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PREPARED BY

5S
HAIDER ALAM

5 S… SEIRI, SEITON, SEISOU,


SEIKETSU, SHITSUKE

5S is the basis of all


operations
5S is the basis of all production
activities

Manufacturing 1
Division
What is 5S ?

Cleaning

To create a safety working environment


To produce good quality products
To achieve maximum efficiency
2
5S
1. SEIRI
2. SEITON
3. SEISOU What do they actually
mean ?
4. SEIKETSU
5. SHITSUKE
3
1. SEIRI
Classify clearly the items into necessary and
unnecessary items, then dispose of unnecessary items

Do not leave SEIRI half done. All of the unnecessary


items should be discarded. Not N Not
a ry eces
Neces s sary

Not
Necessary

Not
Necessary
4
How to implement “SEIRI”
Step1:Classification – Classify into the necessary items and unnecessary items.
Step2:Discard - “ Keep for any possibility to use”←Excuse
Step3:Positioning - Decide “where to use” ”where to place”
“how many” and “how to place”.

All of the non-frequent-use items are unnecessary


  ・ No use more than 1 year --- ‐ Discard
 ・ Use within 6 months to 1 year - ‐ Keep in far distance
 ・ Use within 1 month to 6 months -- ‐ Collect and Keep in one
place of shop floor.
 ・ Use in every week -------- Keep within work area
 ・ Use in every day --------- Easy picking
                  ----- Easy
return
                  ----- Clear
classification
 ・ Use in every hour ----- Place within the arm’s length5
    -- Items of right hand operation should be placed on the
2. SEITON
Place necessary items at proper position
for practical usage and clearly indicate the contents
so that everyone can understand.

B C


6
How to implement “SEITON”
・ Standardized location, Standardized quantity
 - Easy picking, easy locating

・ Visually neat & clean and compact  


- Condition of proper arrangement of passage, operation area, product storage site, jig
&
tools storage site and spare part storage site.

How to implement “standardized location and standardized quantity”


①Where to use   -----→ Clarify the purpose of use, and place of use
②Where to keep  -----→ Place the items near to the place of use
③How many   -----→ Decide the maximum and minimum quantity
④How to keep  -----→ Easy to place, Easy to pick (Use one-touch system)
⑤Indication of storage site ---→ Color, box
⑥Visually understandable →Indication of items (Back Numbers), Indication of quantity
⑦Visually understand the period of stock→Visually understand the stock date,
date of first-in and first-out”
⑧Fix responsible person for control →Clarification of responsible person
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3. SEISOU
Keep cleaning up the working area, floor,
equipments, jig&tools and part shelves and
make them always clean.
“SEISOU is to create the working area where special cleaning become unnecessary
through daily check and measure for cause of dirt.”
In case of oil leakage on floor ・・・
Worker may slip and fall. It may cause an injury.
It increases unnecessary cleaning (man-power and time are required)
and wastes money.

In case cutting powders are clogging ・・・


Products are not fixed well on jig and it causes short stoppage.
Powders come into the oil hole and it affects quality.
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4. SEIKETSU
Keep 3S (Seiri / Seiton / Seisou)
in good condition

Frequent Seiri & Seiton are required.


Seisou with few frequency is no use.

Conduct Seiri, Seiton, Seisou periodically


and keep working place neat and clean.

That means, 3S must be implemented completely.


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5. SHITSUKE
Acquire the habit of doing what has been determined
according to the set rules.

Keep all the rules such as;


Rule to secure safety
Rule to assure quality etc.
Acquire the habit of keeping rules
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How to implement “SHITSUKE”
“SHITSUKE is to create standard to follow
and to grow up the employees who can follow the standard
and to make employees willing to follow ”

The rules difficult to keep for yourself will not be


able to be kept by your subordinates, either.
  

Think about the reasons why rules are not kept


and make rules which everyone can keep.

5S starts from SHITSUKE and finishes at SHITSUKE


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Understanding of 5S

Carry out 5S activity with full understanding.


Know Acquire the knowledge of 5S

Understand Fully understand the meaning of 5S

To be able to Be able to carry out 5S activity


carry out

To be able to Get into the habit of taking 5S activity.


carry out as a habit (Repeatedly take 5S activities.) 12
Utilization of 5S

Visible
5S Control

13
I am taking one piece !

14
Seiri & Seiton are carried out

15
What is missing now ?

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Visible Inventory Control

We can easily and clearly count the No. of items.

“Excess” or “Shortage” can be identified. Inventory reduction has achieved.


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Summary
1. SEIRI
Classify clearly the items into necessary and unnecessary items, then
dispose of unnecessary items
2. SEITON
Place items at proper position for practical usage and clearly indicate the
contents so that everyone can understand.
3. SEISOU
Keep always cleaning up. And make the working area, floor, equipments,
jig & tools and part shelves neat and clean.
4. SEIKETSU
Keep 3S (Seiri / Seiton / Seisou) in good condition.
5. SHITSUKE
Acquire the habit of doing what has been determined according to the set
rules.
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Points to effectively proceed 5S

Point 1 Managerial class should take initiative as a model case.


     ① Show and verify the result to subordinates.
     ② Strengthen leadership ability of managerial class.
      ③ Able to apply and continue for future development

Point 2 All of the employees should participate in activity


   ① Hold “5S time” for approx. 10 minutes every day      
In case “5S time” is held during working time, it become one of their jobs
and they become serious for 5S.
②5S activity should be the activity for all of the departments and sections
such as deskwork staff, sales Div., manufacturing Div. and shop floor.

Point 3 Confirm the results


  ① Shoot videos of your own working area before the 5S implementation,

and make a time-series video of the area according to the activity


progress.          (Fixed location observation) 19
If 5S is carried out well,

- Safety working place is created.


- Good quality products are manufactured.
- Maximum efficiency are achieved.

5S is the basis for all.


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5S
  Basic Education Text Code 3-004
     November 1, 2001 First Edition
October 1, 2002 Revision
June 1, 2005 Revision by NE-T   1

Issuing Department:
Production Engineering Administration Department,
Manufacturing Division,
Suzuki Motor Corporation

This textbook is only for internal use. (All rights reserved.) 21

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