Training module

on

Implementation & Monitoring

of

5S
( Work Place Improvement )
Contents :-
1. What is 5 S ?
2. Implementation methodology.
3. Sustenance ( Holding Gains).
4. Review and measure.
What is 5S ?
 5S?
Housekeeping
 5S
Housekeeping
OR
Improvement Process
 5S

Improvement Process
 5S
=
Work Place
Improvement
1 S,
2 S,
3 S,
4 S,
5 S.
1 Sorting Out. 5 S
2 Systematic Arrangement.
3 Shine Everything.
4 Standardization.
5 Self Discipline.
 5 ‘S’ & It’s Benefits
Topic Understanding Actions to be taken Benefits

1 ‘S’ Sorting Out • Segregate Wanted & Un-Wanted things . Space Saving & Improvement
• Remove Un-Wanted ones. in Work Efficiency .
• Decide on frequency of sorting.

2 ‘S’ Systematic • Decide the Place & Arranging in order.

• A place for every thing and every thing in Search Time reduced.
Arrangement it’s place.

3 ‘S’ Shine Everything •Dust Free Equipment / Work Place. •Healthy Work environment
(Cleaning) • Make it easy to Clean. •Abnormalities are Visible
• Make it easy to Inspect Abnormalities. & Corrected.

4 ‘S’ Standardization •Standard Procedure for all activities. Achieving Higher Productivity
•Review of Procedures and Work and Better Quality.
Instructions at a Fixed Interval.

5 ‘S’ Self Discipline • Forming the Habit / Culture. •Habit of doing it Right
• Regular Training & Update. First Time and Every Time .
• Follow the decided things. Total Employees
Involvement.
1Sorting out :

Sort & Out

What to Sort & What to
send Out ( REMOVE ) ?
1Sorting out :
Sorting:
Identify,Segregate
Wanted & Unwanted things
1Sorting out :
out (REMOVE):
RE - MOVE Unwanted things
to
RED TAG AREA
 RED TAG AREA
‘Red Tag Area’ is a designated place
at all respective zones (Production
/ Non production) where unwanted
things can be collected temporarily
and finally removed.
1 Sorting out

RED
TAG AREA

Removal of unwanted things

1Sorting out :
Methodology to Implement
‘1S’
•Divide entire factory( including Canteen,Offices,Toilets, scrap
yards .) into small Zones.
•Form a Team Leader ( Preferably Senior person of respective
area / Zone) and Team Members ( Group of 4~ 5 people) for
every Zone.Ensure the involvement of all associates.
•Form a committee of senior people( Preferably Department
Heads) who should take a decision for the disposal of
unwanted things / Scrap, out from the factory.
 1Sorting out :
ORGANIZATION CHART FOR '5S' TEAM

CEO
Team members
5S' COMITTEE are operators
COORDINATOR

DEPUTY
COORDINATOR

ZONE-1 ZONE-2 ZONE-3 ZONE-4 ZONE-5 ZONE-6 ZONE-7

TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER

TEAM TEAM TEAM TEAM TEAM TEAM TEAM

MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS
Make zones by allocating a reasonable area
to each leader
1Sorting out :
Methodology to Implement 1S: ( Contd.…)
•Fix a date and time for Red Tag Campaign & carry out the
audit across all Zones.
•Search & Identify unwanted things and tie them with a RED
TAG.
•Other than product scrap, Red Tagged items should be moved
to respective RED TAG AREA.
•All those items which are finally identified unwanted ones
should be reviewed by the review committee and decision for
disposing off should be taken within a fixed time( Maximum
Time Limit is 15 days).
RED TAG CAMPAIGN

Unused Machines & Parts

REDTAG CAMPAIGN

Unused Material and Parts

 RED TAG
CAMPAIGN
Unused Raw Material
due to excess Inventory.

Created Free Space.

