5 S Concepts

One of the easiest ways to

determine a companys attitude
towards improvement activities is to
take a walk around the factory and
review the housekeeping practices on
the shop floor.
If
we
are
observant,
housekeeping often tells us more
about the company than any financial
statement

What is your workplace like ?

In my workplace, everybody throws things around
and there is nobody to clean the place up 3rd
Class workplace
In my workplace, people do throw things around, but
there are cleaners who tidy up the place
2nd Class workplace
In my workplace, nobody throws things around.
Every body helps to keep the place clean
1st Class workplace

Importance of 5S
A clean workplace is high in Productivity
A clean workplace has high Quality
A clean workplace keeps Cost down
A clean workplace ensures Delivery on time
A clean workplace is Safe for people to work
A clean workplace is high in Morale

What is 5S

The term 5S represents 5 Japanese words :

Seiri Take out unnecessary items and throw them away
Seiton A place for every thing Everything in its place
Seiso Clean up
Seiketsu Cleanliness, workplace organisation
Shitsuke Training and self discipline & control

1S - Seiri

Take out unnecessary items and throw them away

First identify goods that seem to be unnecessary
Then post a Disposal Notice Card to each item
describing :
1. What it is,
2. Why it is there,
3. Who it belongs to, and
4. When it is to be disposed of
At the end of the stated period (eg. 1 to 2 months after
posting), review the cards to see if any one has responded
with a need to keep the items.
Items are disposed if there is no response
It is recommended that this approach be used plant wide,
involving people from different disciplines

DISPOSAL NOTICE

Inspectorss name : 5s Facilitator, Manager

Description of Item : Inspector to describe item accurately
Date posted
: To determine period of consideration
Please reply by
: Deadline for reply
------------------------------------------------------------------------------------------

OWNERS REPLY

Description

: The owner should confirm or correct the

description given by the owner
Status
: eg. Defect item, awaiting parts
Disposal Plan : eg. Throw-away, relocate. Date for disposal
action should be stated
Owners Name : Section Leader, Supervisor, Manager, etc.
Date
: Date of reply

2S Seiton
Arrange necessary items in a proper order so that
they can be easily picked up for use
Arrange remaining tooling according to :
- Product group, type, code, etc.
Design better arrangement for storing
Label arranged items

A place for every thing

Everything in its place

3S Seiso

Clean your workplace completely so that

there is no dust anywhere on the floor,
machines and equipment

4S Seiketsu

Maintain high standard of housekeeping and

workplace organisation at all times
System of maintenance using
- Checklist
- Audit

5S Shitsuke

Train people to follow good housekeeping

discipline independently

WHEN TO START 5S ?

1S Seiri

SORT OUT ITEMS AND DISCARD THE UNNECESSARY

Do you find items scattered in your workplace ?
Do you spend time in locating an item ?
Is space not sufficient for storing items ?

2S Seiton

ARRANGE
Are passage ways and storage places clearly indicated ?
Are commonly used tools and stationery separated from those
seldom used ?
Are containers and boxes stacked up properly ?
Are fire extinguishers readily accessible ?
Are there grooves, cracks or bumps on the floor which hinder
work or safety ?

3S Seiso

CLEAN YOUR WORKPLACE THOROUGHLY

Are the floor surfaces dirty ?

Are machines and equipments dirty ?
Are wires & pipes dirty or stained ?
Are machines dirtied by lubricants ?
Are shades, light bulbs dirty ?

4S Seiketsu

MAINTAIN A STANDARD

Is anyones uniform dirty or untidy ?

Are there sufficient lights ?
Is workplace noisy causing discomfort ?
Are pipes leaking ?
Do people eat at designated places only ?

5S Shitsuke

TRAIN PEOPLE TO BE DISCIPLINED

Are regular 5S checks conducted ?

Do people clean up without reminders ?
Do people follow rules and instructions ?
Do people wear their uniforms and safety gear properly ?
Do people assemble on time ?

