HOUSE KEEPINGA base for any improvement

Even before you plan the direction you need to Even before you plan the direction you need to take, you must remove any obstacles to get a take, you must remove any obstacles to get a clear view of the current situation.clear view of the current situation.

House Keeping enhances the results of other House Keeping enhances the results of other activities and simplifies every day operations.activities and simplifies every day operations.

House Keeping must become a habit. It must be House Keeping must become a habit. It must be continuous, or at least continual activity.continuous, or at least continual activity.

WHAT IS HOUSE KEEPING Systematic approach to better workplace.Systematic approach to better workplace.

Involves arrangement, cleanliness, discipline and Involves arrangement, cleanliness, discipline and

maintenance of standards.maintenance of standards.

Assigns a place for every thing and ensures Assigns a place for every thing and ensures

everything in its place.everything in its place.

Is everybody’s responsibility.Is everybody’s responsibility.

Is the starting point of any improvement activity.Is the starting point of any improvement activity.

Means easy retrieval of information.Means easy retrieval of information.

WHY HOUSE KEEPING

LESS EQUIPMENT DOWN TIME.LESS EQUIPMENT DOWN TIME.

MORE USABLE SPACE.MORE USABLE SPACE.

PASSAGE WAYS ARE NEAT AND CLEAN.PASSAGE WAYS ARE NEAT AND CLEAN.

ABNORMALITIES NOTICED AT A GLANCE.ABNORMALITIES NOTICED AT A GLANCE.

ELIMINATES ACCIDENTS.ELIMINATES ACCIDENTS.

PRODUCTIVITY IMPROVEMENT.PRODUCTIVITY IMPROVEMENT.

WHY HOUSE KEEPING

EMPLOYEES FEEL GOOD IF THE WORK PLACE IS EMPLOYEES FEEL GOOD IF THE WORK PLACE IS

CLEAN.CLEAN.

SEARCHING IS AVOIDED.SEARCHING IS AVOIDED.

TIME WASTED IN HANDLING REDUCED.TIME WASTED IN HANDLING REDUCED.

NO UNNECESSARY SUPPLIES.NO UNNECESSARY SUPPLIES.

LESS REJECTION/REWORK.LESS REJECTION/REWORK.

BETTER PREVENTIVE MAINTENANCE.BETTER PREVENTIVE MAINTENANCE.

THE THE FOUNDATION FOUNDATION

OF OF COMPETITIVE COMPETITIVE

SUCCESS.SUCCESS.

5"S"- House Keeping

PRICE

FLEXIBILITY

QUALITYDE

LIV

ER

Y

SE

RS

ER

VIC

E

THE NEED FOR A "5S" STRATEGY

SIMPLE BUT IMPORTANT CONCEPT

A NEAT AND CLEAN FACTORY HAS HIGHER PRODUCTIVITY.

A NEAT AND CLEAN FACTORY PRODUCES FEWER DEFECTS.

A NEAT AND CLEAN FACTORY MEETS DEADLINES BETTER.

A NEAT AND CLEAN FACTORY IS A MUCH SAFER PLACE TO WORK.

THE FUNDAMENTAL TRUTH IF WE CANNOT KEEP OUR IF WE CANNOT KEEP OUR

WORKPLACESWORKPLACES CLEANCLEAN ORDERLYORDERLY ACCIDENT FREEACCIDENT FREE

NOBODY WILL BELIEVE WE NOBODY WILL BELIEVE WE CAN PRODUCE QUALITY CAN PRODUCE QUALITY GOODS OR ATLEAST SERIOUS GOODS OR ATLEAST SERIOUS ABOUT PRODUCING QUALITY.ABOUT PRODUCING QUALITY.

THE CONCEPT OF "5S" SEIRISEIRI SORTOUT (ORGANIZATION) SORTOUT (ORGANIZATION) SEITONSEITON SET IN ORDER (ORDERLINESS) SET IN ORDER (ORDERLINESS) SEISOSEISO SPICK & SPAN (CLEANLINESS) SPICK & SPAN (CLEANLINESS) SEIKETSUSEIKETSU STANDARDIZE (CLEAN UP) STANDARDIZE (CLEAN UP) SHITSUKESHITSUKE SUSTAIN SUSTAIN (DISCIPLINE) (DISCIPLINE)

THE FIRST PILLAR : SORT Sort Means That You Sort Means That You RemoveRemove

All Items From the All Items From the WorkplaceWorkplace That Are That Are Not Needed Not Needed for for CurrentCurrent Production Production OperationOperation..

SEIRI - SEGREGATION

THIS STEP DISTINGUISHES NECESSARY AND THIS STEP DISTINGUISHES NECESSARY AND

UNNECESSARY ITEMS AND ELIMINATES UNNECESSARY ITEMS AND ELIMINATES

UNNECESSARY ITEMS.UNNECESSARY ITEMS.

