5S
5 S Practices
LEAN MANUFACTURING ASSIGNMENT
What is 5s? 5S
5S is the name of a workplace organization method that uses a list of five
Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke.
The list describes how to organize a work space for efficiency and
effectiveness by
identifying and storing the items used
maintaining the area and items
sustaining the new order
Purpose of 5 S
1. TO CREATE A SAFE, COMFORTABLE AND PRODUCTIVE WORKPLACE
2. TO IMPROVE THE QUALITY OF PRODUCTS
3. TO REDUCE TIME REQUIRED FOR FINDING THINGS
5S
Japanese term English Equivalent
SEIRI SORT/TIDINESS
SEITON SET/ORDERLINESS
SEISO SHINE/CLEANLINESS
SEIKETSU STANDARDIZE
SHITSUKE SUSTAIN/DISCIPLINE
5SPRINCIPLES
5S
5S
SEIRI OR SORT
This is the first step in 5S, it refers to the sorting of the clutter from the other
items within the work area that are actually needed.
This stage requires the team to remove all items that clearly do not
belong in the working area and only leave those that are required for the
processes in question.
Launch the Red-Tag Project
Identify the Red-Tag Targets
PROCESS
Set Red-Tag Criteria
Evaluate Red-Tagged Items
Document the results of Red-Tagging
5S
PRIORITY FREQUENCY OF USE HOW TO USE
Less Than Once Per Throw Away
Year
Low
Once Per Year Store Away From
Workplace
Once Per Month
Average Store Together
Once Per Week
Once Per Day Locate At The
High
Workplace
5S
Tools which Tools which Tools which can
are useless are usable be used in
future.
5S
BENEFITS
Necessary items are identified and
positioned in the right workplace and
location.
Unwanted items are eliminated.
Searching time is reduced.
Working environment is improved.
Space utilization is maximized.
5S
SEITON OR STRAIGHTEN
This is the process of taking the required items that are remaining after
the removal of clutter and arranging them in an efficient manner
through the use of ergonomic principles and ensuring that every item
has a place and that everything is in its place.
5S
Action Plan for Seiton
NECESSARY ITEMS Required Items
ITEMS FREQUENTLY USED Can be placed near the
point of use
Items sometimes used Can be placed further away
Items not used at all but must Must be stored with clear
kept identification
BENEFITS 5S
Items easily returned to its designated
location after use.
Required items easily located, stored
and retrieved.
First-In First-Out (FIFO) is practiced.
Retrieval time is reduced.
Right Item, Right Place, Right
Quantity and Right Method (4R) are
in place.
SEISO OR SHINE 5S
This is a process that aims "to make everything shiny clean". The goal is to
set new standards for cleanliness & to maintain the level of cleanliness.
Assign small teams to work on different sections of the factory.
PROCESS
Clean and inspect everything: machinery, work stations, storage
cabinets, open floor spaces.
Take notes of what had to be cleaned or tidied; how frequently it
may be needed; resources required.
Finish documenting the results by taking a photograph of the final
result.
5S
BENEFITS
A safer and more comfortable
work environment.
Less downtime for repairs, since
equipment will be inspected
briefly but regularly; and
because there will be less dirt
clogging the machinery.
Higher morale: workers can take
more pride in a tidy and clean
workplace.
5S
SEIKETSU OR STANDARDIZE
It means setting up standards for a neat, clean, workplace". The goal is to
make abnormalities visible to management, make it easy to move workers
into different areas.
The standardization of methods adopted.
PROCESS
Periodic review of the area.
Follow Seiri and Seiton again for
maintaining the standards.
BENEFITS 5S
Standardization.
Systematic workplace.
The less frequent clean ups.
Consistency in the improvement
processes.
SHITSUKE OR SUSTAIN 5S
It means to maintain what has been accomplished. it helps in
recognizing the improvements and set high standards.
Without Shitsuke sustained discipline at the "end" of the 5S
process, any benefits from the first four steps will gradually evaporate
Maintain & review standards.
PROCESS
Do not allow gradual decline back to the
old ways
With new ways, think of better ways
When issue arises, review th first 4 Ss & make
changes as appropriate
5S
BENEFITS
Discipline in the system.
Waste reduction.
High morale.
Neat and cleanliness.
Easier to work.
Lesser stress at work
5S Case Study Star Cones Loom
Before implementation- Problems
Space crowded with Unneeded items Excess inventory on No proper cleaning of
tools. stacked b/w workers. the floor. workstations.
After implementation- Results
Solution to all the mentioned
Motivated workers. Increase in productivity.
problems.
Benefits to the industry
Reduction in
Defective items Floor space is Material handling Safer work
stoppage time of
are reduced. properly utilized. time is reduced. environment.
the loom.
REFERENCES
http://world-class-manufacturing.com/5S/seiso.html
http://improsys.in/seiketsu.htm
http://world-class-manufacturing.com/5S/Seiketsu.html
https://www.creativesafetysupply.com/content/education-
research/5S/index.html
http://www.indiantextilejournal.com/articles/FAdetails.asp?id=4
499
http://www.rosenberger.com/5s/en/
http://appliedperformance.ca/key-benefits-5s-process-
implementation/
