5s Awareness training

By Manufacturing dept.

Date – 29th May’17 BEBITZ FLANGES WORKS PVT LTD

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 5S - A new way of thinking for change ?

Think of the rocks as barriers because they slow

down the water flow. 5S is the first step to eliminate these barriers.
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Origin of 5s
• 5s originated from Japan

• Toyota was the company which came out with 5s concept.

• One of the biggest reason for Toyota to come out of this concept was to eliminate waste, be flexible, fast, on
time etc…

• 5s is part of the TPS ( Toyota production system) which now used and trying to be used by world wide
companies.

• 5s is 1st step to lean management system. It is the foundation to all the other lean management system.

• It make sense to go to next level of lean management, only if companies have managed to correctly
implement and sustained 5s.

• 5s is probably the most simple system to understand but on the other hand it’s the most difficult system to
sustain as it requires continuous DICIPLINE, PATAINENCE & MONTORING.

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What 5s is…..
• 5S is a method of effective workplace organization.

• It is foundation of continual improvement and elimination waste Lean concepts.

• It Streamlines workflow by reducing time, motion, distance, inventory.

• 5S produces a visual workplace.

• 5S is an employee involvement system that empowers workers to keep the plant in

perfect condition.

• it’s a mindset, a way to live and act.

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7 Types of WASTE elimination
1. Overproduction
2. Waiting
3. Unnecessary Motion
4. Unnecessary Transportation
5. Over-processing
6. Unnecessary Inventory
7. Defects

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What 5s is not…..
• 5S is not housekeeping exercise done once in year/month. It is continuous.

• 5s is not way

o to blame people for defects.

o to force people to do their work .

o to make people work harder or faster.

• 5S is not getting ready for CMD or customer visit.

• 5S is not tool only for lower level operators it is for everyone. Top management to
Operators.

• 5S is not only for manufacturing, it is for every departments viz. Store , Office ,
Canteen etc.
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Typical Benefits By implementing 5s

Decreases
• Injuries
• Production cost
• Downtime
Increases • Defects
• Safety & morale • Supplier mistakes
• Product quality • Inefficient
• Equipment life transportation
• Customer • Underutilized floor
satisfaction space
• Tools searches
• Inventory storage
cost

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The 5S Cycle
1-Seiri
(Sort)

5-Shitsuke 2-Seiton
(Set-in-
(Sustain) Order)

4-Seiketsu 3-Seiso
(Standardise) (Shine)

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Exercise 1

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 Seiri ( Sort )
• Keep only what is needed & eliminate all unnecessary items from the
workplace.

• Every individual walks through assigned area and physically touches

everything , and ask following questions,

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The Red Tag System
Distinction between thing needed & not needed.
items

identified Un-identified

Useful Waste Useful Waste

Keep at the
same Has value No value
Make Can’t be Movable
location identification moved
& keep at the
same location
Can’t be
Can’t be moved Movable moved Movable Red Tag &
Red Tag
shift to red
Red Tag & tag area
Red Tag Red Tag
shift to red Scrap
tag area

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Red tag campaign :-
1. Provide “Red Tags” to each team member which contains
information as Item name, Category , Reason for tag,
Actions to taken etc. and define “Red tag area”
2. It is important that all operators working in that area must
be present.
3. Unnecessary items to be red tagged & recorded in “Red
tag logbook”
4. Move red tagged items to the red tag area once lebelled
& recorded.
5. Evaluate & take require actions.

Unnecessary items Require actions

Items having no value
Items does not belong to the
department
Items having some sale value
Throw away immediately
Inform the respective department
Look for buyer who offer the best
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Red tag campaign examples

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Exercise 2

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 Seiton ( Set in order )
• It reflects a very popular saying: “A place for everything and everything in it’s
place”.
• Arrange all necessary items for ease of use and retrieval.
• Have designated place for everything, lebel, classify & safe storage.

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Set-in-order to Make Life Easy

Necessary items Require actions

Items frequently used Must be placed close to point of reach.

Must be placed further away than

Items sometimes used frequently used but with in working
area.
Must be stored separately
Infrequently used items
with clear identification in store
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Set-in-order to Make Life Easy

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Observe the tools carefully.

There are 16 tools.

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Indicate the tools that are missing here ?

There are 14 tools : which 2 tools missing ?

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 How we do in Set –in-order process ?

