5S Training and Implementation -General Notes

5S Training

1. Total Quality Management - Spring 2010 - IUG 1
Total Quality ManagementTotal Quality Management
Week # 11Week # 11
5S5S
Prepared by: Khalid DahleezPrepared by: Khalid Dahleez
Faculty of Commerce – the Islamic University of GazaFaculty of Commerce – the Islamic University of Gaza
This material was collected from different sourcesThis material was collected from different sources

2. Total Quality Management - Spring 2010 - IUG 2
WHAT IS 5S?
IN ORDER TO ACHIEVE HIGH LEVELS OF
QUALITY, SAFETY,AND PRODUCTIVITY,
WORKERS MUST HAVE A CONDUCIVE
WORKING ENVIRONMENT
Developed by the Japanese
Housekeeping System
Helps Create a Better Working Environment
and a Consistently High Quality Process

3. Total Quality Management - Spring 2010 - IUG 3
What is 5S?
An easy definition is: Finding a place for
everything and putting everything in its place .
5S is also the foundation for Continual Improvement
(CI) and Lean implementation.
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
It’s the elimination of waste Everywhere – while
adding customer value…

4. Total Quality Management - Spring 2010 - IUG 4
1. Sei-ri (Organization)
2. Sei-ton (Neatness)
3. Sei-so (Cleaning)
4. Sei-ke-tsu (Standardization)
5. Shi-tsu-ke (Self-discipline)
5S ONCSS
5S stands for 5 initials of the following
Japanese words:
3

5. Total Quality Management - Spring 2010 - IUG 5
THE 5S PRINCIPLES
SEIRI – Organisation/Sort out
SEITON – Orderliness/Systemize
SEISO – The Cleaning/Shining
SEIKETSU – STANDARDIZE
SHITSUKE - Sustain/Discipline

6. Total Quality Management - Spring 2010 - IUG 6
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
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

7. Total Quality Management - Spring 2010 - IUG 7
•Dictionary definition: To put things in
order (or organize them) according to
a specific rule or principle.
•Industrial definition: To distinguish between necessary things
and unnecessary things, and getting rid of what you do not
need.
Seiri = Organization (SORT)
means we remove all items from the workplace that are
not needed for current production (parts, tools,
equipment, etc).

8. Total Quality Management - Spring 2010 - IUG 8
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

Key Words:
1.Classification management ( Necessary &
unnecessary things)
2.Red tag movement
3.For unnecessary things, find their true
causes.

9. Total Quality Management - Spring 2010 - IUG 9
Why is my desk gettingWhy is my desk getting
messy? messy?
Necessary Unnecessary
Not necessary
now, but maybe
in the future
Every item on my desk belongs to the gray circle

10. Total Quality Management - Spring 2010 - IUG 10
Do you throw these things away?
It works!
It has a value!
It’s still new!
It’s usable!
It looks nice!
Not necessary
now, but maybe
in the future

11. Total Quality Management - Spring 2010 - IUG 11
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

12. Total Quality Management - Spring 2010 - IUG 12
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
RED
TAG

13. Total Quality Management - Spring 2010 - IUG 13
1. Eliminate defects and breakage
2. Organize the warehouse
Before After
T. Sugiyama “The 5S Approach to Improvement” PHP, 1995
Typical Seiri Activities

14. Total Quality Management - Spring 2010 - IUG 14
Dictionary definition: Establishing a neat layout so that you
can always get just as much of what you need when
you need it.
Industrial definition: It is a way of eliminating search.
Seiton = Neatness - Orderliness - Set in Order
ONCE YOU HAVE ELIMINATED ALL
THE UNNEEDED ITEMS
NOW TURN TO THE LEFT OVER
ITEMS

15. Total Quality Management - Spring 2010 - IUG 15
How long is your patience?
5 minutes? 2 minutes??
or
5 seconds???
Question When you ask someone to bring a hammer,
how long can you wait without getting mad?
Organise layout of tools and equipment:
1.Designated locations
2.Use tapes and labels
3.Ensure everything is available as it is needed and
at the “point of use”

16. Total Quality Management - Spring 2010 - IUG 16
30 Second Rule
Workplace Checkpoints:-
1.Positions of aisles and
storage places clearly
marked?
2.Tools classified and stored
by frequency of use?
3.Pallets stacked correctly?
4.Safety equipment easily
accessible?
5.Floors in good condition?

17. Total Quality Management - Spring 2010 - IUG 17
Key Words:
Design an efficient layout (Functional storage)
Eliminate search (Less search)
Everything should have a name.
(A place for everything and everything in its place)
Typical Seiton Activities:
Stripes on files
First in, first out
Easy to read notices
Key Words & Typical Activities

18. Total Quality Management - Spring 2010 - IUG 18
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
Definition: Eliminating trash, filth, and foreign
matters for a cleaner workplace. Cleaning as
a form of inspection.
•SHINE means we sweep floors, scrub machines, apply a
fresh coat of paint, and then we KEEP it that way. This
way, everything will be in top working condition so that it
may be used when it is needed.
•It also means preventive maintenance.