SORT THROUGH AND THEN SORT OUTSORT THROUGH AND THEN SORT OUT

SORT THROUGH WHAT YOU HAVE. IDENTIFY SORT THROUGH WHAT YOU HAVE. IDENTIFY

WHAT YOU NEED AND DISCARD WHAT IS WHAT YOU NEED AND DISCARD WHAT IS

UNNECESSARYUNNECESSARY

INDICATOR OF SUCCESS.INDICATOR OF SUCCESS.

AREA OR PERCENTAGE SPACE SAVED.AREA OR PERCENTAGE SPACE SAVED.

1. 1. CLASSIFICATION : SORT OUT.CLASSIFICATION : SORT OUT.

2. ELIMINATION : REMOVE UNNECESSARY 2. ELIMINATION : REMOVE UNNECESSARY ITEMS. ITEMS.

3. STORAGE : FREQUENT USE/ RARE USE.3. STORAGE : FREQUENT USE/ RARE USE.

CLOSE/ DISTANT LOCATION.CLOSE/ DISTANT LOCATION.

IDENTIFICATION OF ITEMS & IDENTIFICATION OF ITEMS & LOCATIONS. LOCATIONS.

4. FIX & SHARE RESPONSIBILITIES.4. FIX & SHARE RESPONSIBILITIES.

5. USE RED TAG SYSTEM.5. USE RED TAG SYSTEM.

6. MONITOR PROGRESS.6. MONITOR PROGRESS.

WHY SORT IS IMPORTANT??

A WORK ENVIRONMENT IN WHICHA WORK ENVIRONMENT IN WHICH TIMETIME MONEYMONEY SPACE SPACE ENERGY &ENERGY & EFFECTIVE RESOURCES MANAGMENTEFFECTIVE RESOURCES MANAGMENT

PROBLEMS IN PROBLEMS IN WORK FLOW WORK FLOW ARE REDUCED, ARE REDUCED,

CCOMMUNICATIONOMMUNICATION IS IMPROVED, PRODUCT IS IMPROVED, PRODUCT

QUALITYQUALITY IS INCREASED & IS INCREASED & PRODUCTIVITYPRODUCTIVITY IS IS

ENHANCED.ENHANCED.

MUDA ELIMINATION

WWASTEASTE

EELIMINATIONLIMINATION

LLEADS TOEADS TO

CCOSTOST

OOPTIMIZATION &PTIMIZATION &

MMANAGEMENTANAGEMENT

EEXCELLENCEXCELLENCE

THE WASTES IN THE SHOP FLOOR

INVENTORYINVENTORY

RELATED COSTSRELATED COSTS

TRANSPORTATIONTRANSPORTATION

QUANTITY HARDER TO SORTOUTQUANTITY HARDER TO SORTOUT

DESIGN OBSOLESCENCEDESIGN OBSOLESCENCE

QUALITY DEFECTS FROM WIPQUALITY DEFECTS FROM WIP

MACHINE BREAKDOWNSMACHINE BREAKDOWNS

SEIRI

FACTORY OFFICE HOUSE

SCRAPPED MACHINES/EQUIPMENTS

USED/BROKEN PENS BROKEN TOYS

REJECTED MATERIALS USELESS PAPERS/FILES OLD CLOTHES

EXPIRED GOODS OLD DIARIES BROKEN SUITCASE

SCRAPPED/BORKENTOOLS, PALLETS, BINS,TROLLEYS, ETC

BROKEN FURNITURE OLD SHOES

EXCESS PARTS OLD NOTICES/ LEAFLETS OLD LETTERS/MAGAZINES

UNUSED UTENSILS

SEIRIFREQUENCY ACTION

NOT USED FOR AYEAR OR MORE

CONSULT & DECIDEDISPOSAL. SEND TO SOMEOTHERPLACE/SELL/SCRAP

USED ONLY ONCEIN LAST 6-12MONTHS

STORE AT A DISTANCE / INRECORDS ROOM

USED ONLY ONCEIN LAST 2-6 MONTHS

STORE AT A CENTRALPLACE IN THE WORK AREA

USED MORE THANONCE A MONTH

STORE NEAR WORKPLACE

USED WEEKLY /DAILY / HOURLY

STORE NEAR WORKPLACE

THE SECOND PILLAR : SET IN ORDER

Set in Order Can Be Set in Order Can Be Defined As Defined As ArrangingArranging Needed Needed Items So That Items So That They Are They Are Easy to Use Easy to Use and and LabellingLabelling Them Them So That They Are So That They Are Easy to Find Easy to Find and Put and Put away.away.

