CHP 6 FRSI 2043 5S

Welcome to the class….
Maintenance Technology
(FRSI 2043)
5S
5S IN MAINTENANCE
What is 5S and why do we want to do it?

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
DISCOVERY OF 5S
• 30 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
• Health and Safety is ensured

• Machine maintenance
• Quality
• Productivity
• Lean Manufacturing
ADVANTAGES OF 5S
• results in a place easier to manage
• smooth working no obstruction
• no deviation, no problems
• because everyone knows where the things

are spposedf to be
ADVANTAGES OF 5S
• TIME SAVING
• QUICK RETRIEVAL
• ACCIDENTS & MISTAKES MINIMIZED
• INCREASES SPACE
• CREATES WORKPLACE OWNERSHIP
ADVANTAGES OF 5S
• FOUNDATION OF ALL QC TOOLS
• CONTINUOUS QUALITY
IMPROVEMENT
• LEAN MANUFACTURING
• KINDERGARTEN OF QUALITY TOOLS
& TECHNIQUES
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)
METHODOLOGY
OF 5S
THE 5S PRINCIPLES
• SEIRI – Organisation/Sort out
• SEITON – Orderliness/Systemize
• SEISO – The Cleaning/Shining
• SEIKETSU – STANDARDIZE
• SHITSUKE - Sustain/Discipline
5S
1. Sort - All unneeded tools, parts and
supplies are removed from the area
2. Set in Order - A place for everything and
everything is in its place
3. Shine - The area is cleaned as the work
is performed
4. Standardize - Cleaning and identification methods are
consistently applied
5. Sustain - 5S is a habit and is continually
improved
Also - Work areas are safe and free of hazardous or dangerous

conditions
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
RED TAG TECHNIQUE TAG
• 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 re-evaluate 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: Consistentancy 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
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
Some 5S Examples
After 5S - Cleaned,
organized and drawers
Before 5S labeled (less time and
frustration hunting)
5S Examples - Sort, Set in Order
See the difference?

1. Sort - All unneeded tools, parts and supplies are removed
from the area
2. Set in Order - A place for everything and everything is
in its place
5S Examples - Shine
3. Shine - The area is cleaned as the work is performed

(best) and\or there is a routine to keep the work area
clean.
The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S
The Good

CHP 6 FRSI 2043 5S

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Welcome to the class….

What is 5S and why do we want to do it?

In order to achieve high levels of quality, safety and

• Equipments were so clean and well

• Operators spend less time looking for items

• Health and Safety is ensured

• because everyone knows where the things

• visual control to see the abnormalities

Also - Work areas are safe and free of hazardous or dangerous

• Remove unnecessary clutter

• All tools, gauges, materials, classified and then

• Remove items which are broken, unusable or only

• give staff red labels

Low Less than once per year Throw away

Avg. Once per month Store together but

High Once Per Day Locate at the

• once you have eliminated all the unneeded

• now turn to the left over items

Organise layout of tools and equipment

• Create a spotless workplace

• Identify and eliminate causes of dirt and

• 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

Followings can be harnessed form the 5S

See the difference?

3. Shine - The area is cleaned as the work is performed

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