



What is 5S in the Work Place?

Lean Manufacturing ➝ 5S Methodology was developed in Japan and it is a system for organizing spaces so work can be performed efficiently & effectively with safely and it is a fundamental tool of

→ It is a system for organizing spaces so work can be performed efficiently & effectively with safely.

→ Sometimes it is also referred to as a good housekeeping practice but both are different things





History:

→ This methodology was developed in Japan by two gentlemen, Osada, and Hirano who structured a framework for implementing their philosophy.

→ Some say that the principles of this Methodology came from Henry Ford.

→ Henry Ford used the CANDO system (CANDO stands for Cleaning up, Arranging, Neatness, Discipline, and Ongoing Improvement) before the development of this Methodology.





Benefits of 5S:

→ Increase productivity through effectiveness

→ Reduction in delays

Quality → Improved

→ Improve in Safety

→ Set-up times reduced

→ Morale & Motivation Increase

→ Less stress for operators

→ Safer work environment

→ Improvement in the regular process





What does the 5S stand for?

→ It stands for five Japanese words Seiri, Seiton, Seiso, Seiketsu, and Shitsuke.

→ English Meaning of above Japanese words are :

→ (1S) Seiri → Sort or Tidiness

→ (2S) Seiton → Set In Order or Orderliness

→ (3S) Seiso → Shine (Clean) or Cleanliness

→ (4S) Seiketsu → Standardize or Standardization

→ (5S) Shitsuke → Sustain or Discipline

5S Implementation:

→ Now we will see the implementation of 5S step by step.





[1] 1S - Seiri or Sort:

→ The first step is Sort in this Methodology.

→ "Sorting" means to sort everything in each work area that we need and what we do not need?

→ Sort means removing unnecessary items or materials from a workspace.

→ Keep only what is actually required every day from the workspace.

→ Materials, equipment, instruments, or any things that are not frequently used should be moved to a separate, common storage area called Red Tag Zone.

→ Items that are not used should be removed or recycled.

→ Please do not keep anything in your workplace just because it might be used in the future.

→ The whole team should spend a few hours going through the entire area (inside cabinets, under and behind machines.. Everywhere !!!)

→ All obvious scrap should be put in the scrap area / Bin

→ All unidentified things should be put in the “Red tag”/ quarantine area.

→ Only items that are required should remain.





Steps for Sorting:

1. Cleaning

2. Classifying

3. Assign Responsibility

4. Red Tagging of unnecessary things

5. Recycling or Reassignment of things arrived in Red Tag Zone.





→ For better understanding show the below picture of Before-After comparison of Work Place and Red Tag:





5S Examples:

[2] 2S - Seiton or Set In Order:

→ Set in order is for organizing the items or materials at the workplace.

→ “ Define Place for Everything and Put Everything in its place”

→ We can use an organized workplace more efficiently and effectively

→ To arrange all necessary items for the economy of movement.

→ Put things as per the frequency of use.

→ Provide safe storage – heavy items at a low level, light items at a height.

→ If any item is missing then we can easily find out it





Basic Principles of Set in Order:

→ The items that are used very frequently should be kept nearer to where they are used.

→ Items that are used very few times should be kept far compare to frequently used things.

→ After completion of work keep things in its defined place.

→ If several things are used together, then store them together.

→ For example, a welding rod is used with a welding machine then both should be kept together.

→ Store things in place where people can easily find it.

→ Identify all items (including fixtures, gauges, tools, jigs, molds, etc.) and mark identification symbols on them so we can easily identify and return them to their identified storage location.

→ For better understanding refer the below picture of the sort in order.

5S Housekeeping:



[3] 3S - Seiso or Shine (cleaning):

→ After Sort and Set In Order, the workplace requires regular cleaning.

→ Shine is used for regular cleaning of the workplace, tools, and equipment

→ Cleanliness makes defects easier to detect.

→ Better customer satisfaction

→ Aids efficiency and reduces accidents

→ Creates a better working environment

→ It is not just the job of a housekeeper, it is everyone's responsibility

→ Every workplace should have a person, or group, assigned to clean that area.

→ The best approach is that those who work in a workplace are also responsible for cleaning that area.





(A) Cleaning is an ongoing process:

→ Define and document :

→ Decide Who, What, When, Where, How, etc…

→ Who is responsible for cleaning

→ What needs to be cleared and where

→ When it will be done

→ How is it to be done and which tools require

→ For better clarity refer to the below picture in which we can easily see the comparison of the workplace before and after cleaning.





[4] 4S - Seiketsu or Standardize:

→ After completion of Shine or Clean, Standardize will come.

→ Standardize means documenting all necessary processes or activities.

→ In Standardize we can turn Good Practices into Good Habits.

→ By developing standards for process, all person knows what to do, how to do, when to do, and where to do, etc..

→ Give awareness about standardizing to all persons.

→ It will help them to remember the new standards and it encourages them to do the same.

→ We can use labels, symbols, posters, and banners for standardization.





(A) How do we Standardise?