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5S

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Pyramid Quality Systems

Welcomes You

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5S

5S
(House Keeping)

Date :
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5S
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P Y R A M I D

 What is 5s?
5S is a Japanese word meaning Housekeeping.
5S is a basic technique to enhance the workplace
appearance and give a pleasant work environment.
5S is a methodology for organizing, cleaning,
developing, and sustaining a productive work
environment.   

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5S

 What is 5s?
5S is a group activity performing:

1. Seiri Clearing up, sorting

2. Seiton Organizing

3. Seiso Cleaning

4. Seiketsu Standardizing

5. Shitsuke Training and discipline

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 5S
 What is 5s?
QS
P Y R A M I D

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Need for 5S
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P Y R A M I D

Most of the organizations are in the following condition :

Space is crowded with parts and tools

Lot of time in searching things

Unwanted items are stacked between workers

Excess inventory on the floor

Excess items and machines make it difficult to improve

process flow
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Need for 5S
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P Y R A M I D

Equipment is dirty and a collection point for

miscellaneous materials

Needed equipment such as tools are difficult to find

Cleaning the factory before customer visits

Not able to get what we want when it is required

These are symptoms that your workplace may be, in need

of a 5S Program.

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5S

Requirements to implement 5S
Total Employee Involvement
Management Commitment
Developing Self directed employees
Team based activity

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How to Start 5S

Conduct an initial meeting and tell your employees about

starting of 5S Program & get feedback of their
cooperation
Entire Organization should be divided into different
Zones (eg, Raw Material area, Shop Floor, Inspection,
Office, Welding, Press Shop etc.,)
( Click here for Example)
Appoint Zone leaders for all zones. Zone leader should
have work experience & he should have the ability to
guide and control the employees who are all under him.
Draw Zone Map for all Zones & Display it in the
respective Zone.
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How to Start
Take photos of present level (Before Implementing 5S)
(Click here for Example)
Provide 5S photo board for each zone and display all
the before photos. (Click here for Example)
All Employees should be included in 5S Zone
Create 5S Corner – Display 5S Posters, 5S
Organization chart, 5S photo board, 5S improvements
chart etc., in the 5S Corner
Make 5S Organization chart and display it in the 5S
Corner
Implement 1S, 2S & 3S first.
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1S – SEIRI (Clearing)
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SEIRI is distinguishing or sorting out between wanted and

unwanted items in a place and removal of the unwanted.
Implementation Steps
Take Before Photos

SEIRI …
Segregate wanted & unwanted materials in all Zones
Unwanted Items – Examples
Factory : Office : Home :
a. Scrap Machines a. Useless Papers / Files a. Broken Toys
b. Rejected Materials b. Broken Pens b. Old Clothes
c. Expired Goods c. Old Diaries c. Broken Suitcases
d. Broken Tools, Pallets, bins d. Broken Furniture d. Old Packing Cases
e. Old Notices e. Old Notices
f. Waste Materials
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SEIRI …
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Usage Storage Storage

SEIRI …
Item
Pattern Location Area

Every Day Closer Resale Disposal Yard

Once in a Week Little Far Scrap Scrap Yard

Waste Sent out
Sometime Separate (No Value) Immediately
Required Storage
Area Useful to
Red Tag Area
some others
Repair/ Maintenance
Rework Area 13
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Create a Red Tag Area & Red Tag

YOUR COMPANY NAME
RED TAG
STATUS
SURPLUS RESALE
REJECTED SCRAP

SEIRI …
REPAIR WASTE (NO VALUE)
RE USE NOT KNOWN
Red Tag USE FULL OTHERS MATERIAL
MOVE TO
STORE MAINTENANCE
DISPOSAL YARD WASTE AREA
SCRAP YARD RED TAG AREA

DEPT. ACTION TAKEN Regn. No.

TAG BY --------------------- BY ------------
DATE --------------------- DATE --------

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Put Red Tag for Unwanted items and move as per 5S
instruction of Red Tag.
Photos to be taken every time at
a. Same Direction
b. Same Height

SEIRI …
c. Same Camera
d. Fixed Position
Register red Tag & record Disposal Plan.
Should not have Sentimental attachments to any items
Do not keep them with a vague idea that they may be
needed one day. Be ruthless about throwing unnecessary
things away.
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Example:-
Decide: whether to remove the extension portion of office desk.

