Implementation of 5S System
Trainer: Haard Pandya
Idea behind 5S
In order to achieve high levels of
quality, safety, and productivity,
workers must have a conducive
working environment.
5’s objective - 2024
Sr.No Activity Measurable Targets / Day
1S- To eliminate unwanted items, creating more space
1 30 % Space Released
for working and keeping required items.
2S - Reducing the retrieval time (searching time) for
2 3 Min
tools /spares/Stationary.
3 2S- Easy to locate the required items and quantity. 1 Min
4 Reduction of inventory. 20% less than Earlier
Reducing rework or error by seeing the visuals
5 5%
indicators.
Improving the morale of the members by receiving
6 100%
suggestions.
7 To Provide neat and clean Work Place Organization. 100%
5S Fundamentals…
WHAT IS 5S?
• 5S represents 5 disciplines for
maintaining a Visual Workplace
(Visible control and information
system) and helps to create a
better working environment and
consistently high quality process
• SEIRI, SEITON, SEISO, SEIKETSU,
and SHITSUKE
Discovery of 5S..
• It is a structured program to systematically achieve total organization,
cleanliness, and standardization in the workplace.
• 5S Concept was organised by Mr. Takashahi Odasa in year 1977.
• He was also a founder of TQM(Total Quality Management) and TPM(Total
Product Management.
• In India, the first company followed 5S concept was Vikram Cement
Sujjanpur, MP in year 1993
5S in details
1S: Sorting(SEIRI)
Remove item from workplace that not
needed for the current operation
Problem avoiding by Sorting:
• Un-need inventory and machinery are
costly to maintain
• Excess stock on hand hide other type of
problem in production,
• Un-need item & equipment make it
harden to improve process flow
(Don’t keep un-needed item)
Before Implementing 1S
Important in sorting
Improve in quality of 4M
• Man, Machine, Method and Material
• Which save time and increase Money, space, energy and efficiency resource
management
• Problem in workflow will reduced
• Communication will improved
• Product quality increases.
Objective:
• Red Tag
1) Reject or discard policy
2) Repaired (if not working properly)
3) Deploy(re-use)
• Step by Step approach to workplace improved by reducing “Non value
adding activities” ex. Breakdown,Leakage,Accident,Excess inventory, Time
loss extra man power, Extra purchase, extra stock
Important in sorting
Important in sorting
After 1’S Apply on
Floor
Before 1’S Apply
on Floor
2S.Set in Order
Set in order can defined arrangement needed
items so that are easy to use and labelling
them so that they are easy to find and put
away.
Problem can be avoided by improving
waste.
• Motion
• Searching
• Human energy
• Excess inventory
• Defined product
• Unsafe condition
• Floor marking
2S.Set in Order
How to improve 2S…!!!
1) Deciding appropriate location.
• Locate item in workplace(Frequency)
• Place frequency used items near the workplace.
• Store infrequency used item away from workplace.
• A proper arrangement for tools so that they go back to original place of
storage.
2S.Set in Order
2) Sign Board
Identification
• location indication, items indication and amount indication.
Sign board often are used to identify
• Name of the workplace
• Inventory location
• Standard procedure
• Machine layout
• Painting strategy
3S.Shine
Shine means making sure everything in the workplace in proper and cleaned.
Inspection or checking to verify the proper cleaning.
How to improve cleaning:
Determine shine assignment
• 5S assignment MAP
• Who is responsible?
• 5S schedule-day of cleaning by responsible person.
Determine shine method
• Choosing target & tools
• Performing 5s minute shine
• Creating standard for shine
3S.Shine
4S.Standardize
Standardize is the results that exists what the when the first 3 pillar 1S, 2S and 3S is
properly maintain by displaying of Safety item.
How to standardize
• Decide responsibility.
• Integrate 3S duties in register.
• Check how well 3S is maintained.
How to implement
• Visual 5S or Visual control: Ex-Radar Chart displayed in 5S Corner.
• Lock out procedure.
• Distinguish normal and abnormal condition.
• Internal Audit: audit the workplace.
• 5S project.
• Review.
4S.Standardize
5S.Sustain
Sustain means making a habit of properly maintaining current
procedure and internal audit by a team of company i.e. one hr. in a
month.
How to implement:
• Awareness about 5’S.
• Teamwork with responsibilities for achieving 5’S sustenance.
• Structure: Organization, layout and target of implementing.
• Conduct training for contract person by 5S champion and Zonal champion.
• Manage or taking action , review which is the target comes under 5S.
• Support from top management for resources.
• Reward and recognition for motivate.
• Satisfaction and excitement for sustaining 5S activities.
5S.Sustain
5S.Improvement benefits
The 5S methodology can improve a workplace in many ways, including:
Safety
• 5S can help create a safer work environment by eliminating unsafe conditions, like
leaving boxes of supplies in high-traffic areas.
Efficiency
• 5S can improve efficiency by reducing waste and unnecessary downtime.
Productivity
• 5S can increase productivity by making it easier to find tools and materials, and by
reducing the need for unnecessary motion.
Quality
• 5S can improve quality by reducing defects and consistently maintaining equipment.
5S.Improvement benefits
Morale
• 5S can improve employee morale by creating a clean and tidy workplace, and by
engaging employees in identifying and addressing problems.
Cost reduction
• 5S can reduce costs by eliminating waste and improving products and services.
Space reduction
• 5S can reduce the amount of space needed for operations by removing unused
equipment and supplies.
Culture
• 5S can help create a culture of continuous improvement by engaging employees
and making it natural for them to maintain a clean and tidy workplace.
What we learn…?
• Company 5s policy.
• Objective of 5’s.
• 5S Fundamentals…
• Discovery of 5S..
• 5S in details
• Define 1’s,2’s,3’s,4’s,5’s.
• Improvement of 5S
• 5S Corner Board
THANK YOU
