5-s technique

5-STechnique

Engr. Abdun [email protected] ConsultantCentre for Management DevelopmentSEL Centre (6th Floor), 29-West Panthapath, Dhaka-1205, Bangladesh [email protected]

Engr. Abdun Noor, Centre for Management Development, [email protected]

Know 5-S 5-S’s are basic in establishing norms for effective

performance 5-S is a KAIZEN technique to ensure incremental

improvement 5-S was developed in Japan 5-S is the name of a workplace organization

method that uses a list of five Japanese words The most obvious benefit from items being

organized in such a way that improve productivity


Why 5-S? For workplace Management


Where 5-S is Applicable

EverywhereEverywhere


Why Implement 5-S Improves Productivity Helps in proper maintenance Improves Quality Improves Safety Reduces Costs Detects Inconsistency in Workplace


What is 5-S?

Seiri Seiton Seiso Seiketsu Shitsuke

Derived From The First Letters of Derived From The First Letters of

整理整頓清掃清潔躾


What is 5-S?


Meaning Of 5-S’s (1st S)

Distinguishing Between Necessary and

Unnecessary and Getting Rid of What is not

Needed

SEIRISEIRI

SORT/SORT/ ORGANISEORGANISE


1st S: SEIRI Distinguish between necessary and unnecessary Remove unnecessary and dispose them properly Reduce chance of being disturbed with

unnecessary items Evaluate necessary items with regard to cost,

frequency of use or other factors Items or equipment used once a week or once a

month should be kept within the work area


1st S: SEIRI Items or equipment used less frequently should

be stored in a more distant location The items in holding area should be kept up-to a

planned time. If the items are not needed for work, then the items can be disposed.

It is always necessary to verify plans to dispose of items with anyone who had been using these items in the past or are presently using the same or similar type of items


1st S: SEIRI Dispose all items which are broken or have no

value An effective visual method to apply seiri is “Red

Tagging” Ensure that unnecessary do not enter the

workplace As a preventive measure identify how

unnecessary items enters to the workplace


1st S: SEIRI When did you last use this?

More than 5 years


1st S: SEIRI You are

searching for the files more than an hour?

There are many files which have

not been used since 5 years


1st S: SEIRI

Before Sort

After Sort


Meaning Of 5-S’s (2nd S)

Establishing a neat layout such that one can always get as much of what is needed, when needed

SEITONSEITON

SYSTEMIC/SYSTEMIC/

SET-IN-SET-IN-ORDERORDER


2nd S: SEITON


2nd S: SEITON A place for everything and everything in its place

EnsureEverything has a name and locationEasy to keepEasy to takeoutFirst in first out (FIFO)30 Second retrieval


2nd S: SEITON Arrange all necessary items in order so they can

be easily picked for use Taking into account of the work flow, decide

which things to put where This should be done as per the frequency of use

of items. More frequently used items should be kept near the workplace

A holding area should be clearly visible and clearly marked to assure visual control of items


2nd S: SEITON Display pictures of items and place it on a public

board visible to all Make a clear list of items with their locations

and put it on lockers or cabinets Label each locker/drawer/cupboard to show what

is kept inside Outline locations of equipment, supplies,

common areas and safety zones with lines


2nd S: SEITON


2nd S: SEITON

I can pick even closing

my eyes


2nd S: SEITON


Meaning Of 5-S’s (3rd S)

Eliminate trash, filth and foreign matter to have a cleaner workplace. Cleaning as a form of inspection

SEISOSEISO

SHINE/SHINE/

CLEANCLEAN


3rd S: SEISO Adopt cleaning as a daily activity and as a part

of inspection Clean the workplace before starting of the job

and before closing the job Put aside 10 or 15 minutes for the same activity

per day Identify sources and find ways to prevent dirt &

contamination Clean both inside and outside on daily basis Prevent machinery and equipment deterioration


3rd S: SEISO


3rd S: SEISO

Before After


3rd S: SEISO


Meaning Of 5-S’s (4th S)

Keeping everything organized. Standards to maintain

SEIKETSUSEIKETSU

STANDAR-STANDAR-DISATIONDISATION


4th S: SEIKETSU Standardize the first three S’s Establish the routines and standard practices for

regularly and systematically repeating the first three S’s

Create procedures and forms for regularly evaluating the status of the first three S’s

Assign responsibility to individuals for a work area and machinery

Instead of criticizing poor cases, praise and commend good practices or good performers


4th S: SEIKETSU Standardization & Visual Management:

displays to help people avoid making operating errors

danger alerts indications of where things should be put cautions and operating reminders preventive maintenance displays instructions safety/ warning signs


4th S: SEIKETSU

What: Don’t tap switch with left hand

Why: Left hand is close to the heart


4th S: SEIKETSU

What: Don’t tap with wet handWhy: Risk of electric shock

What: Switch with a single tapWhy: Risk of sparking if vibrate


4th S: SEIKETSU


4th S: SEIKETSU

Safety instructions mounted on a machine

Lubricate and gauge levels clearly marked


4th S: SEIKETSU

Has the nut been tightened to the right point?


4th S: SEIKETSU


Meaning Of 5-S’s (5th S)

Doing the right thing as a routine matter

SHITSUKESHITSUKE

SUSTAIN/ SUSTAIN/ DisciplineDiscipline


5th S: SHITSUKE Doing the right thing as a matter of course Make everyone committed to the program Enforce discipline to inculcate self discipline Have a 5-S Patrol Team Senior management should initiate a celebration

for the total 5S implementation Motivate through competitions


5th S: SHITSUKE

Competition and Award


5-S: At a glance

SeiriSeiton

Seiso

Seiketsu

Shitsuke


Some Points on 5-S If you can’t do 5-S, you can’t do other work The company that’s doing badly is doing the 5-S

badly 5-S’s are Crime Prevention 5-S’s are management barometer If you can do 5-S, you can do anything


5-S


Few examples of 5-S:

Before After


Few examples of 5-S:


The Three Types Of Workplaces3rd Class workplaceWhere everyone messes the place and there is no one to clean up

2nd Class workplaceWhere people mess up the place and office helpers, cleaners, janitorial services or servants clean up the place

1st Class workplaceWhere everyone is disciplined and does not mess up and all participate in cleaning

5-s technique

Engineering