What is 5S Methodology?

➝ 5S Methodology was developed in Japan.
➝ 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 principles of 5S 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:

→ 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

Meaning of 5S:

→ It stands for five Japanese words
→ English Meaning of 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 Meaning

    ➤ [1] 1st S - Seiri or Sort:

    → The first step is 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 items 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 items 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
        5Recycling or Reassignment of things arrived in Red Tag Zone.

    ➤ Before-After Photograph of Work Place and Red Tag:

    1st S of 5S Methodology  - Seiri or Sort

    ➤ [2] 2nd 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 height.
    → If any item is missing then we can easily find out it

    ➤ Basic Principles of Set in Order:

    → The things 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.

    2nd S of 5S Methodology - Seiton or Set In Order

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

     After Sort and Set In Order, the workplace requires regular cleaning.
    → Shine or cleaning 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
    → Cleaning 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 is 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
    → Required tools for cleaning

    3rd S of 5S Methodology  - Seiso or Shine (cleaning)

    ➤ [4] 4th S Seiketsu or Standardize:

    → After completion of Sort, Set In Order and 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)
    → 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

    4th S of 5S Methodology - Seiketsu or Standardize

    ➤ [5] 5th S 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”.

    ➤ Top Management's Support needed for Sustain:

    → We can sustain commitment towards 5S 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.
    5th S of 5S Methodology - Shitsuke or Sustain