Seiri

Seiton
Seiso
Seiketsu
Shitsuke
 Quality Improvements

PAN
JA
U.S.A

INDIA

1950 1960 1970 1980

 1. 5S Principles
 Elimination of waste
 Every body is involved,
Co-operative effort
 Attack root cause
 Human being is fallible
 2. Objectives
 Improve housekeeping
 Make every individual responsible
for housekeeping
 Beautify by simple means
 Productivity improvement by
saving time, space etc.
 3. 5S’s
• Seiri - Sorting
• Seiton - Systematic arrangement
• Seiso - Cleaning
Inspection while cleaning
• Seiketsu - Standardization
• Shitsuke - Self Discipline
 5S
If we do not do 5S, we can’t do any
other work efficiently. They are
features which are common to all
places and are the indicators of
how well an organization is
functioning.
 COMMON MIND SETS…

Its an additional burden. Too busy to do 5S

activities.

Why clean it? It will get dirty again

We cannot change the existing setup.

More work pressure – No time for these things

5S means cleaning up the desk

SEIRI
SEIRI == Sorting
Sorting –– Just
Just in
in Case
Case to
to
“Just-in-Time”
“Just-in-Time”
Meaning
Meaning Distinguish
Distinguish between
between necessary
necessary and
and
unnecessary
unnecessary items
items and
and eliminate
eliminate the
the unnecessary
unnecessary items
items

Activity: Establish a criteria for eliminating

unwanted items. - Eliminate unwanted items either by
disposing them or by relocating them.

Success Area saved or percentage of space available

Indicator
SEIRI
SEIRI == Sorting
Sorting –– Fight
Fight with
with
habits
habits
SEIRI
SEIRI == Sorting
Sorting 33 Categories
Categories

√ - Item Required
X – Item Not Required
?– Undecided
Move to Red Tag Holding Area
RED TAG ZONE@SMD
In SMD room
behind shop
floor, through
the pass way of
welding
machine is
defined as Red
Tag Zone
Seiri
Seiri == Sorting
Sorting What is unnecessary

1. Item is not needed

2. Item is needed however quantity in stock is more
than what is needed for consumption in near
future
3. Item is needed but once in a blue-moon

4. Contingency Parts
Critically decide the quantity of contingency
parts to be retained and criteria for such parts
 Organization

Frequency of use Storage Method

*Things you have not used Throw them out

LOW
in the past one year
*Things you have used once Store at distance OR
in the last 6-12 months Keep in store
*Things you have used only Store it in central place
G

once in the last 2-6 months in your zone

A
R

*Things used more than once Store it in central place

E VE

a month in your zone

A

HIGH *Things used once a week Store near the workplace

*Things used daily or hourly Store near the workplace
Seiri
Seiri == Sorting
Sorting Identifying unnecessary

1. Parts & Work in Process (WIP)

• Things fallen back behind the machine or rolled under it
• Broken / some items inside the machine
• Things under the racks/ platform
• Extra WIP
• Stock of rejected items
• Items accumulated over period for rework
• Material awaiting disposal decision
• Material brought for some trial, still lying even after trial
• Small qty of material no longer in use

Contd..
Seiri
Seiri == Sorting
Sorting Identifying unnecessary

2. Tools, Toolings, Measuring devices

• Old jigs, tools not in use are lying
• Modified tools, tooling for trial, are lying after trial
• Worn out items like bushes, liners, toggles etc. lying
• Broken tools, bits, etc. may be lying
• Measuring equipment not required for the operation
being performed, is lying
3. Contingency Parts
• Many times storage place for contingency parts become
a last refuge for broken parts, surplus items and things
nobody is likely to use
Contd..
Seiri
Seiri == Sorting
Sorting Identifying unnecessary

4. Shelves and Lockers

• Shelves and lockers tends to collect things that nobody
ever uses, like surplus, broken items, used tea-cups etc.
5. Passages and Corners
•WIP material waiting for decision or dispatch
• Dust, material not required seem to gather in corner
6. Besides Pillars and under the stairs
• These places tends to collect junk, spittoon etc.
7. Walls and Bulletin Boards
• Old out dated notices which have lost their relevance
• Posters or bulletins on wall
• Dust, remains of torn notices, cell tape pieces Contd..
Seiri
Seiri == Sorting
Sorting Identifying unnecessary

