Introduction To 5S
Introduction To 5S
Introduction To 5S
Contents
1. What is 5S?
2. Planning Stage
3. Implementing Stage
4. Sustaining Stage
01-2
How mess occurs at workplace?
01-3
Why it is important
5S Eliminate Transportation
7 Waste
Inventory Waiting
Correction
Over Processed
01-4
5S Benefits to YOU
01-5
01-6
What is 5S ?
1. Sort Seiri
2. Set-In-Order Seiton
3. Shine Seisou
4. Standardize Seiketsu
5. Sustain Shitsuke
7
What is 5S ?
1. Sort
Remove all items from the workplace that are not
needed for current production or administrative
operation.
“only what is needed, only in the
Keep
8
What is 5S ?
01-9
What is 5S ?
2. Set-In-Order
Arranging needed items in the way easy to use and
so that easy to find and put away(visual
management)
10
What is 5S ?
Set in order
Arrange needed items so;
it is easy to use.
label them so that anyone can find them easily and put th
em agin.
Set-in-order is important because it eliminates;
Time spent searching for an item
Motion wastes
Difficulty returning item to its original place
Excess inventory
Reduce damage
safety
01-11
What is 5S ?
1. Visual Control
2. Motion Economy
01-12
What is 5S ?
01-13
What is 5S ?
01-14
What is 5S ?
1. Signboard strategy
signboards are used to identify what, where a
nd how many
There are three types of signboards
Location indicator
Item indicator
Amount indicator
What is 5S ?
2. Painting strategy
Is a method for identifying locations on floors
and walk ways
01-16
Cont,d
01-17
What is 5S ?
3. Color-Coding strategy
01-18
What is 5S ?
4. Outlining strategy
01-19
What is 5s?
5. Visual Management Board (Kaizen bo
ard) Strategy
Kaizen Board
Standard size 2 times flipchart paper
01-20
What is 5S ?
01-21
What is 5S ?
01-22
What is 5S ?
01-23
What is 5S ?
3. Shine Seisou
24
What is 5S ?
What is Shine
Page 25 of 65
What is 5S ?
Page 26 of 65
TAKE FIVE
Take five minutes to think about the following qu
estion & to jot down your answer.
01-27
What is 5S ?
4. Standardize Seiketsu
28
What is 5S ?
What is Standardize
Standardize is the method you use to maintain the
first three pillars (Sort, Set in order and Shine)
Make it a rule to perform given work in the given
manner.
Standardize is different from the first three pillars b
ecause it is a method used to sustain the first three
pillars rather than housekeeping activity.
What is 5S ?
Benefits from Standardize
The basic purposes are to;
1. Lead to workplace standardization
prevent setbacks in the first three pillars
Make implementing them a daily habit
Ensure that all the three pillars are maintained in t
heir fully implemented state.
2. Lead to work standardization
Muda elimination
Quality improvements
Cost reduction
Delivery time improvements
Process improvements
What is 5S ?
5. Sustain Shitsuke
What is next ?
Planning Stage
1. 5S Organizational Structure
Chairman
5S Promotion Office
company level.
Follow up standardize 5S activities at the
company.
Perform any other 5S related activities.
Organize &Training
Planning Stage
39
Planning Stage
Limiting
Company
to Shop
-wide
Limiting to
Selecting Production
model shop Division
Limiting
to group Others
Variety of Alternatives
40
Planning Stage
Block B Block C
Block D
Block E
Block F
Planning Stage
4. Goal setting
1
Recognition
5S
Of
Of current 22
Committee
condition
Evaluation
Evaluation
33
Setting goal 4
Post
Planning Stage
Sort Activity Plan Sheet (Sample)
01-43
Planning Stage
01-44
Planning Stage
2) Setup of activity time
In case of 5S activity on Sustaining Stage (e.g. Cleaning)
3) Training plan
5S Committee
46
Planning Stage
6. Budgeting
It is necessary to prepare a budget for 5S activity because
it costs money.
Planning Stage
7. Kick-off (Declaration of 5S activity)
Kick-off
Explain
Declare
the activity
the policy
Implementation Stage
Implementing So
rt Activity
01-49
Implementation Stage
Procedure For Sort Activity
Preparation
Set-In-Order activity
Implementation Stage
Implementing Se
t-In-Order Activit
y
01-51
Implementation Stage
Procedure For Set-In-Order Activity
Set targets for Set-In-Order Activity
Implementation of Set-In-Order
52
Implementation Stage
Implementing Sh
ine Activity
01-53
Implementation Stage
Start to shine
54
Implementation Stage
Implementing St
andardize Activi
ty
01-55
Implementation Stage
It is all about
“Make up the rules and follow them!”