1Sorting out :
•RED TAG :- 5 S RED TAG
A Card containing detailed Section / Area :-

information of unwanted things Name of Item : Quantity :

with a given time limit for Reason :-

further action to be taken. 1. Obsolete 5. Unnecessary
2. Defective 6. Mix - up
3. Scrap 7. Unidentified

To be used based on following 4. Not in place 8. Others

questions: Action :-

•What is required ? 1. Move to Scrap Yard

2. Locate properly
4. Rectify
5. Return to Supplier
•How much is required ? 3.Segregate 6. Others

•When is it required ? Target date of disposition:

•Where is it required? Remarks :-

 RED TAG AREA

Collection of Unwanted Things at Red Tag Area

1Sorting out :
Methodology to Implement 1S: (Contd..)
•Prevent generation and accumulation of unwanted things
inside the factory premises.
•Repeat the same exercise at the fixed intervals (Once in a
month ).
•Monitor the performance zone wise for Space Savings,
Reduction in Inventory, Search Time Reduction, ‘1S’ Audit
Score . (Monthly trend should be monitored).
1Sorting out :
Guidelines for conducting 1S Audit
1. Obsolete :- Parts ( Jigs / tooling ) not required as
the design has become obsolete.
2. Defective :- Parts can’t be used as it is ( need
some correction ).
3. Scrap :- Scrap Items not thrown out .
4. Not in place :- Kept at wrong place.
5. Unnecessary :- Extra / not useful.
 1Sorting out :
6. Mix-up :- Mixed parts .. Needs attention .
7. Un-identified :- Nobody’s baby .
8. Items not used for last 6 months.
9. Obsolete documents, not used but still stored for a
long time.
10. Others :- Even what is this part ?… Nobody
knows.
 Potential Areas for practicing ‘1S’
SCRAP LITTERED SWARF LITTERED
IN REDTAG AREA ON WORK BENCH

FILING RACK IN
DIS-ARRAY

BIN USED AS A SEAT

 Example of ‘1 S ’

Before
Habit After
of accumulating unwanted things
 Rack Removal
DISPATCH DEPARTMENT

BEFORE AFTER

RACKS TO BE
REMOVED
6x8 feet space released
Before

Example of ‘1S’ at Office Area

Source: Madras Engg.

After
Example of ‘1S’at Office Area

Before After
Worst Example of “1 S”
Worst Example of ‘1S’
2S

Systematic
Arrangement
2S (Systematic Arrangement)

Objective
•Place for Every Useful Thing & Every Useful Thing is
on it’s place .
•Arranging them in a Systematic manner.

Result: Reduces Search Time

2S (Systematic Arrangement)
Benefits of ‘2S’
• Faster retrieval of things, result in Elimination of
Search Time.
•Opportunity to correct the abnormalities faster as
visibility improves by system itself.
•Space Saving by systematic arrangements.

•Efficiency of work improves as things are available

when they are actually needed.
2S (Systematic Arrangement)

Methodology to Implement ‘2S’

•Check What (Item Identification)?, Where ( Location)?
& How Much ( Quantity)? When ( Time limit)? Before
actually practicing ‘2S’.
•Decide appropriate location for every thing.
•Display identification mark for every location.
•Items stored should have the Identification Mark including
purpose of storage & its review date.
2S (Systematic Arrangement)

Methodology to Implement ‘2S’Contd..

•Every thing should be cleaned thoroughly before they
are stored at its pre fixed location.
•Location and storage of the items should be easily
accessible to all.
•Clear identification and visibility for the location.
•Training and information to all.
•FIFO should be ensured.
2S (Systematic Arrangement)

Presence of Good ‘2S’

•Availability of pre fixed locations for everything.
•Locations are appropriate (Near to use).
•Presence of identification for every thing.
•Containerization- No touching/ damage between two
parts.
•Accessibility is easy and known to every one.
•Locations for fire extinguishers is adequate.
•Gang ways are clearly marked.
2S (Systematic Arrangement)
Presence of Good ‘2S’Contd..
•Direction for Respective Departments,Shops,Reception,
Canteen , Visitor Rooms, Meeting Halls . is clearly
marked and displayed.
•Direction for Toilets and Water Coolers is self informative.
•Display boards are available for Safety / Fire Prone Areas.
•Display of Speed Control of the vehicle inside the factory
premises is adequate.
2S (Systematic Arrangement)
Presence of Good ‘2S’( Contd….)
•Direction for Dispensary is clearly marked & displayed.
•Serial numbers on Fans , Machines, Tube Lights, .are
present & visible.
•Important / emergency Telephone Numbers are displayed
at appropriate locations.
•Instructions for Safety / Quality Standards are clearly
visible.
•Shadow Boards are available at the appropriate locations.
2S (Systematic Arrangement)

Absence of Good ‘2S’

•No visual identification & display boards are available.
•Files / documents / reports can not be found out as the
concerned person is on leave.
•Tables and drawers are filled with full of papers & files.
•Habit of keeping standards, documents, stationary
. in the personal locations exists.
2S (Systematic Arrangement)

Absence of Good ‘2S’contd...