Paint brush 1 Spanner 1 S c r e w driver Measuring tape

Paint brush 2 Spanner 2 H am m er Cutting wheel

Drill M / C 1 Plumber spanner P lie r S aw

Drill M / C 2 Horticulture tool V ic e To rc h

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 Easy traceability

Paint brush 1 Spanner 1 S c r e w driver Measuring tape

Paint brush 2 Spanner 2 H am m er Cutting wheel

Drill M / C 1 Plumber spanner P lie r S aw

Drill M / C 2 Horticulture tool V ic e To rc h

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Set-in-order examples

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 Seiso (Sweep / Shine )
• It involves cleaning everything, keeping it clean daily,
and using cleaning to inspect the workplace and
equipment for defects, problems, looseness, cracks.
– Step 1 - Determine What is to be Cleaned.
– Step 2- Determine the Methods to be Used.
– Step 3 - Prepare the Cleaning Tools and Materials.
– Step 4 - Implement Cleanliness.

Impacts :-
• Higher quality work and products.
• More comfortable and safer work environment
• Employee are delighted.
• Lower maintenance cost & help to maintain value of equipment.
• Creates positive impression on visitors and during customer
inspections
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Shine examples

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 Seiketsu (Standardize)
• This step concentrate on standardising best practises.
• Everyone doing things the same way.
• Create procedures and simple daily checklists which are
to be visibly displayed at every workplace.

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 Standardize examples

75% of what we learn comes through our eyes

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 Shitsuke (Sustain)
• Forge a workplace with good habits, discipline &
continue to improve everyday.
• It requires self-discipline & shared values.
• Shared values are achieved through coaching and team
participation, not shouting orders and imposing
penalties.
• Reward and recognise efforts of staff.
• Weekly 5S check audit.
• One-point lesson – one sheet, one topic.
• Daily 5-minute 5S activities.

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 5S-Audit
Workplace: Completed by: Date: 0: A lot of deviations 

Score
2: Few deviations 
4: Perfect score 
5S cat Check item Score*
All materials are being used regularly. 0 1 2 3 4 Sub-
All equipments are being used regularly. 0 1 2 3 4 total
Seiri:
Sort

All tools and parts are being used regularly. 0 1 2 3 4

All documents, books and files are being used regularly. 0 1 2 3 4
All unnecessary items are marked or labelled as such. 0 1 2 3 4

Sub-
Workplace
Everything has a fixed place and is located in that place. 0 1 2 3 4
All storage locations have signs showing which item goes where. 0 1 2 3 4 total
Measurement
Set in Order
Seiton:

The max. and min. quantities for consumables are indicated. 0 1 2 3 4

Walkways, storage areas and areas to keep free for safety
reasons are indicated with colour coded floor markings.
All items are stored efficiently based on frequency of use and
0

0
1

1
2

2
3

3
4

4
Checklist – tracking
such that anyone can find, take and return them easily.

All floors, walls and ceilings are kept shiny and clean. 0 1 2 3 4 Sub-
total
your performance
All equipments, parts, tools and storage locations are clean. 0 1 2 3 4
Seiso:
Shine

Associates combine cleaning with inspection in daily routine.

In each area a person(s) is responsible for cleaning & inspection.
0
0
1
1
2
2
3
3
4
4 weekly
Associates are self-motivated to keep their workplace clean. 0 1 2 3 4

5S standards are documented using images where possible. 0 1 2 3 4 Sub-

Standardise

total
Seiketsu:

5S standards are visualized at the workplace. 0 1 2 3 4

Deviations from the 5S standards are apparent to anyone ‘at a
0 1 2 3 4
glance’ so that countermeasures can be taken immediately.
Critical 5S issues have been mistake (fool)-proofed. 0 1 2 3 4
Associates can find any needed item within 30 seconds always. 0 1 2 3 4

5S audit is used monthly and score is visualized in workplace. 0 1 2 3 4 Sub-

Shitsuke:
Sustain

Associates regularly write 5S improvement proposals and total

0 1 2 3 4
management follows up on these within 2 weeks.
5S best practices are shared and replicated within the site. 0 1 2 3 4
5S standards are regularly reviewed and updated. 0 1 2 3 4
The workplace gives any visitor a “World Class” impression. 0 1 2 3 4

* Circle the appropriate value

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Weekly and Monthly Feedback on
Performance
Being Visual

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Before and After photographs of 5S

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 Revision
5S Terms Definitions
Sort Throw away rubbish and unrelated materials.

Set In Order Set things in proper place for quick retrieval and
storage.

Sweep / Shine Clean the workplace. Everyone should be a janitor.

Standardize Standardize the way of maintaining cleanliness.

Sustain Make it a way of life. This means commitment.

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To Find Answer To Any QUESTION/PROBLEM ?
One Needs to only Ask WHY?
Why has this problem occurred ?.....Most of the
time answer will be known to us or if not we
will be on the right path to find the answer.

So We Just Need To Learn To Ask WHY?

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Thank You

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