDoes the inventory or in-process inventory include unneeded mtrl / parts

3

Machines / Equipment

Are there any unused machines or other equipment 1

Papers / Plastic Mtrl Is there any paper / plastic scrap around 2 0

Visual Control Is the waste identified 2

Sub Total 0 1 4 3 0

2S Check Item DescriptionScore

0 1 2 3 4

SE

ITO

N

Location Indicators Are shelves and other storage areas marked with addresses 2

Item Indicators Do the shelves have signboards showing which items go where 2

Qty. Indicators Are Max / Min Inventory levels indicated 1Walkway Demarcation

Storage areas / Process Area / Units marked 3

Sub Total 0 1 4 3 0

3S Check Item DescriptionScore

0 1 2 3 4

SE

ISO Floor / Work station Are floors / work station shiny to spot any waste 2

M/c & Equipments Are they Dust free, running healthy with allowed noise / vibration 2

Cleaning Stewards Is there a dedicated staff / do they do it voluntarily 3

Sub Total 0 0 4 3 0

4S Check Item DescriptionScore

0 1 2 3 4

SE

IKT

SU

Improvement Idea Is any action plan in place for its deployment 1

Standard procedureIs the 5S implementation plan documented / published / communicated

1

Future scope Any continual improvement idea / process / recognition 2

First 3S Is Seiri / Seiton / Seiso maintained 2

Sub Total 0 2 4 0 0

5S Check Item DescriptionScore

0 1 2 3 4

SH

ITS

UK

E

Equipments / Process

Are they easily gettable / managable 1

Stock levels Is the inventory control adhered to 2

Training Is Training / 5S awareness in progress 2

Support Is top management active support available 1

5-S Billboards Are they updated 1

Sub Total 0 3 4 0 0

PILOT TEST CONDUCTED FOR 5S

A pilot allows teams to test and revise solutions before deploying them across an organization.

SEIRI

SEITON

SEISOSEIKTSU

SHITSUKE

0

5

10

Audit Result