•Scarcity of accidents at the work place is available.
•Fire Extinguishers are not available at the desired
locations.
•Visitors are roaming as there are no road maps displayed.
•Frequently asked questions by the visitors are: Excuse me,
Where is toilet?, Where is drinking water? …….
•Difficult to identify between Good & Bad.
2S

Right Things in the Right Place.

2S (Systematic Arrangements)

Before

Pre-Fixed After
Locations
2S

Pre-Fixed
Locations
‘2 S’
Pre fixed
locations
2S
Search
Time
Elimination
Fan &
Electrical
Switches
Identified
2S Shadow Boards
Shadow board means if you take tool / gauge /
any displayed item from the board , shadow of
that tool/gauge/ item should remain on the board
(empty place )
… refer next slide
2S Shadow Boards
Only shadows on board
Shadow board with
.. Empty board
tools
2S
Pre fixed location
2S
Example : Broom storage arrangement
2S Fixed Point Photograph Location
2S Fixed Point Photograph display Location

Communicating visually through fixed point photographs

Display boards at fixed place
2S
Pre-Fixed
Locations-
Shadow
Boards for
Gauges
2S Example of ‘2S ’

Before After
Wrong place for wrong Tool Correct Tool on correct place
2S Example of ‘2S ’

Before After
Wrong place for parts
2S ‘2S’ in Office
• Can you see at a glance
whether files are out of
place ? Elimination of
• Can you detect disorder search time
from a distance ?

Before After
2S Example of ‘2S’ at office area
2S See through , see without touching / opening

Example: Transparent Storage Cupboards

2 S Example of ‘2S’ at office area
Before After
2S Identity at empty place

You know who has taken the file

‘2 S’

Place for Parts under investigation.

‘2 S’

TOOL STORAGE
AT CORRECT
LOCATION
2S
COCONUT TO CAR PARKING
BEFORE AFTER

Solutions are available even for complicated things

2S
COCONUT TO CAR PARKING

BEFORE AFTER
2S
COCONUT TO CAR PARKING

BEFORE AFTER
2S
COCONUT TO CAR PARKING
BEFORE AFTER

No touching between two parts

2S
Operation Standards At Operator’s Eye Level

Correct Positioning for Effectiveness

2S Visual Aids

No Fire Don’t Danger Use Vehicle

Smoking Touch Helmet

Direction Dispensary

ATTENTION
240/440 V
DANGER

Fire Hose Fire Electricity

Extinguisher
3 S (CLEANLINESS)

Shine
Everything
3 S (Shine everything )
means……

1.Six side cleaning for all.

