Welcome to

5S Orientation
(System of Good
Housekeeping)

Conducted for
Shimizu Philippine Contractors Inc.
April 25, 2007/9-12 am
Training Objectives :

#1 Learn the Japanese principles of 5S as it relates to

workplace organization - how to apply to one’s
workplace.

#2 Understand and use the tools needed to systemize

the workplace - and make it work.

#3 “Total Customer Satisfaction”.

Advocate 5S as a means in attaining

#4 Sustain and make it a way of life.

SOFT 5S environment 5S

HARD 5S system &

procedures
 Expectation for
Implementation of 5S’s + 1

• Clean work place

• Visual Control

• Worker’s Morale
Clean Workplace
improve
environment
no obstacles in workplace
easy to work
keep good quality

dispose unnecessary items

arrange in good order
leakage prevention
noise suppression
dust prevention
clean sight
 Visual Control

Control Label
prevent from mis- -machine name
operation -person in charge
-kind of material
-safe mark Limit Indication
- level mark
- limit line
easy to check - zone mark
easy to repair
easy to help each other
Visual Aid
- transparent cover
- color coding
- operation label
Worker’s Morale
improve self
management level

keep rule and standard

do things spontaneously

communication group responsibility

human relations personal responsibility
teamwork elimination of absenteeism
comradeship don’t trouble others
vitality
productivity ???

Productivity is . . .
Some Key Results of Productivity
Tools & Techniques

Elimination of Quality Stability of

loss and wastes Operation
customer’s
satisfaction daily maintenance &
over production reduction of
waiting time adjustments
defects and prolong life cycle
transportation and rework
material handling shorten set-up time
improper operation visual control
inventory holding Morale smooth prod’n flow
unnecessary worker’s standardization
motion education & training
prod’n defective communication
small group Safety
activity
work attitude
5S + 1 Key Principles :

 Organization makes work and life easier.

 Organizing is a skill that can be learned.
 Becoming organized is a two step
process.
1. getting organized
2. staying organized
Japanese VS. Western
attitude / culture

Kaizen
-continuous improvement restriction oriented
“superstar”
willingness to do more

group consciousness thick walls between classes

little distinction bet. classes

individual performance
individual responsibility
is limited
limited mutual
broad mutual responsibility responsibility

teamwork
independent
loyalty / family ties
5S + 1 in Three Languages :

Japanese Filipino English

 Seiri  Suriin  Sort
 Seiton  Sinupin  Systemize
 Seiso  Simutin ang dumi  Sweep
 Seiketsu  Siguraduhin ang  Standardize
kalinisan
 Shitsuke  Sariling disiplina  Self-
 Shikkari  Sundan ang discipline
nasimulan  Sustain
1S SEIRI - SORT

Take out unnecessary items and dispose

them.

This is the most important step.

Separating things in terms of what is

necessary from those that are not.
Sort - ( SEIRI )

Purpose :
1. To make the work easy by eliminating
obstacles.
2. To eliminate the need to take care of
unnecessary items.
3. To provide no chance of being
disturbed by unnecessary items.
4. To prevent misoperation and fault
caused by unnecessary items.
Flow of Sorting Process

Identify the Make a list of

Workplace all items
to be found within
sorted. the
Workplace

Classify the
needed and Verify to
not needed ensure the
list
SEIRI
No potential Immediate
use disposal

Consider
Potentially where
things not useful or useful &
needed valuable move

Arrange
Requiring responsible,
special inexpensive
disposal disposal
2S SEITON - Systemize

Arranging necessary items in good order

for use.

Eliminating time wasted in searching

for things we need.

Functional storage

Organizing
Systemize - ( SEITON )

Purpose :
1. To prevent loss & waste of time.
2. To be able to find out & pick-up
necessary items easily.
3. To ensure first come-first serve basis.
4. To make production flow smooth &
work easy.
SEITON
things used place as
constantly close as
possible

place a
things things used
little
needed occasionally farther

enclose in a
separate,
seldom
designated
used
place
Steps in systemizing your
workplace:
1st : Make sure all unnecessary items are
eliminated from your workplace.

2nd : Decide where to put your items for

efficient operation.

“The more frequent the item is used, the

nearer the item should be to the user.”
3S SEISO - SWEEP

cleaning your workplace and

eliminating the root cause.

creating a spotless work place

removing everything from the work that

should not be there
Sweep - ( SEISO )

Purpose
1. To keep environment condition as the level
necessary for the products.
2. To keep machinery & equipment so as to
check abnormality & to prevent them from
deterioration.
3. To keep workplace safe & easy.
SEISO
Checkpoints for the workplace :

1. How much dirt and dust can you find

when you look around your workplace?

2. Are any part of your equipment dirty

with oil and grime?

3. Are light bulbs dirty?

4S SEIKETSU - STANDARDIZE

maintaining high standard of

housekeeping

it involves the development of a clear

system for maintaining cleanliness
and orderliness

standardization can be achieved

through “visual control” system.
4S SEIKETSU
Checkpoints for the workplace :
1. Do you have a standard filing system ?

