5 ‘S ’

•Total Quality remains incomplete unless suitable Environment for creation & sustenance of Quality is provided.

• Much importance not for good

housekeeping . 1

What is 5 ‘ S ’

• Many have confused 5 ‘ S ’ with

cleanliness .

• A systematic approach leading to a

Cleaner, Safer & Better workplace which

is fundamental to Productivity & Quality is

known as 5 ‘S ’ & pioneered by Toyota

Motors in early 80’s and created super

Quality of workplace 2

5 ‘S ’ refers to the first alphabet of

five Japanese words for 5

different components JAPANESE ENGLISH

SEIRI SORTING

SEITON SYSTEMATISING

SEISO SWEEPING

SEIKETSU SANITISING

SHITSUKE SELFDISCIPLINE3

5 ‘S ’ is systematic participation programme for improving the workplace environment which is base of continual improvement in the organisation

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SHITSUKOKU STICKINGLY

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•Quality Improvement

•Accident prevention's

•Pollution prevention's

•Productivity improvement

•Cost and down time reduction

•Creativity improvement

Main objectives of 5 ‘S ’

•5S concept is itself not a theory but a very powerful tool when every employees from top to workers should participate

• It is management barometer , if you can do 5S you can do anything,

•The company is doing badly is doing its. 5S badly

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1. SORTING ( SEIRI )

MEANING

Distinguishing between the necessary & the unnecessary and getting rid of the unnecessary.

PRINCIPLES

Stratification Management ( Entailing value

judgement & creating strata of importance )7

TYPICAL ACTIVITIES (SEIRI )

• Identify the unnecessary

IN & OF

Shelves, lockers , drawers , Racks, Passageways, Corners, Floors , Pits, Partition, storehouse ,sheds, Walls , Bulletin board, Tools, Measuring devices , Spares ,Small items, Consumables,wires,ducts, oils ,etc.

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•Throw out the things not needed.

•Through house cleaning.

•Deal with the causes of dirt & leaks.

•Treat defects & breakage.

•Organise the warehouse .

•Eliminate grime & burrs . 9

2.SYSTEMATISING(SEITON )

MEANING

Establishing a systematic layout so you can always get just as much of what you need when you need it

PRINCIPLES

Functional storage of all items based on 5W’s and 1H

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•Everything's at designated place.

•Thirty second storage & retrieval .

•Filing standards.

TYPICAL ACTIVITIES

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•Zoning & placement marks .

•First in & First out.

•Neat notice board.

•Easy to read notices

&

•Functional placement for

Material, Parts, Carts, Tools, Equipment's , Files , Stationery items and Everything else

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3. SWEEPING ( SEISO )

MEANING

•Eliminating trash, filth & Foreign matter for a cleaner workplace

PRINCIPLES

•Cleaning as a form of inspection

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•Cleaning, inspecting & correcting minor problems.

•Pneumatics,,Mechanical,Electrical, tools, Measuring devices , Stationery, Hydraulics.

•Cleaning even the places most people do not notice Making cleaning and inspection easier .

TYPICAL ACTIVITIES

OF & FOR

4.SANITISING ( SEIKETSU )

MEANING

Making everything pollution free & supportive to healthy Environment .

PRINCIPLES

Making Environmental friendly noise or any vibration . 15

•Reducing air & water pollution.

•Proper illumination without glare in working area . 16

•Dealing with leakage of toxic & explosive fumes.

•Dealing with any uncomfortable Chemical

waste treatment.

TYPICAL ACTIVITIES

•Pure drinking water .

•Spotless cleanliness of workplace, floor, tables, ceiling, equipment's etc.

•Temperature & humidity maintenance.

•Effective air ducting & suction system for reducing fly content.

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5.SELFDISCIPLINE(SHITSUKE )

MEANING

Doing the Right thing Naturally.

PRINCIPLES

Good habit formation and discipline .

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TYPICAL ACTIVITIES

•All together cleaning training and

practice for regular cleaning.•Training & insistence on wearing safety workplace glasses , shoes etc.

•Telephone,communication & feedback practices.

•Follow-up on standardization and checklists

•Practice for dealing with emergencies. 19

6.STICKINGLY ( SHITSUKOKO )

MEANING

Ensuring 5 S , avoid making status is maintained or repetition of sanitizing,sorting

,systematizing &sweeping .

PRINCIPLES

•Visual Management & 5S standardization 20

TYPICAL ACTIVITIES

•Displays to help people operating errors.

•Danger alerts.

•Indications where things should be .

•PM displays.

•Equipment's designations,Inspection marks .

•Color coding,warning colours.

•Fire extinguishers sign.

•Open-shut & other directional labels 21

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CLUE FOR 5 S SURVEY

Lighting -

Operation difficulty by insufficient light / bother by glare,reading the instrument dial , bulletin board reading

Smell -

•Any leakage of toxic ,uncomfortable or explosive fumes.

•Any leakage of toxic or explosive material at workplace .

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Noise

•Any squeaking , uncomfortable noise

•Any action for elimination of source of uncomfortable noise

•Any noise source that is identifiable

Vibration -

•any uncomfortable vibration felt continuously or occasionally

•Any vibration sources that are identifiable

Temperature

•any low or high temp in shopfloor

•Heat sources which can be eliminated

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POWDERY DUST

•Any uncomfortable powdery dust floating in workplace occasionally or continuously.

TOXIC , VOLATILE & EXPLOSIVE MATERIAL •Identify & indicate clearly as a dangerous material.•Establish & disseminate emergency evacuation procedure to every one. 25

WORK SHOP

•Install all necessary safety media

•Have enough open space in every workshop

•Maintain slip free floor

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COLOUR CODING

•Specify colour coding on dangerous /risky area / material

•Specify colour coding for eye fatigue protection for using equipment.

•Specify colour coding for operational limits on instruments / indicators.

HUMAN BEHAVIOUR

•Use of PPE such as safety shoes , helmet, masks ear plugs , goggles, etc.

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