2. Refurbishing everything
3. Make things easy to clean
3 S (Shine everything )
Six sides of Equipment/Work Place are:

•Top & Bottom side

•Front & Rear side

•Right & Left side

3 S (Shine everything )
Objectives and Benefits of Practicing
‘3S’
•Provides dust free environment.
•Creates safe & healthy work place.
•Ensures higher quality of work & products.
•Increases the efficiency & life of equipment .
•Improves Visibility to identify abnormalities.
3 S (Shine everything )
Presence of Good ‘3S’
•Every thing is dust free (All six sides).
•Visibility is clear, no darkness.
•Clean and safe work place.
•No leakage of oil on the machine/ floor ( Wet to Dry).
•No abnormal sounds / vibrations at the work place.
3 S (Shine everything )
Absence of Good ‘3S’
•Poor condition of Canteen & Toilets.
•Work place & offices are dark.Windows are badly
dusty & dirty that does not allow sun light to enter
even on a sunny day.
•Tube-lights/ bulbs have a layer of dust-allowing less
light.
•Walkways on the shop-floor are dark, generally having
a coat of muck piled on it.
3 S (Shine everything )
Absence of Good ‘3S’contd..
•Puddles of oil & water cause slipping & injury.
•Machines are so dirty & oily that it is hard to know their
original color.
•Oil & air-pressure gauges are hard to read as they are coated
with dirt.
3 S (Shine everything )
Absence of Good ‘3S’contd..
•Workmen’s dress/ uniforms and shoes are dirty.
•People with soiled clothes,working in dirty environment
tend to have low morale.
•Surroundings are with full of garbage, no greenery seen.
•Higher defectives are produced due to uncleaned machines .
•Machines tend to have frequent breakdowns due to dust & dirt.
3 S (Shine everything )
Methodology to implement ‘3S’
•Divide entire work place into small zones.
•Define the responsibility of person ( Area wise).
•Prepare a check list containing following information:
•Check Items.
•Tools to be used.
•Frequency of inspection.
•Person In charge name.
3 S (Shine everything )
Methodology to implement ‘3S’contd….
•Check list along with the photograph of the person in charge
should be displayed at the respective work place.
•Status of ‘3S’ should be recorded in the check sheet,
abnormalities if found should be recorded and corrected.
•Actual status of ‘3S’ should be audited by a team of senior
people on weekly basis.(GENBA visit by CEO)
•Culture should be developed to clean the work place/
equipment before the start of work.( First 5 minutes).
3 S (Shine everything )
Methodology to implement ‘3S’contd….
•Shine everything by thorough cleaning from Roof
to floor.
•Office: - Clean top & below of the tables, cupboards
& filing racks.
•Shop floor :-Clean machines, equipment,walls,fans.
•Canteen, toilets, and outskirts of the company.
3 S (Shine everything )
Preventive measures to maintain
‘3S’
• Use of dust collecting covers or devices to prevent
possible dirt generation or reduce the amount of dirt.
• Investigating the causes of dirtiness and implement a
plan to eliminate the sources of dirt.
3 S (Shine everything )
Preventive measures to maintain ‘3S’ contd..

•Operators clean their own equipment and working area

and perform basic preventive maintenance( Habit of
self cleaning) .
•Keep everything clean for a constant state of readiness.
•At the end of the shift ,work place should be cleaned as
good as it was seen in the morning. (Fresh Look).
3 S (Shine everything )
List of Tools used for cleaning
Brooms
• Used for Preliminary Sweeping of dust, chips on the Floor.

Mops
• Used for wiping Floors,Table Top, Shelves .

Dusting Cloths/ Rags

• Use dusting cloths for Work Tables, Desks, Chairs, .
• Use wet rags if there is a lot of dirt & dust.
• For polishing or removing oil use dry dust cloths or rags.
3 S (Shine everything )
Good Example of ‘3S’

Factory Surroundings
3 S (Shine everything )
Front area and Scrap yard are comparable

31.03.02

FACTORY ENTRANCE SCRAP YARD

3 S (Shine everything )
Neat & clean Gang ways , painted floor
3 S (Shine everything )
OVERHEAD PIPES FOR AIR SUPPLY TO
LAYOUT ENSURE BETTER FLEXIBLITY FOR
LAYOUT CHANGESC no pipes on floor
CHANGE
BEFORE AFTER
3 S (Shine everything )
Example of ‘3S’at Shop Floor
3 S (Shine everything )
Example of ‘3S’: Shop Floor
3 S (Shine everything )
Example of ‘3S’: Shop Floor

Before After
3S
Before

Wet to Dry….
Nothing is on the floor

After
3 S (Shine everything )
Example of Wet to Dry

Machine lifted above the floor…

… easy to clean from 6 sides
3 S (Shine everything )
Wrong handling of
material.. Falling on
floor DOOR

BEFORE AFTER
3 S (Shine everything )
MAXIMUM UTILISATION OF NATURAL LIGHT

Transparent
Sheets

Dark to bright
4S
Standardization
4 S (Standardization)
Objective
• To set standard practices for carrying out
routine / repetitive work in the best known way.

