5S- HOUSE KEEPING
OR
WORK PLACE MANAGEMENT
Dr. Mohamed Riyazh Khan – DoMS, SNSCE
5-S: HOUSE KEEPING
WHAT IS 5-S
SEIRI
SEITON
SEISO
SEIKETSU
SHITSUKE
CLEARING
ARRANGING
SWEEPING
CLEANLINESS
DISCIPLINE
NEED FOR 5-S
• There can be no TQM without 5-s
• A dirty factory can not produce quality
products.
• If housekeeping is weak in a plant, no
further quality diagnosis is required to
know that it produces poor quality
products.
NEED FOR 5-S
• An orderly mind alone can create
well- ordered surroundings.
• Conversely, an orderly environment
promotes an orderly mind
• Clutter hides problems. A neat work
place promotes easy
discovery of
abnormalities.
WHY 5-S
5-S Contributes to
1. Safety
2. Quality
3. Productivity
5- S Facilitates
4. Visual Control
WHY 5-S
Safety
If Clearing and arranging are done well
then the work place has more space.
There is less clutter.
Work preparation is easier, efficiency is
raised, things do not get lost and the
general atmosphere is more pleasant.
These conditions promote safety.
Also, accidents often occur because
of tripping over something on the floor
where it is not supposed to be something
falling down a cupboard because it is kept
improperly or in the wrong place.
Our hands or clothing getting caught
in something which is out of place.
A hazardous chemical is spilled or
touched because of wrong location or
missing labels.
Orderliness promotes safety whether
at home, office, shop floor or on the road.
Why 5-S
*
Quality
A clean and orderly work place is a
pre-requisite for making good products.
* If a factory has poor housekeeping,
no further analysis is required to
know it has quality problems.
Poor 5S causes poor quality in
many ways:
1. Use of wrong parts or materialsespecially if they look similar.
2. Mix-up of rejects and good ones in
stores, causing rejects to be issued to
the shop.
3. Rejects getting mixed in the shop it
self, or going to the next line for
further processing and even to the
customer.
Poor 5S causes poor quality in
many ways:
4. Some process getting missed altogether
examples: parts waiting for heat
treatment getting mixed up with parts
already heat treated.
5. Dusty parts or materials getting used to
the detriment of performance or
impression of the customer
Poor 5S causes poor quality in
many ways:
6. Shelf-life expired materials may
get used.
7. Searching for things takes time away
from quality improvement
Poor 5S causes poor quality in
many ways:
Machines wear out faster if they are not
free of dust and this reduces their
accuracy and variability causing
defectives.
9. An Attitude is generated which say that
orderliness, discipline are not
important hence quality also not
important.
8.
Why 5-S
Productivity
To improve productivity, it is vital to
provide a clean, cheerful and well
organized environment in order that
everyone can work efficiently.
Why 5-S
Productivity
Productivity is very much a function of morale.
Good morale is promoted when people can feel
proud about the way they maintain their
workplace.
5-S promotes productivity in
many ways
1. Time spent in searching for things
(parts, tools or paper) is eliminated.
5-S promotes productivity in
many ways
2. Production loss due to a part or a
material or tool or anything else
which is supposed to be available
but can not be traced is eliminated.
5-S promotes productivity in
many ways
3. Production loss due to use of wrong
materials, mix-ups of materials and
other such defectives are eliminated.
4. Machines break down more often
when they work in dusty conditions.
5-S promotes productivity in
many ways
5. The
act of thorough cleaning of
machines often highlights things that
need attention. Without such cleaning,
timely attention may not be given
causing breakdowns
5-S promotes productivity in
many ways
6. Lack of punctuality affects the
productivity of all members of a
workplace even if only one person
is late.
5-S promotes productivity in
many ways
7. Abnormalities which cause
production stoppages can be spotted
easily
example: a bin without enough
materials on the shop floor, or a pileup of rejection bins
Why 5-S
Visual Control:
The job of a manager is to so organized
his plant so that the slightest abnormality
becomes visible immediately.
The most effective system of daily
checking or control is the visual one 5S
makes visual control possible and hence
improves the quality of management.
5-S promotes productivity in
many ways
Where house-keeping is poor, it is hard
to separate the normal from the
abnormal.
Where things are lying all over the
place how does one spot anything
unusual ?
5-S promotes productivity in
many ways
On the other hand where good 5S is
practiced, a manager may get to know
the situation by mere observation.
For example: “Line X seems to be
having higher defectives to day”.
5-S promotes productivity in
many ways
“Why is line A carrying an extra trolley
of in-process goods?
They must have lost production last
night.”
“There seems to be a breakdown in the
middle of a process. There is a pile-up
out there.”
5-S promotes productivity in
many ways
“This line is not balanced. There is no
even flow of materials.”
Managers must learn to spot
abnormalities so that they can take
actions quickly.
Abnormalities must be made strikingly
visible. That can be done only if the
normal is define d and visibly enforced.
5-S promotes productivity in
many ways
Visual control is promoted by
standardizing 5S and practicing with
use of clear signs, labels, colors and
systems of orderly arrangement.
Why 5-S
Visual Control
1.
2.
3.
4.
What needs monitoring?
How are abnormalities defined?
How easy is checking?
What actions should be taken?
Why 5-S
Visual Control
• The signs must be recognizable at a
glance, under-stand able to everyone.
