5 s methodology

1S - Seiri or Sort
2S - Seiton or Set In Order
3S - Seiso or Shiny Clean up
4S - Seiketsu or Standardize
5S - Shitsuke or Sustain

1. “5-S Methodology”

2. 5S is an approach originally developed in Japan for better house keeping. Now it is been utilized for keeping better work place.It includes 5 steps which are to be followed sequentially. Following Japanese terms collectively are as called 5S 1S - Seiri or Sort 2S - Seiton or Set In Order 3S - Seiso or Shiny Clean up 4S - Seiketsu or Standardize 5S - Shitsuke or Sustain By Implementing 5S one will get to know how cleanliness, orderliness, safety practises and better work environment results in increased free space, higher yield and transparency in work.

3. Requirements of 5S To implement 5S following are the requisites Consciousness for Strong determination Training Constant Efforts Ability to Judge what is important Attention to details Continuous implementation through total employee participation and better communication

4. 1 st ‘S’ – Seiri or Sort Step 1 : Tagging the following Not needed at all Needed But Not Now Needed But Not Here Needed But Not So Much Quantity Step 2 : Entry in Red tag Register Step 3 : Assign Red Tag area and dump the scrap It aims at taking out unnecessary items and dumping it into garbage( i.e Red Tagging)

5. Action during Seiri

6. Key Indicators Indicators of success Decrease in unnecessary items and reserved stocks Reduction in sq.ft area consumed Checklist – Do you find items scattered in your workplace? Are the boxes ,papers and other items left in a disorganized manner? Are there equipment and tools on the floor ? Are all items sorted out and placed in designated spots? Are tools and stationary properly sorted and stored ?

7. Result from Seiri Created free space

8. 2 nd ‘S’ – Seiton or Set In Order It aims at arranging the necessary items in proper order so that they can be easily picked up for use Steps for Seiton Systematic Arrangement is a form of standardization 3 Keys are the basic rules for Storage Fixing Position Fixing Quantity Signs for Storage of Work-in Progress

9. Systematic Arrangement KEYWORD 3 POINTS 3 KEYS - Anybody - Immediately Can see Can take out Can return Where ?.. Fix position What? …Fix items How many? Fix quantity 3 KEYS It answers the question What items are to be kept ,where and in how much quantity ?

10. Rules for Storage Search – Free Count – Free Air – Free Climb – Free Bend – Free First – In, First – Out Heavy/ Tall Things On Bottom Shelves Fast Moving Materials Close To Point-of-use/ Point-of-issue Adequate Lighting Adequate Ventilation

11. Street numbers Address of bin: A32=Block A, Street 3, House 2 House numbers Block tables Fixing Position

12. Tools For Eg . Colour coding for files/tools , tool organizer to organize tools, shelf colour/tagging etc. The purpose of 5S Seiton is to find a place for everything within your working area , everything should be located as close as possible to where it is needed and at a location that is both safe and easily reached Following are few eg .

13. Examples Before After

14. Seiton for Store Make your Store: Search free Air free Climb/Bend free Count free FIFO Warehouse is where material is dumped in any quantity. Store has Reserved Seats.

15. Two-Bin System Kanban card When bin is empty, card is placed here, to be picked up periodically by Purchase Seiton

16. Seiton Success Indicator Reduction in handling/searching time Checklist Are passage ways and storage places clearly indicated? Are commonly used tools and stationery separated from those seldom used? Are containers and boxes stacked up properly? Are fire extinguishers and hydrants readily accessible? Are there grooves, cracks or bumps on the floor which hinder work or safety?

17. 3 rd ‘S’- Seiso or Shiny Clean up 1/2 Clean your workplace so that there is no dust. In workplace, it becomes easy to trace leaks, cracks etc. This stage has two goals: Determine and gain agreement on the desired level of cleanliness Learn how to make new routines so this will become standardized (in the Seiketsu stage ) Several questions help this stage to be more than just "polish until it shines for inspection": How much cleanliness is required for safety, for ease of use, and to minimize equipment breakdown? How clean should the environment be for comfort and morale?

18. Seiso 2/2 How will cleanliness improve product quality ? While cleaning , do we notice maintenance issues that should be addressed ? Surroundings Equipment Storage Areas Cleaning Targets

19. Floors Work areas Aisles Walls Pillars Ceilings Windows Rooms Electric Lights Surroundings : What to Clean ?

20. Are there any unnecessary items around you ? Are all files & folders immediately accessible ? Is cleaning done every morning ? Is clearing up done every day after work ? Maintaining A Spotless Workplace

21. Example of ‘3S’ Factory Surroundings

22. FACTORY ENTRANCE SCRAP YARD Front area and Scrap yard are comparable

23. Seiton Indicators of Success Reduction in machine downtime Increased life of machine parts Reduction in number of accidents Reduction in rejection/rework Checklist Are the floor surfaces dirty ? Are machines and equipment dirty? Are wires and pipes dirty or stained? Are machine nozzles dirtied by lubricants and ink ? Are shades, light bulb and light reflectors dirty?

24. 4 th ‘S’- Seiketsu or Standardize This phase draws on the notes from the Seiso stage A practical target is to have all workers take five minutes every day to tidy up after themselves including the time to complete and sign the checklists By dividing the work among all the employees: No-one has a huge burden No-one seems unproductive Morale improves because everyone has a common purpose Supervisors should monitor compliance with Seiketsu . The checklists make this both important and achievable.

25. What Is To Be Standardised Workstation layout, work area layouts. Work in Process (WIP). Sequence of work. Cycle time of work . Material and tools used. Machines and their process parameters. Quality parameters, methods of measurement, reaction plan and reporting method. “ What, Where, When, Who & How ” of work .

26. Methodology to practice ‘4S’ Preparation of S.O.P. ( Standard Operating Procedure) for all the activities to be carried out to maintain 1S,2S, & 3S. Following areas shall be covered while preparing S.O.P. : Machine & Equipment maintenance. Manufacturing Processes maintenance. Work Place maintenance. Quality Standards and Procedures maintenance.

27. Seiketsu Indicators of Success Number of areas/cover made transparent Number of new problems exposed & solved Checklist Is the standardization system company-wide ? Is the setting, revision , and abolition of standards encouraged ? Have official procedures been laid down for setting, revising, and abolishing standards ? Is accumulation of technology promoted ? Are standards being utilized ? Are standards up to-date and capable of being put into practice

28. 5 th ‘S’- Shitsuke or Sustain 1/2 Clear deliverables & communication. Score Keeping Continuous improvement with cyclic mini-5S events. Tools: Training and Awareness of 5S Dedicated 5S team Clear 5S Map and Responsibilities/Ownership.

29. Shitsuke Indicators of success High Employee morale Involvement of people in the movement Checklist Are regular 5S checks conducted? Do people clean without reminder? Do people follow rules & instructions? Do people wear their uniforms & safety gear properly? Do people assemble on time?

30. THANK YOU 