• To ensure that quantity & quality of work is

consistent.
• To provide a basis for improvement.
• To provide a basis for daily management /
supervision.
4 S (Standardization)
Benefits
•Sustains the benefits achieved by implementing 1S,
2S & 3S.
•Avoids Re-occurrence.
•Ensures availability of procedures for every activity.
•Ensures continuity of work .
•Provides systematic approach.
•Provides guidelines for the new people.
4 S (Standardization)
What Is To Be Standardised
• Workstation layout, work area layouts.
• Work in Process (WIP).
• Sequence of work.
• Cycle time of work .
• Material and tools used.
• Machines and their process parameters.
• Quality parameters, methods of measurement, reaction plan
and reporting method.
• “ What, Where, When, Who & How ” of work .
4 S (Standardization)
Standardization of Colour coding for
Pipe Lines /Containers
Colour Codification Colour Name Description for Application
Green Water
Light Blue Air
Silver Gray Steam
Purple Acids
White Oxygen
Brown Flammable Oils /Liquids

Arrows should be marked to indicate the Direction of Flow. (Colour--- Yellow)

And opening / closing positions of valves
4 S (Standardization)
EXAMPLES OF COLOUR CODING

AIR LINE LIQUIDS/LUBRICATION

LINE
4 S (Standardization)
DIRECT LOADING ON LINE

Method of handling finished parts

standardized.
4 S (Standardization)
Methodology to practice ‘4S’
•Preparation of S.O.P.( Standard Operating Procedure) for all
the activities to be carried out to maintain 1S,2S, & 3S.
•Following areas shall be covered while preparing S.O.P. :
•Machine & Equipment maintenance.
•Manufacturing Processes maintenance.
•Work Place maintenance.
•Quality Standards and Procedures maintenance.
4 S (Standardization)
Methodology to practice ‘4S’ contd…
•Preparation of check sheet as per S.O.P. for all the activities.
•Check sheet shall clearly define the followings:
•Work to be done.
•Tools / method to be used.
•Frequency of work to be done like: daily start up check sheet, weekly
check sheet, Monthly &Quarterly check sheet .
•Person responsible to carry out and maintain the activity.
•Record of observations/ result for the activity carried out.
4 S (Standardization)
Methodology to practice ‘4S’contd...
•Work place cleaning before start of work.
•Utilities maintenance like: Canteen, Toilets, Garden,Roads,
Fans, Tube Lights .
•Safety Equipment maintenance like: Fire Extinguishers,
Fire Hoses .
•Preventive plant maintenance.
5S

Self
Discipline
5 S (Self Discipline)
Follow the Standards

“Whatever has been

decided must be
followed exactly as
per the standard”.
5 S (Self Discipline)
Objective
To bring a cultural change in the
organization…...

…….Achieve through

‘Total Employee Involvement’.

5 S (Self Discipline)
Methodology to Implement ‘5S’
•‘Practice makes the person perfect’,Ensure that practices
set are followed exactly as per standard.
•Motivate people to get involved in the improvement process.
•Form the teams at all levels.
•CEO to interact personally with all teams by meeting at
GENBA.
5 S (Self Discipline)
Methodology to Implement ‘5S’contd..
•Training / retraining to all employees for continuous
improvement.
•Effective communication through Sun Rise Meeting .
•Prepare check list for carrying out audits for ‘5S’.
•Audit shall be conducted at a regular interval ( 1/week)
•Score of audit ( Zone wise and separate for all 5S ) shall be
monitored and displayed at the respective areas.
5 S (Self Discipline)
Methodology to Implement ‘5S’contd..
•Abnormalities found should be analyzed for the root cause
and actions are taken to prevent reoccurrence.
•Good and Bad areas( Zones) should be identified and
displayed .
•Reward distribution for the best area ( month wise).
•Zone wise competition should be created for healthy
environment.
 Sustenance or Holding Gains

•Progress monitoring through Audit Scores.