WHY 5S ?
An edge over competitors in terms of
- Productivity, Quality, Cost, Delivery
Disciplined workforce
Waste Elimination
Better organised workplace
A safe working environment
A motivated workforce

BENEFITS OF 5S ?
Non-value added (Waste) time is reduced in
Searching
Idle time for machine and man
Increase in Production output

Machine troubles can be detected at an earlier stage to prevent a

major breakdown when machines are cleaned daily by operating
people
Inventory of materials and work-in-progress will become clearly
visible
Reduced material handling

BENEFITS OF 5S

Neat and clean workplace

Improved safety
Ownership
Confident workforce

Removing Red Tagged stuff

What Stuff would you Red Tag in these pictures ?

Think Break

Picture A__________________________________________________________
Picture B _________________________________________________________
21

Think Break

In the following pictures, identify some of the finding wastes ( assume you work in a
distribution center and you have to fill an order with product located in the following
pictures).

Finding Wastes
___________________
___________________
___________________
___________________

___________________
___________________
___________________
___________________

_________________
_________________
_________________
_________________

Everything has a useable place

22

Some evidence of standardized work areas

Clear, shiny aisle ways

Color coded areas
Slogans, banners

No work-in-process ( WIP )
One-Piece Flow
Standardized Work Sheets

23

WASTE - DEFINED

ANYTHING OTHER THAN THE MINIMUM AMOUNT OF

EQUIPMENT, MATERIALS, PARTS,

SPACE AND

WORKERS TIME WHICH ARE ABSOLUTELY ESSENTIAL

TO ADD VALUE TO THE PRODUCT

IF IT DOESNT ADD VALUE, ITS WASTE

WASTE - SCENES IN FACTORY

CARRYING HEAVY
WORKPIECES

WASTE - SCENES IN FACTORY

TEMPORARY
STORAGE

WARE HOUSE

WASTE - SCENES IN FACTORY

COUNTING THE
NUMBER OF PARTS

1, 2, 3 ...

PACK
BOX

WASTE - SCENES IN FACTORY

OVER PRODUCTION AND DOUBLE HANDLING

WASTE - SCENES IN FACTORY

PARTS SHORTAGE

WASTE - SCENES IN FACTORY

WATCHING THE
MACHINE RUN

LATHE MACHINE

WASTE - SCENES IN FACTORY

TRANSFERRING
PARTS OVER A
LONG DISTANCE

WASTE - SCENES IN FACTORY

MACHINE
BREAKDOWN

!
DRILLING

WASTE - SCENES IN FACTORY

LOOKING FOR
TOOLS

WASTE - SCENES IN FACTORY

ACCUMULATING
INVENTORIES

WASTE - SCENES IN FACTORY

REWORK AND
REJECTS

NOK
OK

WASTE - SCENES IN FACTORY

Peoples effort is not being wasted as long as they are busy.

Do you Agree?

WASTE - SCENES IN FACTORY

Unnecessary Tasks

Unnecessary parts of tasks

Task that could be made quicker

Tasks that could made be easier

WASTE - SCENES IN FACTORY

Ten ways to make task easier

Eliminate lifting wherever possible

Use colour and symbol coding to reduce decision

making

Provide checklists of optimum set up and operating

conditions machine speed, temperature and feed rates
etc.

Use pop-in fasteners rather than threaded ones

Use hand power tools as much as possible and multiple

tools (perhaps colour coded to prevent confusion) to
avoid changing bits or drills

WASTE - SCENES IN FACTORY

Ten ways to make task easier

Use gravity assemble downwards rather than upwards

even if this means turning the assembly upside down

Use short bolts that are as short as possible

Keep workplaces tidy and uncluttered

Have everything that is needed within arms reach (rather

than just a step away)

Replace all broken and worn hand tools that dont work
first time every time

VALUE ADDED TIME

TIME SPEND BY PEOPLE
WAITING FOR MATERIALS
WATCHING MACHINE RUN
PRODUCING DEFECTS
LOOKING FOR TOOLS
FIXING M/C BREAKDOWN ETC.