SEITON --ARRANGEMENT

THIS STEP ENABLES DETERMINATION OF THE THIS STEP ENABLES DETERMINATION OF THE

TYPE OF STORAGE SYSTEM AND LAYOUT THAT TYPE OF STORAGE SYSTEM AND LAYOUT THAT

WILL GUARANTEE THAT REQUIRED AMOUNTS WILL GUARANTEE THAT REQUIRED AMOUNTS

OF NECESSARY ITEMS WILL BE EASILY OF NECESSARY ITEMS WILL BE EASILY

ACCESSIBLE.ACCESSIBLE.

SET THINGS IN ORDER BY CREATING PLACE SET THINGS IN ORDER BY CREATING PLACE

FOR EVERYTHING .FOR EVERYTHING .

PUT EVERYTHING IN IT’S PLACEPUT EVERYTHING IN IT’S PLACE . .

SEITON --ARRANGEMENT

KEEPING ACCESSIBILITY AS EASY AS KEEPING ACCESSIBILITY AS EASY AS

POSSIBLE .POSSIBLE .

USE THE PRINCIPLE OF WIDE RANGE USE THE PRINCIPLE OF WIDE RANGE

AND SHALLOW DEPTH FOR STORAGE.AND SHALLOW DEPTH FOR STORAGE.

TIME SAVED IN SEARCHING.TIME SAVED IN SEARCHING.

TIME SAVED IN HANDLING MATERIAL.TIME SAVED IN HANDLING MATERIAL.

PROBLEMS AVOIDED BY IMPLEMENTING SET IN ORDER

WASTE OF WASTE OF MOTIONMOTION SEARCHINGSEARCHING HUMAN ENERGYHUMAN ENERGY EXCESS INVENTORYEXCESS INVENTORY DEFECTIVE PRODUCTSDEFECTIVE PRODUCTS UNSAFE CONDITIONSUNSAFE CONDITIONS

HOW TO IMPLEMENT SET IN ORDER

DECIDING APPROPRIATE LOCATIONSDECIDING APPROPRIATE LOCATIONS LOCATE ITEMS IN THE WORKPLACE ACCORDING LOCATE ITEMS IN THE WORKPLACE ACCORDING

TO THEIR TO THEIR FREQUENCYFREQUENCY OF USE OF USE

PLACE FREQUENTLY USED ITEMS PLACE FREQUENTLY USED ITEMS NEARNEAR THE THE

WORKPLACEWORKPLACE

STORE INFREQUENTLY USED ITEMS STORE INFREQUENTLY USED ITEMS AWAYAWAY FROM FROM

THE PLACE OF USE.THE PLACE OF USE.

A A LET GOLET GO ARRANGEMENT FOR TOOLS SO THAT ARRANGEMENT FOR TOOLS SO THAT

THEY GO BACK TO ORIGINAL PLACE OF STORAGETHEY GO BACK TO ORIGINAL PLACE OF STORAGE

HOW TO PROMOTE GOOD ORDER

Seldom used, enclose in a separate designated Seldom used, enclose in a separate designated

place.place.

THINGS NOT NEEDED:THINGS NOT NEEDED:

No potential use, immediate disposal after careful No potential use, immediate disposal after careful

analysis.analysis.

Potentially useful, move to a separate Potentially useful, move to a separate

designated place.designated place.

Require special arrangement disposal. Require special arrangement disposal.

THE THIRD PILLAR : SHINE Shine Means Sweeping Shine Means Sweeping

Floors, Whipping off Floors, Whipping off Machinery, and Machinery, and Generally Making Sure Generally Making Sure That Everything in the That Everything in the Factory Stays Clean.Factory Stays Clean.

SEISO - CLEANING

This step eliminates Dirt, Dust and other foreign This step eliminates Dirt, Dust and other foreign

matter to make the workplace clean.matter to make the workplace clean.

Clean Equipment,Furniture,Notice Boards Clean Equipment,Furniture,Notice Boards

Records Etc.Records Etc.

Keep the workplace Spotless.Keep the workplace Spotless.

Sweeping,wiping,polishing,painting Etc.Sweeping,wiping,polishing,painting Etc.

THE FOURTH PILLAR :STANDARDIZE

Standardize Is The Standardize Is The Result That Exists Result That Exists When the First Three When the First Three Pillars - Sort, Set in Pillars - Sort, Set in Order and Shine Are Order and Shine Are Properly Maintained.Properly Maintained.

STANDARDIZATION

Set in Order

Machinery

WhereThingsAre Kept

OPERATION

Critical Processes

Communication

Inventory

STANDARDIZATIONSTANDARDIZATION

PROVIDE OBJECTIVES AND INDICATE TRAINING GOALS.

PROVIDE A BASIS FOR TRAINING

CREATE BASIS FOR AUDIT AND DIAGNOSIS.

PROVIDE A MEANS FOR PREVENTING RECURRENCE OF ERRORS AND MINIMIZING VARIABILITY.