Example:-

SEIRI …
In a shop floor, instead of installing a working desk per supervisor, we
can have this shared working desk concept: This will save working
space and encourage direct visit to actual shop floor.

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Before 5S

Unused, Useless items has

to be removed from
workplace;
Make the storage standard
Neat

SEIRI …
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Benefits

Getting more Space

Get to know the availability of wanted items
immediately

SEIRI …
Easy access to things
Required materials are located easily
Better Working environment
Improved Safety
Cost recovery by periodic disposal, which can be used
for other developmental activities.
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2S - SEITON (Organizing)
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A Place for everything and everything in its place

Implementation Steps

Identify all materials by Name/Number/Colour code

SEITON …
etc.,
Design a suitable storage place / parking slots and fix
the place for storing each item depending on the
frequency of usage
Establish a method of storage for each item which is
easy to see, pick and place with X,Y alignment.
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Implementation Steps

Identify all the activity area from security to scrap

yard by identification boards.
Mark the gangways, parking slots, do not store area,

SEITON …
Furniture / equipments location marks in the floor.
Identify all the machines, equipments, computers &
Accessories, Lights, fans, Switches, cables, Pipe lines,
Storage Cabins, Racks etc.,
Make storage more transparent & with visual controls.
Establish storage procedures & Display instructions.
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Y R A M I D Before Examples After 5S

SEITON …
Cleaning equipments lying at a
corner in the work place

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Examples 5S

SEITON …
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Examples
Factory :

SEITON …
Office : Home :
a. Layout disorganized a. File cabinets a. Cluttered drawers,
unlabelled cupboards, book
b. Cables, Pipes in
cases
disarray b. Cluttered drawers,
shelves, book cases, b. Kitchen things in
c. Tools, bits heaped in
tables disarray
shelves
c. Records and
d. Stores location system
documents not
unclear
arranged well
e. Things lying on the
d. File heaps and
floor
papers all over

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SEITON …
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SEITON …
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Benefits

Time saved in searching & retrieval of items.

Movement of Material & Man for different activity

SEITON …
minimized
Easy to identify when materials are taken out from
their location
Safety in handling etc.,

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3S – SEISO (Cleaning)
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Sweep your workplace thoroughly so that there is no

dust anywhere.
Implementation Steps
Prepare Cleaning schedule for all Zones covering

SEISO …
a. Where to clean - Area
b. What to clean - Item
c. When to clean - Frequency
d. Who has to clean - Responsibility
e. How to clean - Method & Cleaning tool or
Kit.
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Implementation Steps

Give the responsibility to individual to clean their

working area, equipment etc.

SEISO …
Shortest route for collecting waste in different place to
be identified and a route map to be prepared and given
to the person concerned.
Painting schedules to be made to all machines,
equipments and areas.

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Cleaning Schedule
P Y R A M I D

X
Cleaning Schedule

Zone Nam e : Month :

Zone Leader :

S.
Cleaning Area Frequency Method Who 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
No.
Concerned
Machines Daily Cotton was te
operator

Floor Daily Broom Helper

Roof Once in a week Broom Helper

SEISO …
Windows Once in 2 days Cotton was te Helper

Tools Rack Once in a week Cotton was te Operator

Sign

 Indicates cleaning com pleted

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Benefits

Good, neat and clean working place

During cleaning you can identify the causes of

SEISO …
leakages, strain, dirt and defects.
Hygiene and pleasant place keeps the people more
healthy.
Extends machine and equipment life.
The company gets appreciation from the users /
Consumers.

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4S – SEIKETSU (Standardizing)
Standardizing all the 5S activities throughout the
organization
Implementation Steps
List out the various activities of 5S.

