5S in the Workplace | 5S Implementation

What is 5s implementation?

1. How to start 5s Implementation? 5S Methodology was developed in Japan and it’s a system for organizing spaces so work can be performed efficiently & effectively safely it’s a fundamental tool of Lean Manufacturing
2. It’s a system for organizing space so work can be performed efficiently & effectively with safety.
3. Now and then it’s also referred to as a good housekeeping practice but both are different things

Benefits of 5S Quality 5s meaning | What does the 5S Stand for? |How To Start 5S Implementation

1. 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.

2. Benefits of 5S

• Increase productivity through effectiveness
• Reduction in delays
• Improved

3. Quality

1. Improve in Safety
2. Set-up times reduced
3. Morale & MotivationIncrease
4. Lessstress for operators
5. Safer work atmosphere
6. Improvement in the regular process

4. 5S Meaning| What does the 5S stand for?

• It stands for five Japanese wordsSeiri, 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

5. how to start 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 sorting everything in each work area that we need and what we do not need.
• Sort means removing nonessential items or materials from a workspace.
• Keep only what’s actually needed every day from the workspace.
• Materials, equipment, instruments, or any things that aren’t constantly- used should be moved to a separate, common warehouse area called Red Tag
  Zone.
• Items that aren’t used should be removed or recycled.
• Please don’t keep anything in your plant just because it might be used in the future.
• The whole team should spend a few hours going through the entire area (inside closets, under and behind machines. Everyplace!!!)
• All obvious scrap should be put in the scrap area/ box
• All unidentified things should be put in the “ Red label”/ quarantine area.
• Only items that are needed should remain.

Steps for Sorting

1. Cleaning
2. Classifying
3. AssignResponsibility
4. Red Tagging of nonessential things
5. Recycling or Reassignment of things arrived in Red Tag Zone.

• For a better understanding of how the below picture of the Before-After comparison of Work Place and the Red Tag

5S Exemplifications

(2) 2S-Seiton or Set In Order

• Set in order is for organizing the items or materials at the plant.
• “ DefinePlace for Everything and Put Everything in its place”
• We can use a systematized plant more efficiently and effectively
• To arrange all necessary items for the economy of movement.
• Put things as per the frequency of use.
• Provide a safe warehouse – heavy items at a low rank, light items at a height.
• If any item is missing also we can fluently find out it

Basic Principles of Set-in Order

• The items that are used really constantly should be kept nearer to where they’re used.
• Items that are used really multiple times should be kept far compared to constantly used things.
• After completion of work keep things in their defined place.
• If several things are used together, also store them together.
• For illustration, a welding rod is used with a welding machine also both should be kept together.
• Store things in a place where people can fluently find
• Identify all items ( including fixtures, gauges, tools, jigs, molds, etc.) and mark identification symbols on them so we can fluently identify and return
  them to their identified warehouse place.
• For better understanding refer to the below picture of the sort in order.

5S Housekeeping

(3) 3S-Seiso or Shine (cleaning)

• After Sort and Set In Order, the plant requires regular
• Shine is used for regular cleaning of the plant, tools, and equipment
• Cleanliness makes defects easier to detect.
• Better client satisfaction
• Creates a better working atmosphere
• It isn’t just the job of a housekeeper, it’s everyone’s responsibility
• Every plant should have a person, or group, assigned to clean that area.
• The best approach is that those who work in a plant are also responsible for cleaning that area.

(A) Cleaning is an ongoing process

• Define and document
• Decide Who, What, When, Where, How, etc …
• Who’s responsible for cleaning
• What needs to be cleared and where
• When it’ll be done
• How is it to be done and which tools demand
• For better clarity related to the below picture in which we can fluently see the comparison of the plant before and after cleaning.

(4) 4S-Seiketsu or Standardize

• After completion of Shine or Clean, Standardize will come.
• Standardizing means documenting each necessary process or activity.
• Standardizing can turn Good Practices into Good Habits.
• By developing standards for process, all person knows what to do, how to do it, when to do it, where to do it, etc.
• Give awareness about standardizing to all persons.
• It’ll help them to remember the new standards and it encourages them to do the same.
• We can use tags, 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 methodologies to show where the work enters and leaves the cell.
• Standard methodologies for identifying components and tool places

(D) 5S Audit

• Independent audit of an area
• Capture current state – Use color photos

(5) 5S-Shitsuke or Sustain

• Sustain needs to maintain 5S within the plant or work pace.
• Keep a record of progress with evaluations, communication, and training-related activity.
• Assign continuing responsibility.
• Sustain keeps watch on ongoing training activity and maintains the Established System.
• Maintaining Audits
• Maintaining cleaning
• Making it “ A Way of Life”.

you can also avail 5s Training from us

Top Management’s Support needed to Sustain

• We can sustain our commitment to the 5S methodology in our industry with the help of Top management’s support.
• Top Management should be involved in these activities similar 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 workers.
• Participation in promotional events at the plant.

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