8.Floor, Pits, Partitions

• Defective parts
• Protection caps, shoe covers
• Packing material, stickers, barcodes, cut-leads
• Hardware items, small items, runners, plastic granules
• Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
• Many unwanted, outdated, temporary files pile up
•Old dated mails still remaining in inbox and sent items
•Deleted mails not being purged when closed
•Recycle bin not emptied
Seiri
Seiri == Sorting
Sorting TAGGING

TAG No ______________ Date _________

ITEM NAME________________ QTY ______

Tag Created By: _________________________________

RED TAG

Reason: ________________________________________
G IC

_______________________________________________
_______________________________________________

Decision Date: ___________ Decision By: __________

To Scrap To Reuse after Salvage To Dispose

Seiri
Seiri == Sorting
Sorting Improvement methods

1. Flow Process Chart (Procedural Analysis)

Drawing a process flow chart for the system
eg. How to make and use category wise grouping

2. Operational Analysis
Preparing the sequence of operations for system
eg. How to perform Seiri (sorting)

3. Check List
A check sheet is used to decide what sort of main system
and sub system are necessary.
 1 - S CHECKLIST - SHOPFLOOR
PLANT: DATE:
AREA: PERSON RESPONSIBLE:
No. PARAMETERS EXCE. GOOD AVG. BAD POOR
POINTS 5 4 3 2 1

1 Is there any UNWANTED item present in area

2 Is there any item more than required

3 Is there any item on different location

4 Is there proper Red Tag Area identified

5 Is the list of all items in Red Tag Area available

6 Is there any classification done for Wanted items

7 Is there any item not used for more than a year

8 Is there criteria present to eliminate unnecessary items

9 Is there any unwanted dirt/dust present

10 Is there any leakage present (Air, Water, Oil or Material)

11 Is there any defective item present or Unsafe item in the area

12 Is there any spilled item on the floor

13 Are all Equipments, Jigs & Machines working OK

14 Is there minimum 20 % storage free space available

15 Are People working in the area aware about 1 - S

OVERALL SCORE
REMARKS:

NOTE: MINIMUM 75 % REQUIRED FOR NEXT STEP AUDIT

Seiri
Seiri == Sorting
Sorting Dealing with papers

How to reduce papers on

your table ?
1. Make a single pile of papers
2. Go through them and sort in
following categories
a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information
Seiri
Seiri == Sorting
Sorting Dealing with papers

How to reduce papers on

your table ?

4 D Principle

DO
DELEGATE
DELAY
DUMP
SEITION
SEITION == Systematic
Systematic Arrangement
Arrangement

Meaning
Meaning To
Todetermine
determinetype
typeof
ofstorage
storageand
andlayout
layoutthat
that
will
willensure
ensureeasy
easyaccessibility
accessibilityfor
foreveryone
everyone. .

Activity - Functional storage

- Creating place for everything and putting
everything in its place

Success - Time saved in searching (30 sec to locate an item)

Indicator - Time saved in material handling
SEITION
SEITION == Systematic
Systematic Arrangement
Arrangement

In
In short,
short, SEITION
SEITION means
means PEEP
PEEP

Place for Everything

&
Everything in its place
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

How to achieve Systematic Arrangement ?

• Decide where things belong

• Decide how things should be put away

• Obey the Put away rules

Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

How to achieve Systematic Arrangement ?

• Decide where things belong
- Standardize Nomenclature
- Determine an analytical method of storage
• Decide how things should be put away
- Name & locations to everything. Label both item
and location
- Store material functionally
- Prevent mistakes with coding by shapes & color

contd..
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

How to achieve Systematic Arrangement ?

• Decide how things should be put away
- Follow first in first out rule
- If two identical items are to be located, then store
them separately, color code them.