01-56
Implementation Stage
01-58
Implementation Stage
Standards for Shine
Clean and Inspect (C&I)
Show the task, person responsible, items
needed, frequency, desired workplace
Where to keep cleaning supplies,
how to replenish when finished
more…
01-59
Implementation Stage
Implementing Su
stain Activity
01-60
Let’s sustain the gains !
The Questions Is
“How to Sustain ?
61
Let’s sustain the gains !
1. Patrolling
a. Top management Patrol
Must
Check Up the activities Comprehensively
Give emphasis on sustaining of the activity
consider committees feedback
62
Let’s sustain the gains !
63
Let’s sustain the gains !
64
Let’s sustain the gains !
c. Mutual patrol
Check mutually among 5S groups
d. Self patrol
5S leader and members check the results of activity b
y themselves.
e. Checklist patrol
Point out the problems by themselves at site as well a
s evaluate the results and encourage members to urge K
AIZEN.
f. Camera patrol
Visibly highlight the problems and progress of the activity
using photographs.
65
2. Use Slogan and Poster of 5S Activity
It encourage all the participants.
< Samples of slogan >
“Refresh yourself and workplaces by 5S activity.”
01-66
< Sample of poster >
01-67
Let’s sustain the gains !
3. Awarding System
01-69
Thank
K
I
You
E
01-70
* Sort-Red Tag
1. Sort activity No.
Red Tag
Red Tag Sample Name of applicant: Date
Name of item: Quantity:
Part No.:
Location:
Classification
□1.Material □2. Part □3. Inventory in-process □4.Product
□5.Equipment/facilities □6.Cutting tool □7.Jig □8.Fixing
□9.Others
71
* Sort-Red Tag
Front Back
01-72
* Sort-Red Tag
Obsolete
equipment
Unused machinery
or equipment
Doubtful item
01-74
* Sort-Red Tag
A B
Disposal of unnecessary items
Office Storage
Holding Area
75
* Sort-Planning Stage
1. 5S organization structure
2. Recognition of current condition
3. Activity range
4. Goal setting
5. Planning stage
6. Budgeting
7. Kick-off
76
* Sort-Evaluation of unnecessary items
01-77
* Sort-Stock List
01-78
*Sort-Red Tag
01-79
*Set-In-Order - Decision of location and method
01-80
*Set-In-Order - Decision of location and method
Temporary
Storage
81
*Set-In-Order - Decision of location and storage method
01-82
*Set-In-Order - Decision of location and storage method
01-83
*Set-In-Order -Decision of display method
There are two types of indication.
Indication by classification
Indication by location [Process, Production line, Partition]
Indication by classification Indication by location
Spanner
Spanner
Scissors
Pincher
Pliers
Cart Cart
Common tools
01-84
*Set-In-Order -Decision of display method
Example ..
01-85
*Set-In-Order -Decision of display method
Standards for indication of fixed position
01-86
*Set-In-Order -Decision of display method
Example ...
fixed position Indications
01-87
*Set-In-Order -Decision of display method
Example ...
A1 A2 A3 A4 A5 A6 A7
A1 A2 A3 A4 A5 A6 A7
B1 B2 B3 B4 B5 B6 B7
B1 B2 B3 B4 B5 B6 B7
C1 C2 C3 C4 C5 C6 C7
C1 C2 C3 C4 C5 C6 C7
01-88
*Set-In-Order -Decision of display method
Indication of pathways
01-89
*Set-In-Order – Preparation Of Tools
90
**Determine shine assignments
5S assignment map. (Layout chart)
1. Demarcation for each teams
2. Who is responsible for each block
Sample
Production
Block A
RM
Material Finished
Machining Packing
Block
Block Block Block B YYYY
Painting
Goods
Block
Block A
Production
Carrying-in
Block B
route for
materials YYYY
Maintenance Stock Room
Sales Block Warehouse XXXX Shipping
Machining Block
Block B
Block&
Admin. Block 1
Block
Rest Room
Accounting
Block Production
Block
**Determine shine assignments
01-92
**Determine shine assignments
Ex shine schedule
Minor operation
Daily cleaning 5 – 10 min. before/after working hour Team A, Team B
at each shop
01-94
** Determine shine methods
Developing Inspecting methods
(How and When)
Visual sense
Tactile sense
• dirt • Heat
• Breakage • Overcooling
• Missing parts • Bolt/nut loosening
• Oil leakage
• Water leakage
01-95
** Start to shine
Example
01-96
** Start to shine
97
01-98
1