SEIKETSU …
Follow the guidelines for floor marking through out
the organization.
The Following things to be standardized:
1) Company Colour
2) Switch / Machine / Fan
3) Machine I.D
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4) Areas & Buildings Name 17) Light I.D

5S
5) Fire Warning 18) Parking/No Parking Area
6) Name Board 19) Rooms & Cabins
7) Personal Name Board 20) Floor Marking
8) Emergency/Exit 21) Valve Control Direction

SEIKETSU …
9) Pipe Line I.D / Colour 22) Danger/Voltage labels
10) Warning Signals 23) Do’s/Do not
11) Instrument I.D 24) Electric / Telephone
12) Computer Cable I.D 25) Direction boards
13) Letter Colour 26) Letter Size
14) Checklist Format 27) Audit Format
15) Equipment Details 28) Dept. File I.D
16) Street Sign board
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Examples 5S

SEIKETSU …
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Colour Coding 5S

S.
Area Colour Type Size
No.
Roads, Corridor, Aisle and Work
1 Yellow Solid 10 cm
areas
2 Dividing Lines of Dept/Section Yellow Solid 10 cm
3 Traffic Flow Lines Yellow Arrows 5 cm

SEIKETSU …
4 Work in progress areas Yellow Solid 5 cm
5 Door openings / Exit & Entrance Yellow Broken 5 cm
6 Steps - Front face Yellow & Black Stripes 5 cm
Moving Trolleys, cranes - Front & Rear
7 Yellow & Black Stripes 7.5 cm
Face
5 cm leaving 10
Work Bench, Table, Racks, Stands,
8 Yellow Corner lines mm gap to
Dustbins
length of the leg.
Parking slot for vehicles, Forklift,
9 Sky Blue & White Stripes 5 cm
Trolleys & all mobile equipments.
Control Panels, Fire hose,
10 Extinguishers, Emergency exits and Red & White Stripes 5 cm
all hazardous areas

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Implementation Steps 5S
Painting to the floor
Different colours to be used for floor depending
upon the function.
Light Colours in the relaxing areas.

SEIKETSU …
Maintenance of 1S,2S & 3S.
Pictorial Instructions should be provided regarding
5S, Safety, DOs & Don'ts etc.,
Plants & Flower Pots to be provided in the
reception, entrance, relaxing places etc.,
Direction boards to be provided wherever
applicable.
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SEIKETSU …
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SEIKETSU …
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SEIKETSU …
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Benefits

Neat & Nice Working area

Employees, Visitors, Customers can identify the

SEIKETSU …
areas, equipments and do the activities without
asking others
Saves time in locating the areas and equipments
Better visual control for all the activity
Any Non conformance in following the system can
be easily identified.

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5S – SHITSUKE (Training & Discipline)

Measure, Maintain & Continuously improve the 5S

activities.

Implementation Steps

SHITSUKE …
5S Chairman & Zone leaders should monitor all the
5S activities continuously
Create work discipline with the help of employees
working in the particular area and to suit the
requirement.

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Implementation Steps

Create a Suggestion Form and circulate it to all

zones. All suggestions to be obtained through this
form & it is to be approved for implementation.

SHITSUKE …
Award for best suggestions every month.
5S Audit checklist to be prepared for all zones &
displayed in the respective zones.
5S Champion should do Audit periodically as per
the checklist & Suggestions to be given for
improvement.

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Implementation Steps 5S

Introduce score board & Trend chart in all level.

Analyze Audit report, identify slow runners,
organize for training, list out the audit findings, take
suitable action, check for the completion of the

SHITSUKE …
action.
If you are recruiting anybody, he/she undergo 5S
Training first and then he/she should enter his/her
regular work.

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Suggestion Form 5S
X
Suggestion Form
Employee Name : Date :
Zone Name : Sug. No. :

Idea Suggested :

SHITSUKE …
Benefits :

Estimated Cost :

Signature of Employee
Reviewed by :
Status : Approved / Not Approved
Reward : Recommended / Not Recommended
Signature of Reviewed person
Implementated date & details :

Benefits achieved :

Signature of Benefited Person

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5S Check List
Office
Rating ( 1 to 10 Scale ) Suggestions
5S
Month : Week :
1. Disposal of unwanted Papers, Materials
2. Disposal of Broken Furnitures and any unused items
SEIRI
3. Disposal of Outdated Notices from Display Board
4. Disposal of Obsolete documents / Files
1. Notice Board at easy location to see/Read
2. Even Floor, No Damage, Crack in the walls
3. All Items,Files are arranged in necessary racks and identified
SEITON
4. Computers, Tables, Chairs are well arranged for easy movement

