Académique Documents
Professionnel Documents
Culture Documents
Step-by-Step Implementation
5S
Textbook &
Instructors manual
August, 2006
Japan Productivity Center for Socio-Economic Development
(JPC-SED)
Japan Productivity Center for Socio-Economic Development 1
Purpose of Instructors Manual
The global economic challenge have changed the perspectives of working
culture towards excellent working performance with the adoption of best
practices. One of the tools to achieve organizational excellence is the 5S
management techniques.
5S management
g techniques
q have contributed significantly
g y to improve
p internal
efficiencies, operational effectiveness and foster on time delivery system to the
delight of customers. To achieve this, organizations should integrate 5S
activities into their business functions as their organizational culture.
National Productivity Corporation (NPC) has been the leading organization and
disseminator of 5S best practices. It has continuously been improving 5S
activities as a more effective approach in business operations.
Accumulation of Wastes 4
Implementation of 5S 13
5S & KAIZEN 77
Visual Control 102
Throw away
Seiri Sort Organization
unnecessary items
30 second retrieval
Seiton Set in order Neatness of a documents /
tools
Individual cleaning
Seiso Shine Cleaning
responsibility
Standardizati Transparency
p y of
Seiketsu Standardize
on or Hygine storage
Sustain /
Shitsuke discipline
p Do 5S dailyy
Discipline
Japan Productivity Center for Socio-Economic Development 15
3 Definition of 5S
3.
5. Sustain (Shitsuke)
To train people to practice the 5S system continuously so
that it becomes habitual and ingrained in the culture of the
organization.
It does
d not require the
h understanding
d d off difficult
d ff l
terminologies.
It is simple, driven by logic and natural to human
behavior.
It is within the reach of all type and size of industry or
organization.
P,Q,C,D
Improvement of operation
5S efficiency
Sort (Seiri)
S
Set in Order (Seiton)
Improvement in safety
Shine (Seiso)
Standardize (Seiketsu)
Sustain (Shitsuke) M
Improvement in morale
Raw materials or products that are not put properly, oil spilt
on the floor, etc. may cause workers industrial
accidents.
Work management
Production control
Qualityy management
Q g
Productivity improvement
5S
Preparation
- Provide training and education for everyone
- Form 5S team
- Set up 5S zone
- Determine 5S objectives, goals and implementation
phases
- Make 5S action plan and launch 5S.
Sort:
- Identify what is necessary
Set in order:
- Define what and how to arrange
Shine:
- Identify dirt sources
- Identify root causes
- Take an action to eliminate dirt sources and root causes
Standardize:
- Who is responsible?
- What
Wh t actions
ti to
t ttake
k tto maintain
i t i th
the d
desired
i d condition?
diti ?
- When must those action be taken?
- Where
h must they
h apply?
l ?
- What procedures need to be followed?
Sustain
- Everyone understands, obeys and practices the rules
and procedures
Japan Productivity Center for Socio-Economic Development 31
6 3 Check
6-3
Assessment
- Conduct internal 5S audit.
- Benchmark within the department and with other
organization.
- Ensure the established 5S procedures and follow them
thoroughly.
Continuous improvement
- Develop 5S practices into a HABIT.
- Compare actual goals with set goals.
- Reward and recognize efforts of staff.
- Register 5S Certification.
- Review Plan-Do-Check-Act Cycle.
P Sort
R
E Set in order
P
Shine
5S CONTINUAL
A
R Audit IMPROVEMENT
A Standardize
T
I Sustain
O
PHASE PHASE PHASE PHASE
N
1 2 3 4
ENABLERS RESULTS
Japan Productivity Center for Socio-Economic Development 34
7 Plan
7.
Objectives:
To enhance total participation at all levels of employees and
to develop a continuous improvement culture and best
performance spirit in the teams.
P id t
President
5S 5S
Committee Facilitator
5S 5S 5S 5S
group group group group
Decision-making
Decision making of 5S activity
Leveling of 5S activity of each group
Assisting the facilitator
Diagnosis by the top management
5S POLICY
We shall continuously maintain a high standard of 5S practices
at our workplace through teamwork and self discipline.
