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5S

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5S is a method of creating a clean and orderly workplace

that exposes non value added activities and makes

abnormalities immediately visible.

When someone refers to 5S, theyre generally referring to 5

Japanese words those start with S. But, it would seem,

contrary to what many people assume the origins of 5Smay not be Japanese after all.

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This is a Japanese method of creating a highquality and highly productive environment or it isa systematic 5 step method of organizing yourwork place.

To reduce wasted effort

To reduce wasted time

To reduce money To enhance value of output

To improve employee moral and motivation


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History of 5S

In fact, Henry Fords CANDO program which stands forcleaning up, arranging, neatness, discipline, and ongoing

improvement seems to be the obvious precursor to what we

call 5S today. This actually seems very logical since the

Japanese studied Fords method shortly after the war

ended. But to be sure, the 5S were focused on in this course

and in most lean manufacturing situations is based on 5

Japanese words.


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They are:

Seiri (sort)which is commonly translated as sort

Seiton (set in order) which means to straighten

Seisou (shine) which means to sweep or shine

Seiketsu (standardize) which actually means tosanitize but is most commonly referred to as

standardize today Shitsuke (sustain) which means self discipline or

sustain

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1.Sort : Sort the first S, focuses on eliminatingunnecessary items from the work place that are notneeded for current production operations. An effectivevisual method to identify these unneeded items is called

redtagging,which involve the necessity of each itemin a work area and dealing with it appropriately. A redtag is placed on all items that are not important for alloperations or that is not in the proper place. Once thered tag items are identified, these items are then moved

to a central holding area for subsequent disposal,recycling and reassignment. Organizations often findthat sorting enables them to reclaim valuablefloor space and eliminate such things as broken

tools, scrap and excess raw materials.

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YELLOW LABEL METHOD:

When you are not sure.

On a fixed day label the item and mark date.

If labeled items used there after, remove the label.

Inspect after a specific period of time - which items stillhave labels, then put red tags on them.

If still not sure repeat inspection after some specific

period of time. Dispose of (if possible convert to cash) all obsolete

items.


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2. Set in order: Set in order can be defined as arrangingneeded items so that they are easy to find and put away. Set inorder can only be implemented once the first pillar Sort has

cleared the work area of unneeded items. Strategy for effectiveset in order include affixing labels to designate proper storagelocations.

every thing has a specific place

and every thing is in its place

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Implement a sign board strategy so that any locationcould be found easily.

Implement a grid system in large factories, offices andwarehouses.

Implement a floor painting strategy where all aisles,storage spaces, traffic flow lines are marked.

Implement a danger marking system.

Label all switches, fans, machines, chair tables actually

every thing. Clearly mark places for all tools, trolleys, vehicles,

guides, folders, needles and other maintenance andmechanics related tools.


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GRID SYSTEM:

Every building to be named A, B, C etc.

Grid system in large factory buildings andoffice buildings.

Every room to be labeled.

Every location of the factory should be able tobe located without difficulty.

Label strategy from the entrance.


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FLOOR PAINTING STRATEGY:

Working areas - green.

Aisles orange.

Warehouses gray.

Door opening marks.

Traffic flow direction lines.

You can mark with tiger pattern any where youneed to watch your steps, uneven steps, slipperyplaces.


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SIGNBOARD STRATEGY:

Factory ,work place, line, process.

Large and clear signs.

Use colors to distinguish.

All machines identified by name and number.

All assets to have inventory number. All employees should have a name and unique ID

number.


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STORAGE OF RESISTERS AND FILES:

File index displayed.

Color code.

Oblique lines.

Easy to see, easy to get and easy to return.

Identification strips on registers and books.

Homes for registers and books.

Tags for important pages.


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VISUAL CONTROL:

By color, shape etc.

Something that hits you in the eye easily.

To easily locate things.

To detect automatically.

To easily see current situation.

To easily see current problem.


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SAFETY SIGN:

DONTDO signs. MUSTDO signs.

Warning signs,

Safe way signs. Different colors.


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PROPER-AXIS ALIGNMENT:

Every thing should be aligned along proper axis.

Notice boards, charts on walls, calendars, paintings etc.

Machines and furniture wherever possible.

Shoe racks etc.

Vehicle parking

Things on the table tops.

No one should be allowed to keep anything out ofalignment.


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3. Shine: Shine means sweeping floors, cleaning machineryand make sure everything in the floor stays clean.

Working in a clean environment enable workers to noticemalfunctions in equipments such as leaks. These changesif left unattended could lead to equipment failure and lossof production. Organizations provides tools for cleaning

before starting shine operations.

Example : Machineries dust off and maintained.

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Introduce self cleaning culture.