SHITSUKE …
5. Rare using Items are arranged in back.
6. Frequently using items are arranged as easy as to use.
1. Dirt free Lights, Walls, Tables, Chairs, Computers, Glasses, files etc.,
SEISO 2. Cleaning of Floor
3. Clear responsibilities assigned to all persons
1. Adequate light, Ventilation, Safety items are Provided
SEIKETSO 2. No Leakage of Electricity and Water
3. Maintenance of 1S, 2S, 3S.
1. Punctuality
SHITSUKE 2. Make Procedures a habit
3. No wastage of work time in private Conversation
Total
Scale/ Marks Selection Criteria
1 Awareness totally absent
Poor ( Concern )
2 Partial Awareness
3 No Control on disposition. No Procedure available Not Satisfactory
4 Procedure available not followed ( Must Improve )
5 There is a Scope for Improvement
Satisfactory
6 To be sustained
7 Just meets the requirements Good
8 Can improve further ( Keep it up further )

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9 Very good Very good
( Sustain & Improve )
Checked by 44
10 Excellent
 PYRAMID QUALITY SYSTEMS
5S
Rating ( 1 to 10 Scale ) Suggestions
5S Check List
QS Production Area
P Y R A M I D

Month : Week :
1. Disposal of unwanted Tools, Materials, Burrs, Clothes etc
2. Disposal of Broken tools and Broken machine parts
SEIRI
3. Disposal of Scraps
4. Disposal of Unwanted wires, expired items.
1. Arrangement of Cutting tools in a separate area and identification
2. Arrangement of Raw Materials in a specified area and identification
3. Arrangement of Maintenance tools in a easy handling area
4. Arrangement of Finished and work in process products in the specified area
and Identification with tags
SEITON 5. Rare using Items are arranged in back.
6. Frequently using items are arranged as easy as to use.
7. Arrangement of Measuring Equipments

SHITSUKE …
8. Arrangement of Safety items and clothes
9. Arrangement of Machine Parts
10. Cables, Pipes in disarray
1. Dirt free Lights, Walls, Tables, Chairs, Glasses, files etc.,
2. Cleaning of Floor
SEISO 3. Clear responsibilities assigned to all persons
4. Cleaning of Machines
5. Cleaning of Measuring Equipments, Tools, Jobs, Safety items.
1. Adequate light, Ventilation, Safety items are Provided
2. No Leakage of Electricity and Water
3. Maintenance of 1S, 2S, 3S.
SEIKETSO
4. Location of Materials, Jobs, Tools in the Identified area
5. Handling of Hazardous Chemicals
6. Toilets not disinfected
1. Punctuality
2. Make Procedures a habit
SHITSUKE
3. No wastage of work time in private Conversation
4. Team Work
Total
Scale/ Marks Selection Criteria
1 Awareness totally absent
Poor ( Concern )
2 Partial Awareness
3 No Control on disposition. No Procedure available Not Satisfactory
4 Procedure available not followed ( Must Improve )
5 There is a Scope for Improvement
Satisfactory
6 To be sustained
7 Just meets the requirements Good
8 Can improve further ( Keep it up further )

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9 Very good Very good
Checked by 45
10 Excellent ( Sustain & Improve )
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Benefits

Easy Identification of Mistakes

Organization wide success in implementation,
sustaining and continuous improvement.

SHITSUKE …
All the peoples are motivated to continue the 5S
Journey.
Recognized individual/Zone/Zone leaders by
displaying the photos, results in the 5S corner make
them more involved.
Develops Teamwork

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5S CLIPPINGS

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5S Organization Chart
P Y R A M I D

5S Champion

5S

Mr. K.Sakthi Manikandan

Zone – 1 Zone – 2 Zone – 3 Zone – 4 Zone – 5

Office Stores Shop - 1 Shop - 2 WIP Stores

Mr. M.Kannan Mr. G.Mahendran Mr. R.Mohan Raj Mr. G.Ramesh

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5S Corner
P Y R A M I D

5S Photo
Board

5S Posters &
Company
PQCDMS Profile
Board

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5S Photo Board
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5S Photo Board

Zone : Stores Zone : Shop Floor Zone : Press Area

Before After Before After Before After

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Before After 5S

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Y R A M I D Zone Name : Stores 5S
5S Improvements
Before After

After After After

Benefits :
Searching & handling time reduced from 35 sec to 10 sec (25 sec saved) due to Spares Rack &
Finished Product Stores Arrangement
Employees Facility Improved
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5S Audit Board

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Pyramid Quality Systems

Thank you

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