WASTE

1st Qtr
2nd Qtr

VALUE ADDED
PORTION OF TIME

TIME SPEND BY MATERIALS

TRANSPORTATION
STORAGE
INSPECTION
RE-WORK
SET-UP TIME
M/C BREAKDOWN
UNPRODUCTIVE MAINTENANCE
UNNECESSARY MOVEMENT
OF MACHINERY
PRODUCING PARTS WHEN
NOT NEEDED

WASTE

1st Qtr
2nd Qtr

VALUE ADDED
PORTION OF TIME

UTILISATION OF MACHINES
WASTE

1st Qtr
2nd Qtr

VALUE ADDED
PORTION OF TIME

7 BIG WASTES OVERPRODUCTION

1. WASTE FROM OVERPRODUCTION :
WASTE TO PRODUCE UNNECESSARY PRODUT, UNNECESSARY QUANTITY AND
AT UNNECESSARY TIME
BY-PRODUCTS OF OVERPRODUCTION :

EXTRA HANDLING

EXTRA INVENOIRY
EXTRA SPACE
EXTRA INTEREST CHARGES

WASTE OF OVER
PRODUCTION

EXTRA MACHINERY
EXTRA DEFECTS
EXTRA OVERHEAD

EXTRA INVENOIRY

EXTRA INVENOIRY

7 BIG WASTES OVERPRODUCTION

ONE OF THE WORST WASTE COMMONLY FOUND IN FACTORIES.

CREATED BY PRODUCING GOODS OVER AND ABOVE THE AMOUNT REQUIRED BY THE
MARKET.
THE EFFECTS OF OVERPRODUCTION ARE COMPOUNDED AND RESULTS INTO MORE
PROBLEMS.

CAUSE :
TOO MANY OPERATORS, OVER CAPACITY OF FACILITY, BIG LOT PRODUCTION,
PRODUCTION SYSTEM NOT TO PREVENT OVERPRODUCTION
COUNTER MEASURES:

ONE LESS AT A TIME PRODUCTION (ONE PIECE FLOW)

QUICK TOOLING CHANGE
FLEXIBILITY
MULTI LOADING
FORECASTING OF MARKET DEMAND AND EQUIALIZED PRODUCTION
STRATEGIC VENDOR MANAGEMENT

7 BIG WASTES WAITING TIME

2. WASTE OF WAITING TIME :
WASTE TO WAIT NEXT NEXT JOB (OPERATION, TRANSPORTATION, INSPECTION,
MATERIAL, etc.) AND WASTE OF WATCHING, etc.
EXAMPLESWATCHING MACHINES RUN, WAITING FOR MATERIAL, SPARES, TOOLS,
WAITING FOR MACHINE REPAIR ETC.

CAUSE :
BIG LOT PRODUCTION, INAPPROPRIATE LAYOUT, UNBALANCE OF PRODUCTION
CAPACITY OF THE FACILITY, TROUBLE OF PREVIOUS OPERATION, etc
COUNTER MEASURES:

LINE BALANCING or EQUALIZED PRODUCTION

FACILITY LAYOUT BY PRODUCT (U-SHAPE)
FOOL PROOF or AUTO STOP MECHANISM DETECTING DEFECT, etc

7 BIG WASTES TRANSPORTATION

3. TRANSPORTATION WASTE :
-

WASTE OF UNNECESSARY TRANSPORTATION, UNNECESSARY TRANSFER,

UNNECESSARY PILING, etc.

DOUBLE OR TRIPLE HANDLING BETWEEN TEMPORARY STORAGE & WORK CENTRE

INTER DEPARTMENTAL/ LONG DISTANCE HANDLING

CAUSE :
BIG LOT PRODUCTION, INAPPROPRIATE LAYOUT, UNBALANCE OF PRODUCTION
CAPACITY OF THE FACILITY, TROUBLE OF PREVIOUS OPERATION, etc
COUNTER MEASURES:

LINE BALANCING or EQUALIZED PRODUCTION

FACILITY LAYOUT BY PRODUCT (U-SHAPE)
FOOL PROOF or AUTO STOP MECHANISM DETECTING DEFECT
5S & HOUSE KEEPING, etc.