19. Total Quality Management - Spring 2010 - IUG 19
Keep things clean + Inspection
(Caring attitude)
Key Words:
1.Divide areas into zones
2.Define responsibilities for cleaning
3.Tools and equipment must be owned by
an individual
4.Focus on removing the need to clean

20. Total Quality Management - Spring 2010 - IUG 20
Sanitation engineers
Laundry
Dry cleaner
Janitor
Garbage collector
Pollution control operator
Clean-room designer
One-third (1/3) or one-fourth (1/4) of the total
investment amount is used for cleanliness.
Cleanliness is a big business today.

21. Total Quality Management - Spring 2010 - IUG 21
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

22. Total Quality Management - Spring 2010 - IUG 22
Definition:
Keeping things organized, neat,
and clean, even in personal and
environment aspects.
Seiketsu = Standardization
SEIRI SEITON
SEISO

23. Total Quality Management - Spring 2010 - IUG 23
Ideal State Current State
GAP
Seiketsu = Standardization
1.Define an ideal state
2.Standardize the solution (5S standardization)

24. Total Quality Management - Spring 2010 - IUG 24
1. Make quality manual
2. Directional markings
3. Color-coded pipes
Typical Seiketsu Activities
•STANDARDIZATION happens when the first three S’s
are properly implemented and maintained.
•It means that racking, paint colors, labeling, operational
layouts are designed in a standard fashion.
•Everything will be in place so everyone will know exactly
what they are responsible for; and, exactly when, where,
and, how to do it.

25. Total Quality Management - Spring 2010 - IUG 25
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

26. Total Quality Management - Spring 2010 - IUG 26
Definition:
Doing the right things
as a matter of course.
Shitsuke = Self-discipline
We SORT areas. We SET IN ORDER work places. We
SHINE areas. With STANDARDIZATION it is easy to
identify anything out of place.
SUSTAIN is different: It isn’t a single separate activity; We
SUSTAIN when we have developed habits of always using
the first 4 S’s together on a daily basis.

27. Total Quality Management - Spring 2010 - IUG 27
1.Habit formation (Make it a habit)
2. Create a disciplined workplace
Key Words & Typical Activities
1. Wear your safety shoes
2. Exercise time
3. No smoking at workplace
Typical Shitsuke Activities

28. Total Quality Management - Spring 2010 - IUG 28
WHAT U HAVE COME ACROSS
Followings can be harnessed form the 5S
1.NEAT & CLEAN WORKPLACE
2.SMOOTH WORKING
3.NO OBSTRUCTION
4.SAFETY INCREASES
5.PRODUCTIVITY IMPROVES
6.QUALITY IMPROVES
7.WASTAGE DECREASE
8.MACHINE MAINTENANCE
9.VISUAL CONTROL SYSTEM
10.EMPLOYEES MOTIVATED
11.WORKSTATIONS BECOME SPACIOUS

29. Total Quality Management - Spring 2010 - IUG 29
Sort
Clear out rarely used
Items by Red Tagging
Straighten
Organize and Label a
Place for Everything
Shine
Clean It Standardise
Create Rules to Sustain
the first 3 5’S
Sustain
Use Regular Management
Audits to Stay Disciplined Eliminate
Waste
5 S’s

30. Total Quality Management - Spring 2010 - IUG 30
When Does 5S Happen?
ALL THE TIME!! 5S is a mindset and a
culture. The 5S’s are a part of each
Associate’s workday. There will also
be CI Events and WPO (WorkPlace
Organization) Events. In an Event,
Associates are taught how to
implement the principles of Continual
Improvement.

31. Total Quality Management - Spring 2010 - IUG 31
How is 5S Implemented?
By the associates! Who has a better idea
to make our jobs easier than us? Our
management is committed to improving
how we work.
We want to work smarter, not harder.
Along the way, support will come from
EVERYONE.
We will teach the 5S process, and together
we will implement it and make it work.

32. Total Quality Management - Spring 2010 - IUG 32
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
A clean and tidy workplace leads to greater well being
and increased motivation
Company image improves

33. Total Quality Management - Spring 2010 - IUG 33
ADVANTAGES OF 5S
Health and Safety is ensured
Machine maintenance
Quality
Productivity
Lean Manufacturing
TIME SAVING
QUICK RETRIEVAL
ACCIDENTS & MISTAKES MINIMIZED
INCREASES SPACE
CREATES WORKPLACE OWNERSHIP

34. Total Quality Management - Spring 2010 - IUG 34
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 SPPOSEDF TO BE

35. Total Quality Management - Spring 2010 - IUG 35
ADVANTAGES OF 5S
FOUNDATION OF ALL QC TOOLS
CONTINUOUS QUALITY
IMPROVEMENT
LEAN MANUFACTURING
KINDERGARTEN OF QUALITY TOOLS
& TECHNIQUES

36. Total Quality Management - Spring 2010 - IUG 36
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)