5S Methodology  Implementation  Benefits  Case Study

What is 5S in the Work Place?

➝ 5S Methodology was developed in Japan and it is a system for organizing spaces so work can be performed efficiently & effectively with safely and it is a fundamental tool of Lean Manufacturing
→ It is a system for organizing spaces so work can be performed efficiently & effectively with safely.
→ Sometimes it is also referred to as a good housekeeping practice but both are different things.

History:

→ This methodology was developed in Japan by two gentlemen, Osada, and Hirano who structured a framework for implementing their philosophy.
→ Some say that the principles of this Methodology came from Henry Ford.
→ Henry Ford used the CANDO system (CANDO stands for Cleaning up, Arranging, Neatness, Discipline, and Ongoing Improvement) before the development of this Methodology.

Benefits of 5S:

→ Increase productivity through effectiveness
→ Reduction in delays
→ Improved Quality
→ Improve in Safety
→ Set-up times reduced
→ Morale & Motivation Increase
→ Less stress for operators
→ Safer work environment
→ Improvement in the regular process

👉 5S PDF Download


5S Meaning | What does the 5S stand for?

→ It stands for five Japanese words Seiri, Seiton, Seiso, Seiketsu, and Shitsuke.
→ English Meaning of the above Japanese words are :
→ (1S) Seiri → Sort or Tidiness
→ (2S) Seiton → Set In Order or Orderliness
→ (3S) Seiso → Shine (Clean) or Cleanliness
→ (4S) Seiketsu → Standardize or Standardization
→ (5S) Shitsuke → Sustain or Discipline

5S explanation

5S Implementation:

→  Now we will see the implementation of 5S step by step.

[1] 1S - Seiri or Sort:

→ The first step is to Sort in this Methodology.
→ "Sorting" means to sort everything in each work area that we need and what we do not need? 
→ Sort means removing unnecessary items or materials from a workspace.
→ Keep only what is actually required every day from the workspace.
→ Materials, equipment, instruments, or any things that are not frequently-used should be moved to a separate, common storage area called Red Tag Zone.
→  Items that are not used should be removed or recycled.
→ Please do not keep anything in your workplace just because it might be used in the future.
→ The whole team should spend a few hours going through the entire area (inside cabinets, under and behind machines.. Everywhere !!!)
→ All obvious scrap should be put in the scrap area / Bin
→ All unidentified things should be put in the “Red tag”/ quarantine area.
→ Only items that are required should remain.

Steps for Sorting:

    1. Cleaning
    2. Classifying
    3. Assign Responsibility
    4. Red Tagging of unnecessary things
    5. Recycling or Reassignment of things arrived in Red Tag Zone.

→ For better understanding show the below picture of the Before-After comparison of Work Place and Red Tag:

5S Examples: 


1S Seiri or Sort

[2] 2S - Seiton or Set In Order:

→ Set in order is for organizing the items or materials at the workplace.     
→ “ Define Place for Everything and Put Everything in its place”
→ We can use an organized workplace more efficiently and effectively
→ To arrange all necessary items for the economy of movement.
→ Put things as per the frequency of use.
→ Provide safe storage – heavy items at a low level, light items at a height.
→ If any item is missing then we can easily find out it

Basic Principles of Set in Order:

→ The items that are used very frequently should be kept nearer to where they are used.
→ Items that are used very few times should be kept far compare to frequently used things.
→ After completion of work keep things in its defined place.
→ If several things are used together, then store them together.
→ For example, a welding rod is used with a welding machine then both should be kept together.
→ Store things in place where people can easily find it.
→ Identify all items (including fixtures, gauges, tools, jigs, molds, etc.) and mark identification symbols on them so we can easily identify and return them to their identified storage location.
→ For better understanding refer the below picture of the sort in order.
2S Seiton or Set In Order

5S Housekeeping:


[3] 3S - Seiso or Shine (cleaning):

→ After Sort and Set In Order, the workplace requires regular cleaning.
→ Shine is used for regular cleaning of the workplace, tools, and equipment     
→ Cleanliness makes defects easier to detect.
→ Better customer satisfaction
→ Aids efficiency and reduces accidents
→ Creates a better working environment
→ It is not just the job of a housekeeper, it is everyone's responsibility
→ Every workplace should have a person, or group, assigned to clean that area.
→ The best approach is that those who work in a workplace are also responsible for cleaning that area.