7 BIG WASTES - PROCESSING

4. PROCESSING WASTE :

ORIGINALLY UNNECESSARY PROCESS ( THOUGHT TO BE NECESSARY)

CAUSE :
INADEQUATE STUDY OF PROCESS, OPERATION AND MATERIAL or WRONG
PROCESSING METHODS, INEFFICIENT JIGS & FIXTURES, UNDER UTILISATION OF
CAPACITY, IMPROPER PRODUCTION PLANNING & CONTROL , etc
COUNTER MEASURES:

REVIEW OF PROCESS DESIGN AND OPERATION

EFFECTIVE PRODUCTION PLANNING AND CONTROL SYSTEMS
IMPROVEMENT OF JIG/FIXTURES
VALUE ANLYSIS/ VALUE ENGINEERING, etc

7 BIG WASTES - INVENTORY

5. INVENTORY WASTE :
- WASTE OF MATERIAL PARTS, SUB ASSEMBLY TO BE STAGRANT, WORK IN IN
-

PROCESS, etc.
EXCESS INVENTORY INCREASES THE COST OF A PRODUCT. IT REQUIRES EXTRA
HANDLING, EXTRA SPACE, EXTRA INTEREST CHARGES, EXTRA PEOPLE, EXTRA
PAPERWORK, AND SO ON.

CAUSE :
IMPROPER LINE BALANCING, INAPPROPRIATE LAYOUT, PROCUREMENT IN LARGE LOT
SIZE, MANUFACTURE PRODUCTS IN LARGE BATCH SIZE, IMPROPER HOUSE KEEPING, etc

COUNTER MEASURES:

BETTER INVENTORY MANAGEEMENT

U-SHAPE LAY LAYOUT
BALANCED PRODUCTION
QUICK TOOLING CHANGE /JIT etc.

7 BIG WASTES - MOTION

6.

WASTE OF MOTION:
- WASTE OF UNNECESSARY MOTION, SLOW MOTION, NON-VALUE ADDED MOTION etc.
- UNWANTED MOTION DOES NOT NECESSARILY ADD VALUE TO THE PRODUCT ITSELF.
-

EXAMPLES: MOVE, PICK &PLACE , WALKING

CAUSE :
OPERATION AT ISOLATED ISLAND, SPREAD OF OF OIL, INAPPROPRIATE LAYOUT, LACK
OF OPERATOR TRAINING, etc

COUNTER MEASURES:

OPERATION IN FLOW
U-SHAPE LAY LAYOUT
STANDARD OPERATION
OPERATOR TRAINING etc.

7 BIG WASTES - DEFECTS

7.

WASTE OF MAKING DEFECT:

WASTE MAKE DEFECTS, REPAIR WORK/ REWORK, INSPECTION TO PICK OUT DEFECTS

PRODUCT DEFECT RESULTS INTO DIRECT WASTE IN MANUFACTURING SETUPS.

ADDING COST COST TO THE PRODUCT DUE TO RESOURCE WASTE, INCREASED

PRODUCTION LEADTIME, REWORK/ REPAIR, INSPECTION PERSONNEL, WARRANTY COST ,
ADDITIONAL DELIVERY COS, ETC..

CAUSE :
INAPPROPRIATE METHOD (OPERATION, INSPECTION), OVER QUALITY, DOWNSTREAM
QUALITY CONTROL, etc.

COUNTER MEASURES:

STANDARD OPERATION
FOOL PROOF/ AUTO STOP MECHANISM DETECTING DEFECT
EFFECTIVE QUALITY CONTROL METHODS/ 7QC TOOLS, etc.

Waste Identification Map

Manager or Team Leader

Over production

Delays

(Section A)

Area or Process Name (Section B)

Transportation

Process

Inventory

Motion

Person Preparing This Sheet

Defective Product

Untapped
Resources

Defective

(Section C)

Mis-used
Resources

9 Waste Radar Chart

% of Waste Before 5S
% of Waste After 5S
Transportation

P
rocess

70

10

20

40
30

50

80

100
90

O
verproduction

60
U
ntapped
R
esources

D
elays

Inventory

M
otion

M
is-used
R
esources
D
efectiveProduct

The Nine Wastes

Overproduction

Before

100
90

Percentage
of Waste
%of Waste

80
70
60
50
40
30
20
10
0

After

Delays

Before

After

Transportation

Before

After

Inventory

Before

After

Motion

Before

After

Processes

Before

After

Defective
Products
Before

After

Untapped
Resources
Before

After

Mis- Used
Resources
Before

After