5s
Key to work place improvement
Kaizen Institute
Africa Asia Pacific
402, Abhishek
72, B.M.M. Society
Ellis Bridge
Ahmedabad –380006 - India
Tel: + 91 –79- 6588634 / 9562 / 5616
Mobile: (0) 9825073146
Email: jmurthy@kaizen-institute.com
Lead By:
Jayanth Murthy
www.kaizen-institute.com
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Putting 5s to Work
Who does not like a
-Clean
-Orderly
-Disciplined
Environment ?
At home & At work !!!
5s AIMS at achieving this state
Mess ?!
Clean & Organized – Puts A Smile On Your Face !
One Way to Do It !!
The 5s Way To Do It !!
One to Keep Files !
The 5s Way To Do It !!
The 5s Way To Do It !!
The 5s Way To Do It !!
The 5s Way To Do It !!
5-S
• Seiri - sort out
• Seiton -systematic arrangement
• Seiso - Scrub clean, Spic & Span
• Seiketsu – Standardize - State the rules
• Shitsuke - Self-discipline (Follow rules)
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Step Zero - of 5s
Identify strategic Spots & take Photos / Video – To Capture Current Status
1st Step of 5s
SEIRI
•Sorting of all items
•Segregate Necessary from Unnecessary
•Take action on Unnecessary
• Red Tagging & Red Tag Areas (set Rules first)
• Heaps to Come out – 10 trucks (in a factory)
Red Tag To,
•Stock
•Facilities
•Locations / Space
•Documents
•Computer Files
•Machines
•Stationary
•Not People !!
When In Doubt,
Throw It Out !
Seiri
• Classify into: wanted, ?
and unwanted
• Discard unwanted
• Create red tag area for ?
•Wanted but not here
items
•Wanted but not in this Qty
• Move ? Items to red tag
•Wanted but not now
area
•Not Wanted at all
• Put red tag on
unmovable ? items
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Before Seiri
Before Seiri
Before Seiri
After Seiri
2nd Step of 5s
SEITON
Systematic Arrangement
A Place For Every Thing & Every Thing In Its Place
•Arrange Necessary Items Systematically
•Easy to identify, find, take & put back
•Everything to have a place & label
This Leads To Standardizing Of Storage.
Any Body Can :
- See Things (floor lines, door opening lines, labels etc)
- Can Take out it fast (less than 30 sec)
- Can Return It
- Where, What, How Many ? (Define & label)
Seiton
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Make Place for all wanted items
Target: Max searching time: 30 seconds
Sign boarding/labeling
Outlining
Color Coding
Visual Controls
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Does It Ring A Bell ?
Before
Before
Before
After Seiton
After Seiton
Before
After Seiton
After Seiton
After Seiton
After Seiton
The 5s Way To Do It !!
After Seiton
After Seiton
After Seiton
After Seiton
Before Seiton
After Seiton
After Seiton
After Seiton
After Seiton
3rd Step of 5s
SEISO
Spic and Span – Collective Cleaning
Autonomous Cleaning
•Cleaning is Inspection
•Cleaning with meaning
• Seiso Boards (tools)
• Seiso calendar & responsibility charts
• Decide What, When, Who and How to clean
Seiso
COT
•Cleaning with meaning
•Seiso calendar/map
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Cleaning using your own hands
Cleaning using your own hands
After Seiton
Before
After Seiton
After Seiton
Before
After Seiton
Seiso Board
Seiso Board
4th Step of 5s
SEIKETSU
Standardization (so that first 3
‘S’ is maintained AND…
No – Unnecessary items pile up
No – Mess / out of place items
No - Dirt
• Make the rules & Follow them
• SDCA
•5 min / 10 min 5s
•Setting Standards
Seiketsu
Setting up of Rules:
• Place token when tool (or file) is taken
• Make schedule to restore basic conditions
• Establish measures to track adherence to
rules
• answer the 5w1h as regards first 3 S
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Token System For Tracing Tools
Token System For Tracing Tools
Standardize
First Aid Point, Emergency Tel No & the Telephone next to it !!
5th Step of 5s
SHITSUKE
•Self Discipline
•Training & People Involvement
• Follow the rules set (if not use ..Retraining / Disciplinary Measures !)
•Photo Gallery
• Slogans
• Audit
• Radar Charts
Shitsuke
Self Discipline of adhering to Rules:
• Adhere to rules yourself
• Post adherence on visual displays
• Spread rules and adherence by teaching
others and tracking everybody’s
performance on visual displays
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Audit Format
- For Office Environment 5s Audit
- For Production / Factory Environment 5s Audit
- Casting a Radar Chart & Keeping it Updated
Some More Cases
On
5s
Seiton
Seiton
Seiton
Seiton
Seiton
Seiri
Seiton
Seiso
Seiton
Seiton
What is 5s ?
Seiri – Sorting of all items
Segregate Necessary from Unnecessary
Take action on Unnecessary
Seiton – Systematic Arrangement
Arrange Necessary Items Systematically
Easy to identify, find, take & put back
Everything to have a place & label
Seiso – Spin & Span
Everything to be clean
Use cleaning as inspection
Seiketsu – Setting Standards
Set standards & rules
5 min / 10 min 5s
Audit
Shitsuke – Self Discipline
Training & People Involvement
5s Requires Team Work
Three More Things
1 Top management Commitment
2 Top management Commitment
3 Top management Commitment
KAIZEN INSTITUTE OF AMERICA
KAIZEN INSTITUTE OF EUROPE
KAIZEN INSTITUTE: AFRICA-ASIA-PACIFIC
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Founder:
Masaaki Imai
Head (Bus. Dev):
Bud H. Cox
Africa-Asia-Pacific:
S.Gondhalekar, Mumbai Jayanth Murthy, Africa
S.Durairajan, Chennai ,V.K.Grover, Pune
Kristianto Jahja , Jakarta
Over 160 consultants worldwide.
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Consulting Clients in Africa-Asia Pacific:
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Bidco, Nairobi
Spinners and Spinners, Kenya
Superfoam Ltd, Kenya
Taj group of hotels
Milton Plastics
Bombay Oil Industries
• Rallis, India & Hitech Gears (supplier to Honda)
Latest additions (from March 2000):
• Spencon - Uganda / Zambia / Kenya
• Comcraft Group Of Companies
• Power techniques .
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN
Unique Features of Consultancy:
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Hands-on consultants
Implementation in shortest time
Cash-stingy solutions
Energizing people
Release of latent capabilities
Human development
Learning organization
KAIZEN and GEMBAKAIZEN are registered trade marks of
KAIZEN INSTITUTE -JAPAN