training material on 5s

5S

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PURPOSE OF 5S

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1. TO CREATE A SAFE, COMFORTABLE AND PRODUCTIVE WORKPLACE2. TO IMPROVE THE QUALITY OF PRODUCTS3. TO REDUCE TIME REQUIRED FOR FINDING THINGS

THE PURPOSE OF 5S IS :

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DO WE NEED 5S ?

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1. DO EMPLOYEES COME LATE FOR WORK/ MEETING?2. ARE THE OLD AND NEW VERSIONS OF DOCUMENTS MIXED TOGETHER?3. ARE THINGS KEPT DISORDERLY AT THE SPECIFIED LOCATION?4. DO EMPLOYEES OFTEN COMPLAIN ABOUT LACK OF TIME/ BUSY?5. DOES IT TAKE TIME TO RESPOND TO DEFECTS, PROBLEMS?6. DO YOU RUN OUT OF CONSUMABLES/ DOCUMENTS WHEN THEY ARE NEEDED?7. IS LOTS OF REWORK/ CORRECTION NECESSARY?

SIGNS THAT 5S NEEDS TO BE IMPLEMENTED

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WHAT IS 5S ?

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JAPANESE ENGLISH

SEIRI: SORTSEITON: SET IN ORDERSEISO: SHINESEIKETSU: STANDARDIZESHITSUKE: SUSTAIN

THE TERM 5S IS MADE FROM THE FIRST LETTER OF THE BELOW 5 WORDS

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SEIRI

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DIFFERENTIATE BETWEEN NECESSARY & UNNECESSARY THINGS AND DISPOSE OFF THE UNNECESSARY THINGS

DEFINITION OF SEIRI:

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SEITON

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DECIDE THE STORAGE LOCATION & STORING METHOD FOR THE NECESSARY THINGS AND DO PROPER LABELLING SUCH THAT THEY CAN BE QUICKLY TAKEN OUT

DEFINITION OF SEITON:

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SEISO

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CLEAN PROPERLY SUCH THAT THERE IS NO DIRT OR DUST

DEFINITION OF SEISO:

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SEIKETSU

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THOROUGHLY IMPLEMENT “SEIRI SEITON SEISO” AND MAINTAIN THE CLEAN CONDITION OF WORKPLACE

DEFINITION OF SEIKETSU:

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SHITSUKE

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MAKE IT A HABIT TO DO THE DECIDED THINGS IN THE DECIDED WAY

DEFINITION OF SHITSUKE:

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HOW IS 5S DONE ?

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SEIRI

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SEIRI MEANS TO DIFFERENTIATE BETWEEN NECESSARY & UNNECESSARY THINGS AND DISPOSE OFF THE UNNECESSARY THINGS.

AFTER DOING SEIRI, ONLY THE NECESSARY THINGS WILL REMAIN.

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`

BEFORE AFTER

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EXAMPLES OF SEIRI IMPLEMENTATION

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SEITON

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SEITON MEANS TO DECIDE THE STORAGE LOCATION & STORING METHOD FOR THE NECESSARY THINGS AND DO PROPER LABELLING SUCH THAT THEY CAN BE QUICKLY

TAKEN OUT

IT IS IMPORTANT TO DO SEITON AFTER SEIRI, OTHERWISE WE WILL END UP STORING AND LABELLING THE UNNECESSARY THINGS ALSO !!

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1. FIX THE POSITION

DECIDE A STORAGE LOCATION NUMBER FOR EACH OBJECT (JUST LIKE PEOPLE HAVE THEIR HOUSE ADDRESS). THE STORAGE LOCATION

NUMBER SHOULD BE SHOWN ON THE LAYOUT SO THAT PEOPLE CAN QUICKLY

ACCESS IT.

THINGS TO BE CONSIDERED DURING SEITON

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2. FIX THE QUANTITY

DO VISUALIZATION SUCH THAT THE QUANTITY CAN BE JUDGED JUST BY

LOOKING. DECIDE THE MIN AND MAX QUANTITY SUCH THAT IT CAN BE EASILY

MANAGED.


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3. FIX THE DIRECTION

FIX THE DIRECTION OF STORING THE OBJECT SUCH THAT IT IS EASY TO TAKE OUT.


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4. DO LABELLING

MENTION THE NAME OF THE OBJECT AND THE RESPONSIBLE PERSON SUCH THAT THERE IS A

PROPER SYSTEM TO MAINTAIN IT.


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SEISO

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DIRT CAN BE CLASSIFIED AS BELOW (BASED ON SIZE):

1. SMALL UNNECESSARY THINGS THAT CAN BE HELD IN YOUR HAND2. THINGS THAT CAN BE PICKED UP BETWEEN FINGERTIPS (EG. THREAD, PAPER)3. DUST WHICH WILL FLY OFF IF YOU BLOW AT IT4. OIL, ETC WHICH CANNOT BE PICKED UP

SEISO MEANS TO CLEAN PROPERLY SUCH THAT THERE IS NO DIRT OR DUST.

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EXAMPLES OF SEISO IMPLEMENTATION

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SEIKETSU

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SEIKETSU MEANS TO THOROUGHLY IMPLEMENT “SEIRI SEITON SEISO” AND MAINTAIN THE CLEAN CONDITION OF WORKPLACE

FOR THIS THERE NEEDS TO BE A SYSTEM OF PERIODIC INSPECTION SUCH THAT CONDITION OF “SEIRI SEITON SEISO” CAN BE MAINTAINED.

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EXAMPLES OF SEIKETSU ACTIVITY:

1. ALL EMPLOYEES COME UP WITH KAIZEN PROPOSALS MENTIONING WHO WILL DO WHAT BY WHEN.

2. LATER, THE RESULTS AFTER IMPLEMENTATION ARE WRITTEN.

3. EVERY THREE MONTHS, ALL EMPLOYEES OBSERVE THE PLANT/ OFFICE AND REPORT ABOUT UNNECESSARY THINGS, LACK OF PROPER MANAGEMENT, DANGEROUS PLACES, INSUFFICIENT 3S ETC

IN THIS WAY CONDITION OF “SEIRI SEITON SEISO” IS MAINTAINED.

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EXAMPLES OF SEIKETSU IMPLEMENTATION

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EXAMPLES OF SEIKETSU IMPLEMENTATION

BEFORE AFTER

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SHITSUKE

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SHITSUKE MEANS TO MAKE IT A HABIT TO DO THE DECIDED THINGS IN THE

DECIDED WAY

FOR THIS, YOU NEED TO CREATE A HABIT OF FOLLOWING COMPANY RULES SUCH

THAT “SEIRI SEITON SEISO SEIKETSU” CAN BE MAINTAINED.

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EFFECT OF 5S

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BEFORE AFTER

BEFORE-AFTER PHOTO OF 5S IMPLEMENTATION

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PHOTO OF 5S IMPLEMENTATION

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5S MINDSET

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IDENTIFY THE PROBLEM CONSEQUENCES SOLUTION IN THE FOLLOWING SITUATIONS

DEVELOP A 5S MINDSET

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SEIRI

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1. PROBLEM2. CONSEQUENCE3. SOLUTION

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SEITON

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SEISO

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SEIKETSU

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SHITSUKE

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training material on 5s

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