Implement cleaning responsibility and schedule.

Prepare appropriate cleaning tools, methods and

materials. Implement a garbage bin strategy.

Introduce a daily 5s 5 minute system where everyone

participates in cleaning activities.

Investigate sources of dust and grime.

Use 5 human senses for checking while cleaning.

Dirt and dust prevention is better than always cleaning.


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CLEANING:

What to clean.

When to clean.

In which order to clean. Who is responsible.

How to clean.

What tools to use.

What materials to use. Storage of cleaning tools.

Teach people how to use them.


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5 minute cleaning:

Fixed or ad-hoc time.

Bell or alarm or music.

Procedure for checking.

Everyone must participate.

Rigidly applied even when on the phone orhaving visitors.


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THE 5S PLEDGE:

I will not get things dirty.

I will not spill. I will not scatter things around.

I will clean things right away.

I will make cleaning a habit.

I will appreciate people who maintains highstandard.

I will encourage people for preventive cleaning.


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4. Standardize: Once the first three S have beenimplemented, the next pillar is to standardized the bestpractices in the work floor. Standardize, the method toperform the first three pillars creates a consistent

approach with which tasks and procedures are done.

Standardization is the process to make sure that the entire

organization follows the same rules, same procedure, same

color code, same names, same philosophy.


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The two steps in the process are-

Assigning 5S job responsibilities.

Integrating 5S duties into regular work duties.

The second part of standardization is prevention preventing accumulation of unneeded items, preventing

equipments and floors from getting dirty.


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5. Sustain : Sustain is a habit of maintaining correctprocedure. Without sustain other four pillars will not last longer.Changing behavior of the people is very difficult and there is a

tendency among the people that they want to go back to oldmethod. Proper monitoring and corrective actions are requiredfor this pillar.

The success of 5S pillar depends on:

Proper training.Participation of all workers.Correct procedure to do a particular job.Managers commitment to carry on better procedure.

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Create a 5s culture where everyone willingly

participate.

Motivate through inter departmental

competitions.

Organize a 5s petrol team.

Reward good practices.

Top management should regularly inspect.


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Precondition for sustain:Awareness: you and your employees need to understandwhat the five pillars are and how important to carry on these

things.

Time: you need to have and make enough time in your workschedule to perform 5s daily.

Structure: you need to have support for your efforts fromyour top management in terms of resources and otherfacilities.


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Procedure for implementing 5S: Form a 5S team.

Develop a plan for each S.

Publicly announce the program.

Provide training and education to employees.

Select a day from when everyone starts formally practicing

5S.

Evaluate the results of 5S.

Take corrective actions.


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The Benefits of 5S:

If you paint the floor and machines with light color andclean them regularly, it may decrease energy consumption

because in day time less light will be needed. Painting and cleaning make it easier for the worker to find

any leakage specially oil leakage.

Proper cleaning may reduce accident probability.

Proper cleaning may reduce considerable amount of

defects. Proper sort may increase the real usable space.

Proper set in order can reduce searching time.


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Where can 5S be applied?

In homes

In schools

In offices

In factories

In hospitals

In work sites

In fact any where.


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Purpose of 5S

Improving the image of the company:

5s improves the image of the company. When thebuyers see a company follows 5s activities, theygets an impression that such a beautifullymanaged company must be producing goods ofhigh quality and must be delivering thempromptly and they feel no doubt about it.

Subsequently, the orders they receive to-datewould increase and would even start newtransactions.


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Improving productivity and prompt delivery:

When fabrics, accessories, machine parts etc

are stored in a way that they could be taken

out easily, time wasted for searching them,

planning time, transaction time, working time

could be shortened and by that delays could

be prevented.


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Reducing stocks:

By sorting out (seiri) materials such as

unnecessary stocks could be reduced. Then

arrange them in an order (seiton) and prevent

collecting in excess.


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Cutting down cost:

The above mentioned improvements in

productivity, quality, reduction in stocks etc

connect through to reduce the cost. Then

attempts could be made on cutting down

expenses by taking measures to prevent water

and electricity leakage etc.


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Managing safety:

Passages to walk through safely and area wheresome work could be done are maintainedproperly. Materials garments parts are storedorderly in a way that they would not fall down.The floor is free of cut pieces etc. safe enoughthat nobody will slip and injure themselves. The

rules for needle controlling etc are followed. Byfollowing 5s, safety of the employees could bemaintained.


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Activating a system and improving morale:

To work in a neat and clean work place is a

comfortable feeling for anyone and when it isso, they become interested in work. Also byfollowing the 5s, relationships betweenpeople and team work becomes cheerful andthereby the work place would systemized andmorale would increase.

md. imrul kaes - 5s 2013-4-17

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