2. Do you use visual control (signs, symbols,

codes) to detect abnormalities in the
workplace ?

3. Does everyone understand the system you

have implemented?
What is Visual Control ?

Visual Control is a
technique to enable
people to make rules
easy to follow,
differentiate normal and
abnormal situations and
act accordingly, with the
use of visual acts.
Types of Visual Controls

1, 2, 3 Aa Bc Cc
Alphabetical

Numbered

Pictures

Signs Color Coded

 Use of Colors

Red - when you want people to recall

something

Blue - used for items you want to

play down
- attracts attention

Green - when you have poor lighting

Why Visual Controls ?

1. To help people avoid making errors.

2. Alert dangers.
3. Indicates where to get and return
things.
4. Equipment designation.
5. Cautions and reminders.
6. Preventive maintenance displays.
7. Instructions.
 Points to remember in
making Visual Controls
1. Easy to use.
2. Can be seen from a distance.
3. Easy to tell what is right and wrong.
4. Convenient to use.
5. Anybody can follow and make
corrections.
6. Using them makes the workplace
brighter and more orderly.
 Where to Control . . .

1. Critical points, what needs monitoring.

2. Where should your look-eye level be.
3. What tools need checking.
4. Actions to take.
5. Emergency procedures.
Safety instructions.
6. Needs maintenance and improvements.
5S SHITSUKE-SELF DISCIPLINE

doing things spontaneously without

being told or ordered

developing habits you won’t forget

 Ways to
reinforce the
5S habit

training
develop visual control
document
checking / audits
5S teams
SHIKKARI/SEIKARI - SUSTAIN

continuously perform
the 5S activities and
seek further
improvement
 Key points to remember in the
implementation of 5S + 1
1. Start small and easy, proceed slowly but steadily.
“If you make haste, it is easy to fail.”
For big organizations, start with plot area.
Trial practice at model area and model machine.

2. Start with the most suitable “S”.

For messy workplace, start 1st “S” with “Afakuda
Operation”.
For troublesome machine, first conduct SEISO then do
SEISO inspection.
Everyone can participate in “SEISO” but they need to be
familiar with machines, proper cleaning procedures
and tools.
Key points to remember in the
implementation of 5S +1

3. Only 1st to 3rd S’s are enough for the initial practice
not all
5S’s.
The first 3S’s are action words.
4th S is a CONDITION
5th S is accordingly CULTURE

4. Set simple, easily achievable and step by step targets.

Themes are helpful to concentrate efforts and
achieve
greater results.
Practice 5S together with other movements.
Integration through selection of common themes.
Set SMART target.
 Key points to remember in the
implementation of 5S + 1

5. Everyone’s participation is important.

Two heads are better than one.
Four eyes see more than two.
Encourage participation by :

EDUCATION than by DEMONSTRATION,

later through ACTUAL PRACTICE,
and of course RECOGNITION.

Set aside a day for launching.

 Key points to remember in the
implementation of 5S + 1

6. Management should take leadership of 5S movement.

Lead by example.
Let people know that top management is
interested.

7. Record improvements for comparison.

Record starting points / benchmarks.
Spot shooting

8. Devise schemes to stimulate awareness and sustain

enthusiasm.
PROMOTION IMPLEMENTATION EVALUATION
SCHEMES SCHEMES SCHEMES

banners Big Clean-up Day CEO’s Inspection Tour

slogans 5S Day
posters 3-minute cleaning 5S Evaluation Sheet
newsletters Study tour
badges Spot Shooting Audit by External
competition one point lesson Consultants

Exchange Visits

Periodic Review
Factors Leading to Success of 5S

 Strong sponsorship & leadership of CEO

 Active promoter / 5S committee
 Good launching activity
 Regular audits
 Good documentation
 Visits by external consultants
 Competition
Factors which Hinder Success of 5S

 Project Sponsor is not the decision maker

 Organizational politics
 Lack of experience in undertaking cross-functional activities
 Lack of top management support
 Implementation carried out through
orders from top
 Implementation done by task forces
 5S treated as a project
 Emphasis on immediate results
ONE is best campaign

 location
 day processing
 file projects
 hour meeting
 page memos
 copy filing
 minute telephone
call
 tool work
Office 5S Activities

1. Reducing number of ledgers, forms & tools.

2. Better storage to get anything needed in 30 sec.
3. Keep things in just 1 place.
4. Have just one form of things.
5. Eliminate the idea that everyone has to have his own copy of
everything.
6. Shift from individual - based to group-based work.
7. Standardize and create manuals detailing office procedures.
8. Maintain cleanliness and orderliness.
9. Provide mechanism to evaluate what is happening at anytime.
5S Implementation Guidelines