In doing so, we shall achieve:
Improved productivity
Consistent high quality products and services
Timely delivery
Reduces cost
Safe working environment
5S GOAL
To be recognized as a National 5S Model Company
Japan Productivity Center for Socio-Economic Development 49
8 Do
8.
Description:
Sort focuses on eliminating unnecessary items in the
workplace.
Guidelines:
It is the series of steps which keep only
that is needed
the amount needed and
when
h it is
i needed
d d
Japan Productivity Center for Socio-Economic Development 51
8 1 Guidelines for practicing SORT (Contd.)
8-1 (Contd )
UNNECESSARY REQUIRED
ITEMS ACTION
Items having no
Throw away
value and easy to
immediately
dispose
Disposal
p standard
Potential impacts:
Description:
SET IN ORDER reflects a very popular saying: A place
for everything and everything in its place.
It emphasizes safety, efficiency and effective storage and
consequently improves the appearance of the workplace.
NECESSARY REQUIRED
ITEMS ACTION
Potential impacts:
Description:
SHINE is to clean the workplace thoroughly. It ensures a
more comfortable
f t bl and
d safer
f workplace,
k l as wellll as better
b tt
visibility, which reduces retrieval time and ensures higher
quality work
work, product or service
service.
Everyone enjoys working in a clean environment which morale
and
d increases
i productivity.
d ti it
Potential impacts:
Higher
h quality
l workk and
d products.
d
More comfortable and safer work environment
Greater
G t visibility
i ibilit and
d reduced
d d retrieval
ti l time
ti
Lower maintenance cost
Creates positive impression on visitors and during customers
inspections
Description:
Standardize is to ensure a high standard of workplace
organization by continued employment of SORT, SET IN
ORDER and SHINE.
Guidelines:
Once the 3S are in place, the next step is to concentrate on
standardizing best practices. The plan must include the
creation of procedures and simple daily checklists which are to
be visibly displayed at every workplace.
Potential impacts:
Description:
Sustain is to make it a habit of maintaining the momentum
of the previous four S to ensure sustainability of the system
and to make further improvement by encouraging effective
use of P-D-C-A Cycle.
Guidelines:
Build awareness of the importance of 5S through retraining.
Reward and recognize efforts of staff
staff.
Use techniques / approaches / strategies to sustain
activities.
Review
5S Slogans and posters
5S Newsletters to share the progress of 5S activities
5S Achievements indicators
Potential impacts:
Objectives:
b
To ensure that the organization can assess its strength as
well as the areas for improvement and where the
organization stands in the 5S movement.
p
This evaluation and competition must be linked with a reward
system; most successful organizations offer monthly rewards
for the winning teams in the various 5S categories.
Importance of KPIs
The
h self-assessment
lf and
d 5S certification
f naturally
ll drives
d
the
organization goal to continually improve on the quality and
the cost effectiveness of providing the product or service
through systematic guide using Key Performance Indicators
(KPIs).
Clarification
Cl ifi ti off waste,
t abnormality
b lit
and other problems
Placement standardization
Seiton
Seiri
Define items that are used frequently and then place them
near the workers who use them.
Other less frequently used items are placed farther away.
Hooked signboard
Standing signboard
Example
p of quantity
q y indication
Defective
products WIP
Passage
Position mark
IIndex
d off
Classification Example
activity
Moving on the belt conveyer,
g
Moving 4
lift ca
lift, cart,
t etc
etc.
In the cart or other
In a cart 3
equipment with wheels
Put in a In the box which is in a
2
elevated box elevated position
Where : Place
Who : Person in charge
When : Frequency
How : Cleaning method
Sourcee: Y.Monden,
Y Monden Toyota
Toyota Production System
System , Engineering and Management Press
Source: Y.Monden,
Y Monden Toyota
Toyota Production System
System , Engineering and Management Press
It iis important
i t t tto understand
d t d th the objectives
bj ti tto fform th
the
habit.
Warning signboard
Caterpillar
Danger!
Tube
Production
P d ti achievement
hi t ratio
ti
Limit
Li it samples
l
Control chart