(A) Cleaning is an ongoing process:

→ Define and document :
→ Decide Who, What, When, Where, How, etc…
→ Who is responsible for cleaning
→ What needs to be cleared and where
→ When it will be done
→ How is it to be done and which tools require
→ For better clarity refer to the below picture in which we can easily see the comparison of the workplace before and after cleaning.


3S Seiso or Shine

[4] 4S - Seiketsu or Standardize:

→ After completion of Shine or Clean, Standardize will come.
→ Standardize means documenting all necessary processes or activities.
→ In Standardize we can turn Good Practices into Good Habits.
→ By developing standards for process, all person knows what to do, how to do, when to do, and where to do, etc..
→ Give awareness about standardizing to all persons.
→ It will help them to remember the new standards and it encourages them to do the same.
→ We can use labels, symbols, posters, and banners for standardization.

(A) How do we Standardise?

→ Document standard ways of working (SOPs), Process Flow Diagram or Flow Chart
→ Standardize labeling, signage, and Flow
→ Audits

(B) Standard Work:

→ Document the current agreed way of doing a process
→ Provides a baseline for improvement
→ Reduces variation between people/shifts

(C) Standardized flow and Signage:

→ Common methods to show where the work enters and leaves the cell.
→ Standard methods for identifying components and tool locations

(D) 5S Audit:

→ Independent audit of an area
→ Capture current state – Use color photographs
→ Create simple audit sheets – with a score
→ Conduct audits
4S Seiketsu or Standardize

[5] 5S - Shitsuke or Sustain:

→ Sustain needs to maintain 5S within the factory or work pace.
→ Keep a record of progress with evaluations, communication, and training related activity.
→ Assign continuing responsibility.
→ Sustain keeps watch on on-going training activity and maintaining the established System.
→ Maintaining Audits
→ Maintaining cleaning
→ Making it “A Way of Life”.
Shitsuke or Sustain

Top Management's Support needed for Sustain:

→ We can sustain commitment towards 5S methodology in our industry with the help of Top management's support.
→ Top Management should be involved in these activities such as:
→ Conducting inspections on a random basis for checking the sustenance of the system
→ Establish a proper communication channel from top to bottom and bottom to top.
→ Provides training to employees.
→ Participation in promotional events at the factory.

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57 Comments

  1. Hell friend Please give feedback for improvement

    ReplyDelete
  2. Nice star Nikunj keep it up.
    It will surely usefull to all industrial guys

    ReplyDelete
  3. Very Nice Nikunj. IT is helpful to all and easily understood to any one.

    ReplyDelete
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    ReplyDelete
  5. Very good Nikunj , It is really useful for all of us as well as any manufacturing industries to devlope a basic fundamental.

    ReplyDelete
    Replies
    1. Thank you for your valuable feedback

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    2. Very good information and useful to one and all.pls keep it up.
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      Regards,
      Vasu somanchi,
      Ph no:8639760225.
      Mail I'd:somanchivasu95@gmail

      Delete
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    ReplyDelete
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    Replies
    1. Thank you for your valuable feedback, we will upload as soon as possible

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  9. Great job..keep it up bro...it will help to many freshers...

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    ReplyDelete
  12. Thank you for your valuable feedback

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    Replies
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  15. REQUIRED DAILY UPDATE IN WHATS UP AND PLEASE PROVIDED pdf FORMAT


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    1. Thank you for your valuable suggestion!!! you can join our what's app group for regular updates...

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  16. All topics are very useful thank you so much very neatly explained in simple English thanks a lot n i refer also my team members
    kindly please post about production related topics especially assembly line production engineer or team leader what are basic things know and work in production department and once again thank you n waiting for production related topic
    Regards
    aashik s
    9952495073



    ReplyDelete
    Replies
    1. Thank you for your valuable feedback. We will work on that and surely update the same. Mean while your can read our other articles you can browse it from sitemap section.

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  17. Quality month celebrations explain... Sir

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  18. Very nice , well explained.
    Thanks for your efforts

    ReplyDelete
  19. Content हिन्दी मे चाहिए सर्

    ReplyDelete
    Replies
    1. Thanks for your feedback you can paste our article link on google translator that your can easily refer in your language.

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  20. Hello Nikunj.keep it up your good work .this is very easy to understand any one.

    Thanks
    Aruna
    From Sri Lanka.

    ReplyDelete
    Replies
    1. Hello Aruna, Very much thank you for your valuable feedback. We will continue good work!!!

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