•Improving ownership by Allocating Areas.
•Using Red Tag Campaigns.
• Visual communication through Fixed Point Photography.
•Continuous Training to all employees.
•Periodic Audits at all levels.
•Motivation to employees through Recognition.
•Encouraging house-keeping projects through Total Employee
Involvement (TEI).
 Review and measure
• Start reviews for implementation status ( GENBA ).
• Audit all Zones / Areas for 5 S( GENBA ).
• Auditors should be the Zonal leaders.
• Frequency of the Audit …. Weekly .
• Measure each Zone’s performance by Audit scores.
(Target for 1 S , 2 S and 3 S is min. 75 % )
• Least score out of all zones would be Company’s final score.
• Display Audit scores ( Radar Chart ) and Before - After
photographs .
 Audit Checklist
ZONE NO. ZONAL MGR.

5 S Audit Sheet - Shop floor LEVELS

S.N. 1S Sorting Out (SEIRI) Score 0 5 10 15 20

1 Floor Cleanliness - free from dust, oil, mud etc 20

2 General Cleanliness inside factory - Walls, pillars, pipelines are clean without scaling, paint peeling marks, strains etc. 20
3 Cleanliness of containers/pallets - free from dust, oil. Container/pallet in painted condition and free from damages. 20
4 Cleanliness of parts - free from dust, oil (dry condition) 20
5 Cleanliness of Jigs, Fixtures - free from dust, oil 20
6 Unused/Excess material removed to separate place, away from work area 20
7 No mix up of parts in pallets, containers, trays etc 20
TOTAL FOR 1S 140
1S SCORE = ( TOTAL s core X 100 /140)

S.N. 2S Systematic arrangement (SEITON) Out of 0 5 10 15 20

1 Gangway - Marking is clear and no material in the Gangway. 20

2 Use of right pallet / container, trays etc. 20
3 Right pallets, containers, trays etc in right location 20
4 Right component in right containers/pallets etc 20
5 Only calibrated jigs/fixtures are used 20
6 Fire Extinguisher are in fixed location 20
7 Proper shadow board for tools. 20
8 Proper storage of housekeeping tools. ( Broom, Brush , Small Shovel , Tool for cleaning at Heights ) 20
TOTAL FOR 2S 160
2S S CORE =( TOTAL s core X 100 /160)

S.N. 3S Shine Every thing (SEISO) Out of 0 5 10 15 20

1 Component parts not touching each other in containers, trays etc. 20

2 Containers, Trolleys are OK & clean 20
3 Material movement facilities are neat & clean 20
4 Plant and Equipment available in clean condition - all sides 20
5 Preventive maintenance schedule available and effective 20
6 Chip/Swarf collection and disposable system available. 20
TOTAL FOR 3S 120
3S SCORE = ( TOTAL s core X 100 /120))

S.N. 4S Standardization(Seiketsu) Out of 0 5 10 15 20

1 Retrieval of tools, document is easy ( ask for documents , related tools ) 20

2 Andon Lights On Machines Are Available And Effective 20
3 Localized Shadow Boards, Tools Available For Cleaning And Maintenance And Effective 20
4 Easy To See And Inspect Facility Available On Machines And Equipment's 20
5 Pre-Fixed Quantity Per Container / Pallets Is In Practice 20
TOTAL FOR 4S 100
4S SCORE = ( TOTAL s core X 100 /160)

S.N. 5S Self Discipline (Shitsuke) Out of 0 5 10 15 20

1 People are aware for " 5S " requirement and their doing their role ( ask 2-3 people ) 20
2 Availability of operating Standards ( Operation sheet , work instructions ) and are effective 20
3 Activities are done as per schedule ( Audit , Action on NC products etc. ) 20
4 Appropriate legible Visual Control System In Practice ( area names , displays ) 20
TOTAL FOR 5S 80
5S SCORE = ( TOTAL s core X 100 /80)

Best = 100 % marks, Good= 70 % marks, Average= 50 % marks, Below Av.= 30 % Marks, Poor= 10 % Marks, Not done at all= 0 % Marks.
 Radar Chart
1S
SORT OUT •Section
100 •Date
75
50
5S 2S
SELF 25 SYSTEMATIC
DISCIPLINE ARRANGEMENT
0

4S 3S
STANDARDIZATION SHINE
EVERYTHING

•100
•80
Graph

•60
•40
•20

Marks %
Month
5S is not one time activity, it’s a
Continuous IMPROVEMENT
PROCESS .
No TQM,TPM,TPS..LEAN is
possible without 5 S
5S……..a way of life.
Thank you