5S is a fundamental first step for any manufacturing company, wishing to call itself world class. We will understand this with step by step approach of its deployment. The 5S program mandates that resources be provided at the required location and be available to support work activities. These ideals ensure that operations and tasks can be executed as required.

5 Ss are derived from the first letters of the Japanese words. The five Japanese “s” words for workplace organization are:

1. Seiko (proper arrangement)

2. Seiton (orderliness)

3. Seiketso (personal cleanliness)

4. Seiso (cleanup)

5. Shitsuke (personal discipline)

These are translated into approximate English equivalents as:

1. Sort : Separate out all that is unneeded and eliminate it.

2. Straighten(Set) : Put things in order, everything has a place.

3. Scrub ( or shine) : Clean everything, make the workplace spotless.

4. Standardize : Make cleaning and checking routine.

5. Sustain : Sustain the previous 4 steps and improve continually on them.

The 5S approach shows determination to organize the workplace, keep it neat and clean, establish standardized condition and maintain the discipline that is needed to do the job. Now there have been multiple changes in 5S, it can be reduced to 4S or modified to 6S. The 6th S can be Safety.

1. Sort : Separate out all that is unneeded and eliminate it

Set up a schedule to target each area

Remove unnecessary items in the workplace

Red tag unnecessary items, record everything that is thrown out

Keep repaired items that will be needed

Complete housekeeping and cleaning is done

Inspect the facility for problems, breakages, rust and scratches

List everything that needs repair

Deal with causes of filth and grime. Red tag grime areas and prioritize conditions for correction

Perform management reviews





2. Straighten(Set) : Put things in order, everything has a place

Have a place for everything and everything it its place to assure neatness

Analyze the existing conditions(status quo) for tooling, equipment, machinery, inventory, supplies, wiring, dashboards etc. including retrieval and storage does

Decide where things go, reduce inventories, create name and location for everything

Decide how things should be put away, including the exact location. Use labels, tool outlines and color codes

Obey the rules. Determine everyday controls and out of stock conditions

Define who does the reordering

Determine who has missing items or if they are lost

Use aisle markings for forklifts, boxes etc. and establish pallet zones for work in progress(WIP)



3. Scrub ( or shine) : Clean everything, make the workplace spotless

This is more than keeping things clean, it includes ways to keep things clean

Establish a philosophy and commitment to be responsible for all aspects of working conditions

Clean everything in the workplace, including equipment and correct root causes (identified in step 1)

Perform RCA and remedy machinery and equipment problems

Complete training on basics of equipment maintenance

Divide each area into zones and assign individual responsibilities for each zone

Rotate difficult and unpleasant jobs

Implement 3-min, 5-min and 10-min 5S activities

Use inspection checklists and perform white rag inspections

4. Standardize : Make cleaning and checking routine

Make 5S activities routine so that abnormal conditions show up

Determine the important points to manage and where to look

Maintain and monitor facilities to assure a state of cleanliness

Make abnormal conditions obvious with visual controls

Set standards, determine necessary tools and identify abnormalities

Determine inspection methods, short term countermeasures and long term remedies

Use visual management tools such as color coding, markings(showing direction or position), labels, equipment markings, maps and charts

5. Sustain : Sustain the previous 4 steps and improve continually on them



Sustain the 4 previous steps and continually improve on them

Acquire self-discipline through the habit of repeating the 4 previous steps

Establish standards for each of the 5S step

Establish and perform evaluations for each step

The management commitment will determine the control and self discipline areas for an organization. A 5S program can be set up and operational within 5 to 6 months, but the efforts to maintain world class conditions must be continuous.