• Obey the rules

- Put the things back to their location after
their use
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

USE :

1 ) Signboards

2) Color codes

3) Outline markings

4) Labels
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

Functional

Storage
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

Usage • Store frequently used material

Frequency near the workplace and less
frequently at some distance

Weight & • Heavy material should be stored

Shape of the at lower levels/layers
Place directly on the material
Material
handling device for ease of
handling

Functional Storage
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Same category of material may be

Category
stored in one location.
Eg. Fasteners, Seals , resistors

Operation • All items required for an

Wise operation may be stored in one
location.
Eg. Allen key, spanner etc hand
tools required for setting m/c

Functional Storage
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Outlining and Placement Marks

- Mark boundaries of dept., aisles, Machines
- Follow straight line, right angle rule
- Nothing shall be kept outside the boundaries
• Stands and shelves
- Keep only required number of stands and shelves
- Standardize height, size
- Provide casters where necessary so that it can be
moved
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Wires and Ducts

- Color code
- When there are multiple connections - bundle the
wires, label them and make sure that they are in
straight line /right angle and firmly anchored
• Machine-tools & Tools
- Put the tools in the order you need them
- Location of the tool should be such that it can be
put away with one hand
- Try to eliminate some hand tools by permanently
attaching it to the bolt head
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Blades, Dies, Other important consumables

- Store them in the protected place
- Maintain these things regularly by applying rust
preventive, oiling etc.
• WIP- Work In Process
- Designate a place for each component/part
- Decide on how much quantity to be stored
- Ensure that there is no damage to good part
during transit, they do not get rusty and they are
not mislabeled
Seiton
Seiton == Systematic
SystematicArrangement
Arrangement

• Oils & Lubricants

- Reduce number of oils used (Standardize)
- Color code for oil
- Safety aspects - fire prevention, pollution, leak,
spillage
• Instrumentation & Measuring Devices
- Label them, show direction of flow
SEISO
SEISO == Cleaning
Cleaning
Meaning
Meaning Cleaning
Cleaningtrash,
trash,filth,
filth,dust
dustand
andother
otherforeign
foreign
matter.
matter.Cleaning
Cleaningasasaaform
formofofInspection
Inspection

Activity - Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning inspection

Success - Reduction in machine down time

Indicator - Reduction in no. of accidents
Seiso
Seiso == Cleaning
Cleaning

• Here cleaning means more than just keeping

things clean. Cleaning should be viewed as a
form of Visual Inspection

• Preventive measures should be taken to tackle

problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated
Seiso
Seiso == Cleaning
Cleaning

Various Minor Defects

= Trash = Dirt =Knocking
= Loose parts = Leaks =Scattering
=Skips =Curvature =Abrasion
=Rust =Scratches =Eccentricity
=Lurching =Abnormal =Vibration
Movements
=Abnormal =Heat =Abnormal
Sounds smells
=Faded color =Hisses - Cracks
Seiso
Seiso == Cleaning
Cleaning

5 Minutes Every day for cleaning

• Devote 5 minutes everyday for cleaning your
work area

• Participation of everyone is required

• Attack hard to clean places regularly

Seiso
Seiso == Cleaning
Cleaning

Cleaning-Inspection points for most

equipment
Grime, clogging, dust balls, rust,
Cleaning leakage etc.

No oil, Low oil, leakage, filter clogging,

Oils dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
etc.
Seiso
Seiso == Cleaning
Cleaning

Cleaning-Inspection points for most

equipment
Loose bolts, welding detachment,
Tightening loose parts, vibration or bumping
noise, friction

Heat Oil tanks, motors, heater, axles, control

panels, washing/ cleaning water,
bearing, wiring etc.
Seiso
Seiso == Cleaning
Cleaning

Cleaning-Inspection points for most

equipment
Breakage, cracks, dent on sliding
Breakage, parts, handle has come off, broken
Cracks switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.
Seiso
Seiso == Cleaning
Cleaning

Function wise Cleaning check list of

equipment
Compressed Air lines, air valves,
Pneumatics connections, meters, filters,
reservoirs etc.

Hydraulic oil tank, oil valves,

Hydraulics filters, pumps, hoses, gauges,
cylinders etc.
Seiso
Seiso == Cleaning
Cleaning

Function wise Cleaning check list of

equipment

Mech & Motor fan, fan belt, couplings,

Joints, pulleys, chains, pump
Power Train
bearings etc.

Control panel, lamps, light, switch,

Electrical sensors, wiring, ducts, fuses etc.
Seiso
Seiso == Cleaning
Cleaning

Function wise Cleaning check list of

equipment

Tools, fixtures, gauges, dies,

Toolings measuring instruments, etc.