SEIKETSU - STANDARDISATION

TO ESTABLISH STANDARDS TO TO ESTABLISH STANDARDS TO MAINTAIN THE IMPROVEMENTSMAINTAIN THE IMPROVEMENTS

CREATING RULES FOR CHECKING & CREATING RULES FOR CHECKING & COUNTERMEASURES.COUNTERMEASURES.

VISUAL CONTROLS FOR STANDARDS VISUAL CONTROLS FOR STANDARDS AND TO REVEAL ABNORMALITIESAND TO REVEAL ABNORMALITIES

TO PREPARE CHECKLISTS AND TO PREPARE CHECKLISTS AND ADHERE TO AVOID MISTAKESADHERE TO AVOID MISTAKES

EXAMPLE OF STANDARDIZATION

HOW TO IMPLEMENT STANDARDIZE

VISUAL 5SVISUAL 5S ANYONE SHOULDANYONE SHOULD

DISTINGUISH NORMAL & DISTINGUISH NORMAL &

ABNORMAL CONDITIONS.ABNORMAL CONDITIONS.

AT A GLANCEAT A GLANCE

FIVE MINUTE 5SFIVE MINUTE 5S

HOW TO IMPLEMENT STANDARDIZATION

AUDIT THE SHOP FLOORAUDIT THE SHOP FLOOR

5S PROJECTS5S PROJECTS

REVIEWREVIEW

THE FIFTH PILLAR : SUSTAIN

Sustain means Sustain means making a habit of making a habit of properly maintaining properly maintaining correct procedures.correct procedures.

SHITSUKE - DISCIPLINE

THIS STEP IS TO ENSURE THAT EVERYONE THIS STEP IS TO ENSURE THAT EVERYONE

STICKS TO THE RULES SCRUPULOUSLY AND STICKS TO THE RULES SCRUPULOUSLY AND

MAKES IT A HABITMAKES IT A HABIT

CREATE GENERAL AWARENESS ABOUT 4S.CREATE GENERAL AWARENESS ABOUT 4S.

TRAINING TO EVERYONE.TRAINING TO EVERYONE.

DEVELOP NORMS AND MONITOR SUCCESS.DEVELOP NORMS AND MONITOR SUCCESS.

SHITSUKE - DISCIPLINE

High employee Morale.High employee Morale.

Involvement of People in the Movement.Involvement of People in the Movement.

SEIKETSU - TRAINING & DISCIPLINE

EVERY ONE IS STICKING TO THE EVERY ONE IS STICKING TO THE RULES AND STANDARDSRULES AND STANDARDS

PRACTISE BY EVERY ONE - MAKES PRACTISE BY EVERY ONE - MAKES PERFECTPERFECT

GOOD TRAINING FOR BASIC, GOOD TRAINING FOR BASIC, HABITUAL MOVEMENTS & ACTIVITIESHABITUAL MOVEMENTS & ACTIVITIES

5S IMPLEMENTATION

CONTINUING TO LEARN MORE ABOUT THE 5SCONTINUING TO LEARN MORE ABOUT THE 5S

HELPING TO EDUCATE YOUR CO-WORKERS HELPING TO EDUCATE YOUR CO-WORKERS

ABOUT 5SABOUT 5S

BEING ENTHUSIASTIC ABOUT 5S BEING ENTHUSIASTIC ABOUT 5S

IMPLEMENTATION.IMPLEMENTATION.

HELPING TO PROMOTE 5S IMPLEMENTATION HELPING TO PROMOTE 5S IMPLEMENTATION

EFFORTSEFFORTS..

5S TRAINING

1.1. THERE CAN BE NO TQM WITHOUT 5 S.THERE CAN BE NO TQM WITHOUT 5 S.

2. A DIRTY FACTORY OR OFFICE CANNOT 2. A DIRTY FACTORY OR OFFICE CANNOT

PRODUCE QUALITY PRODUCTS OR PRODUCE QUALITY PRODUCTS OR

SERVICE.SERVICE.

3. CLUTTER HIDES THE PROBLEM. A NEAT 3. CLUTTER HIDES THE PROBLEM. A NEAT

WORKPLACE PROMOTES EASY WORKPLACE PROMOTES EASY

DISCOVERY OF ABNORMALITIES. DISCOVERY OF ABNORMALITIES.

5S IS THE STARTING POINT FOR ALL 5S IS THE STARTING POINT FOR ALL

WORKPLACE IMPROVEMENTS, WORKPLACE IMPROVEMENTS,

PRODUCTIVITY, QUALITY, COST, PRODUCTIVITY, QUALITY, COST,

DELIVERY, SAFETY, SERVICE and DELIVERY, SAFETY, SERVICE and

MORALE.MORALE.