DESKS
 Do not place anything under your desks.
 Dispose unnecessary items in your desk drawers.
 Arrange items in your desk drawers neatly for easy
retrieval.
 Do not pile up documents on your desk top.
 Do not leave unnecessary things in your desk
when you go home.
5S Implementation Guidelines

CHAIRS
 Place your chair under the desk when you leave
office
 Do not place your coat on your chair
 Clean your chair regularly
 Fix your chair when it is unstable or noisy
TELEPHONE

 Clean telephone body and dial

regularly with soft detergent.
 Set telephone wires neatly
around the desk.
 Place it at a most convenient
location for easy use.
 Replace it neatly on the desk
before leaving the office.
5S Implementation Guidelines
CABINETS
 Each cabinet must be properly
labeled indicating its contents
 Provide partitions in cabinet
drawers for small items
 Label each file for easy retrieval
 Do not place anything other than
specified item on top of cabinets
 Rearrange contents of each cabinet
once every three months
OFFICE MACHINES
 Clean computer/copying machines
regularly with soft detergent.
 Set electric wiring neatly for safety and good
appearance.
 Reset office machines for ready use by next person.
 Place expendable papers neatly at designated locations
by type and size.
 Inspect machines regularly and take action for required
servicing.
 Assign ownership
to each machine.
WHITEBOARDS
 Clean whiteboards completely after use.
 Check markers for replenishment.
 Remove & discard outdated notices or poster
on whiteboards.
 Clean erasers from time to time for good
function.
CONFERENCE ROOMS
 Do not allow any item other than those used for each
meeting.
 Replace ash trays, materials, stationery, VTR, etc. to
their original location after use.
 Switch off lights and air conditioners after use.
 Be punctual at meetings.
 Assign ownership at each
conference room.
BOOK SHELVES

 Classify books by category for easy retrieval.

 Always return books to their designated location after
use.
 Keep book shelves clean and tidy.
 Do not place anything other than books in book
shelves.
 Dispose outdated books and
magazines from time to time.
CANTEEN
 Do not leave unnecessary things on the dining table.
 Replace chairs under dining table after use.
 Return chairs and tables to their original location when
relocated for meetings and functions.
 Put away all cups and plates after each meal.
 Clean up tables immediately after each meal.
TOILETS

 Flush toilet bowls after use.

 Wash your hands after using the toilet.
 Clean up toilet and wash basin everyday.
 Replenish toilet paper rolls, soaps and paper towels
once a day.
 All users should always try to keep toilets clean and
tidy.
 Check ventilation fans regularly for effective function.
HALLWAYS

 Clean your shoes before entering the office / lobby.

 Do not place anything in hallways without permission.
 Pick up and dispose any waste paper in hallways.
 Avoid talking loudly along hallways.
 Clearly designate passages by painted lines.
NOTICE BOARDS

Ensure that all information are updated regularly.

Items should be neatly aligned and properly
secured.
Ensure that outdated notices are removed.
Pins must be readily available.
Check that the location of notice board is
appropriate.
MACHINE
 Always follow SOP.
 Prevent machine failure by regularly cleaning and
oiling.
 Check if machine is always in good working condition.
 PM should be done regularly.
 Assign ownership to each machine.
TOOLS & PARTS

 Place tools & parts neatly at designated location at all times.

 Do not let excessive quantity of tools and parts stay in the work
area.
 Replenish minimum necessary inventory of components and parts
and keep them always ready for use.
 Use suitable parts boxes for small items.
 Do not place other items in tool cabinets.
 Return tools and parts to their designated location for easy retrieval.
 Fix/replace damaged tools immediately.
WORK IN PROCESS

Place Work In Process neatly at

designated location.
Label each WIP for easy identification
by everyone.
Do not place WIP in passage areas
without prior permission.
Sort out materials / process defects &
place them at designated location
WORK TABLE
 Always keep your work table clean and tidy.
 Never place your belongings on top or under your
work table.
 Fix your work table in case of damage.
 Do not leave anything on your work
table other than those needed by
next person before going home.
 Do not use the work table
for storage.
PUSH CARTS
 Always return push carts to its designated location
after use.
 Take immediate action for repair when any part of
push cart is damaged.
 Do not store anything on it at all times.
 Move push carts carefully and avoid hitting other
items.
 Load only suitable quantity and weight of items on
push carts.
LOCKERS

Do not place anything on top of lockers.

Place items neatly inside your locker.
Always keep your locker clean.
Do not keep any food stuff inside your locker.
Empty locker and clean them once a month.
 Total Customer
Satisfaction

Physical
Improvement of Self-disciplined
Working Workforce
Condition
Quality
Work
Place
Elimination of Total
Loss & Waste Participation
5S + 1 will give you . . .

more SPACE
better ACCESSIBILITY
improved EFFICIENCY
developed GOOD HABITS
ensured SAFETY
Company gain from 5S + 1

IncreasedProductivity
Improved Quality
Reduced Cost
On Time Delivery
Improved Safety
Improved Morale
“ A place for everything,
Everything on its
place. “