Equipment Furnaces, rollers, chutes,

Specific CNC machines, etc.
SEIKETSU
SEIKETSU == Standardization
Standardization
Meaning
Meaning Setting
Settingup
upstandards
standards//Norms
Normsfor
foraaneat,
neat,clean,
clean,
workplace
workplaceand
anddetails
detailsof
ofhow
howto
tomaintain
maintainthethe
norm
norm(Procedure)
(Procedure)
Activity - Innovative visual management
- Color coding
- Early detection of problem and early action

Success Increase in 5S indicator

Indicator
SEIKETSU
SEIKETSU == Standardization
Standardization
Tools
Tools used
used for
for analysis
analysis ::
MTTR
MTTR
MTBF
MTBF
OEE
OEE
Seiketsu
Seiketsu == Standardization
Standardization

• Regularizing 5S activities so that

abnormalities are revealed

•Make it easy for everyone to identify

the state of normal or abnormal
condition

• For maintaining previous 3S, deploy

visual management
Seiketsu
Seiketsu == Standardization
Standardization

• It has been estimated by scientific

study that 60% of all human activities
starts with sight

• 5S is easy to do once.It is consistency

that is difficult. That is why Visual
Management is so important, so that
everybody will know that there is
some problem. Visual Management
Seiketsu
Seiketsu == Standardization
Standardization

What visual control communicates ?

It grabs one or more of our senses in

order to

• Alert us to an abnormality
• Help us recover quickly
• Promote adherence and prevention
• Enable successful self management
Seiketsu
Seiketsu == Standardization
Standardization

Some methods for visual communication

 Color coding
 Use of Labels
 Danger alerts
 Indication where things should be put
 Directional arrows/ marks
 Transparent covers
 Performance indicators
Seiketsu
Seiketsu == Standardization
Standardization

Some methods for visual communication

Labels
 Precision management labels
 Inspection labels
 Temperature labels
 Responsibility photos
Seiketsu
Seiketsu == Standardization
Standardization

Points to remember in making visual c

control tools
1. Make them easy to see from
distance
2. Put the display on the things
3. Everyone can tell what is right and
what is wrong
4. Anybody can follow them and make
necessary corrections easily
5. Work place should look brighter &
orderly
Seiketsu
Seiketsu == Standardization
Standardization

Some everyday visual management

examples
 Traffic signal
 Zebra crossing
 In car - Petrol indicator
- Speed indicator
 Direction arrows
 Electric danger sign
 Toilet
Seiketsu
Seiketsu == Standardization
Standardization

Some visual communication signs

SHITSUKE
SHITSUKE == Self
Self Discipline
Discipline
Meaning
Meaning Every
Everyone
onesticks
sticksto
tothe
therule
ruleand
andmakes
makesititaahabit
habit

Activity - Participation of everyone in developing good

habits
- Regular audits and aiming for higher level

Success High employee morale

Indicator Involvement of all people
SHITSUKE
SHITSUKE == Self
Self Discipline
Discipline
Activities
Activities ::
5S
5S Committee
Committee
5S
5S Training
Training
5S
5S Competition
Competition // evaluation
evaluation
5S
5S Month
Month
Posters
Posters ,, Literature
Literature etc.
etc.
Shitsuke
Shitsuke == Self
Self Discipline
Discipline

We need everyone to maintain 5S

guidelines.

To maintain DISCIPLINE, we need

to practice and repeat until it
becomes a way of life.

Discipline is the Core of 5S

Shitsuke
Shitsuke == Self
Self Discipline
Discipline

Discipline means making a steady

habit of properly maintaining
correct procedure.
procedure

Time and effort involved in

establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.
Shitsuke
Shitsuke == Self
Self Discipline
Discipline Pledge

It shall be my constant effort to

maintain my workplace in good
order by
 Assigning a place for everything
& keeping everything in its place
 Sorting out unwanted material
periodically & discarding them
 Keeping my work area neat &
clean everyday
SOME IDEAL
PICTURES
Machine
Machine building
building Bay
Bay
Heat
Heat Treatment
Treatment Area
Area
Heat
Heat Treatment
Treatment Area
Area
Machine
Machine Shop
Shop
Some Pictures of
SMD before 5S
 End of the
presentation &
Beginning of 5S
activities….@SMD
THANKS