Tools Lean Production System 4 - 5S

TOOLS
5S
5S
THE SECRET TO
JAPANESE SUCCESS
5S
HOUSEKEEPING
TECHNIQUE
IDEA BEHIND 5S
 In order to achieve high levels of
quality, safety,and productivity,
workers must have a conducive
working environment
WHAT IS 5S?
 Developed by the Japanese
 Housekeeping System
 Helps Create a Better Working
Environment and a Consistently
High Quality Process
THE 5S PRINCIPLES
 SEIRI – Organisation/Sort out

 SEITON – Orderliness/Systemize
 SEISO – The Cleaning/Shining
 SEIKETSU – STANDARDIZE
 SHITSUKE - Sustain/Discipline
DISCOVERY OF 5S
 Thirty years ago researchers started

studying the secret of success of
Japanese manufacturing companies
 5S turned out to be the most

impressive "secret“
 The factories were so well organized

that abnormal situations were
readily apparent
DISCOVERY OF 5S
 Equipments were so clean and well

maintained that any problem such
as a loose bolt or leaking oil could
be easily seen
 This passion of cleanliness and

orderliness became a hallmark of
Japanese organizations
ADVANTAGES OF 5S
 If tools and materials are conveniently
located in uncluttered work areas
 Operators spend less time looking for

items
 This leads to higher workstation
efficiency, a fundamental goal in mass
production
ADVANTAGES OF 5S
 A clean and tidy workplace
leads to greater well being and
increased motivation
 Company image improves

ADVANTAGES OF 5S
 Results in a place easier to manage
 Smooth working no
obstruction
 No deviation, no problems
 B/c everyone knows where the

things are supposed to be
ADVANTAGES OF 5S
 Time saving
 Quick retrieval
 Accidents & mistakes
minimized
 Increases space
 Creates workplace ownership
ADVANTAGES OF 5S
 Visual management system
 Visual control to see the

abnormalities
 Simple signals that provide an
understanding of the condition(
normal/ abnormal)
 A look at the process reveals its
direction (right/wrong)
It’s the elimination of waste Everywhere –
while adding customer value…
It’s a mindset & commitment to

achieve a totally waste-free
operation that’s focused on your
customer’s success… achieved
by simplifying and continuously
improving all processes
METHODOLOGY
OF 5S
1. ORGANISATION(SEIRI)
 Decide what you need
 Remove unnecessary clutter
 All tools, gauges, materials, classified

and then stored
 Remove items which are broken,

unusable or only occasionally used
RED
TAG
RED TAG TECHNIQUE
 Give staff red labels

 Ask staff to go through every
item in the work place
 Ask if needed & those that are
needed,in what quantity
 Not needed red tag it
 Store in the red tag area
RED
TAG
For wavering items
 Place the suspected items in

the red tag area for one week
 Allow the staff to reevaluate
the needed items
 At the end of week those who
need items should be returned
ORGANISATION
PRIORITY FREQUENCY OF USE HOW TO USE

Low Less than once per year Throw away
Once per year Store away from
the workplace
Avg. Once per month Store together but

Once per week offline
High Once Per Day Locate at the

workplace
2. ORDERLINESS(SEITON)
 Once you have eliminated all

the unneeded items
 Now turn to the left over items

ORDERLINESS(SEITON)
Organise layout of tools and

equipment
–Designated locations
–Use tapes and labels
–Ensure everything is
available as it is needed
and at the “point of use”
ORDERLINESS(SEITON)
Workplace Checkpoints:-
 Positions of aisles and storage

places clearly marked?
 Tools classified and stored by
frequency of use?
 Pallets stacked correctly?
 Safety equipment easily accessible?
 Floors in good condition?
3. SEISO (CLEAN/SHINE)
 Create a spotless workplace
 Identify and eliminate causes of

dirt and grime – remove the
need to clean
 Sweep, dust, polish and paint

SEISO (CLEAN/SHINE)
 Divide areas into zones
 Define responsibilities for cleaning
 Tools and equipment must be owned

by an individual
 Focus on removing the need to clean

4. SEIKETSU (STANDARDISE)
 Generate a maintenance system for the

first three
 Develop procedures, schedules,
practices
 Continue to assess the use and disposal
of items
 Regularly audit using checklists and
measures of housekeeping
 Real challenge is to keep it clean
5. SHITSUKE (SUSTAIN / DISCIPLINE)
 Means inoculate courtesy & good habits
 Driving force behind all 5S
 Deming’s point number 1: Constancy of
purpose
 Make it a way of life
 Part of health and safety
 Involve the whole workforce
 Develop and keep good habits
LITMUS TEST FOR 5S
 30 SECOND RULE
 ONE MUST LOCATE THE ITEM WITH
IN 30 SECOND IF 5S IS PROPERLY
IMPLEMENTED
 ALSO APPLIES TO THE ELECTRONIC
RECORDS RETRIEVAL
WHAT U HAVE COME ACROSS
AT THE END OF DAY
Followings can be harnessed form

the 5S
1. NEAT & CLEAN WORKPLACE

2. SMOOTH WORKING
3. NO OBSTRUCTION (halangan)
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
Cont.
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME
SPACIOUS
Tugas (dikumpulkan H-1 Kuliah
berikutnya)
 Merencanakan proyek kecil di tempat

kerja : 5 S
– Pilih lokasi tempat kerja yang akan
menjadi obyek 5 S – foto kondisi before
– Jelaskan tahapan rencana yang akan
dilakukan untuk obyek tsb
– Implementasi dalam 2 minggu
– Evaluasi hasil implementasi : foto kondisi
after dan manfaat proyek

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TOOLS

 SEIRI – Organisation/Sort out

 Thirty years ago researchers started

 5S turned out to be the most

 The factories were so well organized

 Equipments were so clean and well

 This passion of cleanliness and

 Operators spend less time looking for

 Company image improves

 B/c everyone knows where the

 Visual control to see the

It’s a mindset & commitment to

 Remove unnecessary clutter

 All tools, gauges, materials, classified

 Remove items which are broken,

 Give staff red labels

For wavering items

 Place the suspected items in

PRIORITY FREQUENCY OF USE HOW TO USE

Avg. Once per month Store together but

High Once Per Day Locate at the

 Once you have eliminated all

 Now turn to the left over items

Organise layout of tools and

 Positions of aisles and storage

 Identify and eliminate causes of

 Sweep, dust, polish and paint

 Divide areas into zones

 Define responsibilities for cleaning

 Tools and equipment must be owned

 Focus on removing the need to clean

 Generate a maintenance system for the

Followings can be harnessed form

1. NEAT & CLEAN WORKPLACE

 Merencanakan proyek kecil di tempat

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