The Secret To: Japanese Success

5S
THE SECRET TO
JAPANESE SUCCESS
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
ADVANTAGES OF 5S
 TIME SAVING
 QUICK RETRIEVAL
 ACCIDENTS & MISTAKES
MINIMIZED
 INCREASES SPACE
THE 5S PRINCIPLES
 SEIRI – Organisation/Sort out
 SEITON – Orderliness/Systemize
 SEISO – The Cleaning/Shining
 SEIKETSU – STANDARDIZE
 SHITSUKE - Sustain/Discipline
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 Throw away

year Store away
Once per year from the
workplace
Avg. Once per month Store together
Once per week but 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?
 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)
 Driving force behind all 5S

 Make it a way of life
 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
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
 Safety: This component of 7S simply
requires attention to safety throughout the
other steps. It is particularly prominent in
manufacturing and laboratory settings, and
in other contexts where potentially
dangerous equipment or substances may be
involved, and less prominent in office
settings.
 Spirit: As leaders understand the impact
of company culture and the importance of
respect for employees, the need for this
additional component becomes clear.
While some organizations successfully
implement the traditional 5S method,
many are choosing to add Spirit as an
additional piece to make explicit the
reliance on the people factor and the need
to continually keep it in mind as other
steps are undertaken.

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5S

 IN ORDER TO ACHIEVE HIGH

 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

Low Less than once per Throw away

High Once Per Day Locate at the

 ONCE YOU HAVE ELIMINATED ALL

 NOW TURN TO THE LEFT OVER

Organise layout of tools and

 Identify and eliminate causes of

 Sweep, dust, polish and paint

 Divide areas into zones

 Define responsibilities for cleaning

 Tools and equipment must be owned by

 Focus on removing the need to clean

 Generate a maintenance system for the

 Driving force behind all 5S

Followings can be harnessed form the

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