They should help make the place
visually appealing and less cluttered.
Why 5-S
Visual Control
Visual control helps in all areas of 5s-in
storage operations and equipment.
They are also powerful aide in
ensuring quality and safety
(eg. Colors signs on meters)
Why 5-S
Visual Control
As part of standardization, a 5S
manual must be prepared.
This manual must have charts and
others visual displays which make their
meaning clear.
Then the manual can be used for
training of employees, new and old.
Why 5-S
Visual Control
Without the reinforcement through
visual signs, it is easy not to form
habits of 5S and to backslide.
At the same time putting up poster and
signs only without carrying out a
vigorous programme is hollow and will
yield no results.
SEIRI: CLEARING
Take out unnecessary items and throw
them away
Factory floor
•
•
•
•
•
•
Machine to be scrapped Broken toys
Rejected materials clothes
Expired goods Suitcases
Broken tools, pallets
Trolleys, old notices
Scrap heaps outside
SEIRI: CLEARING
Take out unnecessary items and throw them away
Office
Used/broken pens
Useless paper
Old diaries
Broken furniture
SEIRI: CLEARING
Take out unnecessary items and throw
them away
Home
•
•
•
•
Old Clothes
Broken Toys
Broken Suitcases
Useless Tins
HOW TO PRACTISE SEIRI
1. Separate the wanted from the
unwanted
SEPARATE THE WANTED FROM THE UNWANTED
JUNK & WASTE
WANTED
REPAIRABLE
REPAIR
DISCARD
TO THE NEXT ‘S’
HOW TO PRACTISE SEIRI
2. Throw away the unwanted items
Do not keep them with a vague
idea that the may be needed.
If an item has not been used for a
year, get rid of it.
Be ruthless about throwing necessary
things away.
HOW TO PRACTISE SEIRI
3. Classify everything by frequency
of use
SEIRI
FREQUENCY OF USE ACTION
1. Not used for the
year
Throw them away
2. Used only once in
last 6-12 months
Store at a
distance
3.Used only once in
last 2 - 6 months
Store at a central
place
SEIRI
4. Used more
Store at a central
than once in a place.
month
5. Used once a
week or daily
Store near site or
person.
5-S HOUSE KEEPING
SEITON: ARRANGING
Arrange everything in proper order
so
that it can be easily picked up or
use.
SEITON: ARRANGING
Factory floor
1.Unlabelled tool crib
2.Cluttered shelves, lockers
3. Stores-no clear location system
4. Things on the floor
SEITON: ARRANGING
Office
1.Unlabelled file Cabinet
2.Cluttered drawing
3. Shelves, tables
4. File heaps and Papers all over
SEITON: ARRANGING
Home
1. Clutter
2. No orderly Arrangement In Drawing
room or kitchen or anywhere
SEITON:
Consequence of not practicing SEIRI
1. Things are seldom available when
needed. Search squads are all the time
looking for misplaced things.
2. Together with non-practice of SEIRI,
the frustrating effects are:
Items are lost in stores.
Consequence of not practicing SEIRI
3. Items-defectives and good ones, or similar
looking materials get mixed up
4. Accidents or near accidents occur due to
clutter.
5. Visual control of the shop floor is not
possible.
• Consequence of not practicing SEIRI
6. Sometimes production is lost because
an item required is available but can not
be found.
In some offices, the consequences can be
even more serious. Critical excise records.
Or tax Records may not be traceable.
This can lead to financial loss/ persecution.
SEITON
The four steps to SEITON
are:
1. Analyze the present situation
Fix Storage place place
2. Fix2.Storage
Fix Storage Method
3. Fix 3.Storage
Method
4. Keep storage rules
Analysis
• The Steps involved in retrieving any
item, say a jig are.
a) Get the name correctly.
b) Go to fetch it.
c) Search for it.
d) Take it out.
e) Carry it to the workplace.
Analysis
• In Some cases, quantitative analysis of
these steps are required.
• In the best organized shops, things are
retrieved in seconds
SEITON
2. Fix the storage place:
This calls two steps
a) Everything should have a name
b) Consider the storage layout for each
class of items, based on the building
layout
c) 5-S means everything should have an
address.
SEITON
3. Fix the method of storage
a) Decide between storage by function or
storage by workplace of process, or a
combination
SEITON
3. Fix the method of storage
b) Select or design the appropriate
storage method. Here is where
creativity can be used to help
orderliness and easy retrieval.
SEITON
3. Fix the method of storage
c) Do not be restricted by available
standard storage systems.
d) Display names of items and storage
place clearly and prominently.
SEITON
4. Follow the rules
a) It all comes to good daily
management. The best storage system
can work only if it is maintained that
way, everyday.
b) Stock outs must be prevented and
items taken out must be returned.
SEITON
4. Follow the rules
c) Even if an item is used by some one, it
should be made to visually striking.
d) Storage areas should be clearly marked
and things should be within yellow and
white lines marked on the floor.
Passages Should be kept clear.
There should be no storage in the wrong
places or available open places on the
pretext of keeping them “temporarily”.
SEISO: SWEEPING
Sweep your workplace thoroughly
so that there is no dust anywhere.
Our environment is among the most dusty,
anywhere in the world.
We should therefore take even more trouble
to sweep and mop than they do elsewhere
Factor floor
•Dirty machines
•Dust on products, parts, raw
Materials
•Dirty jigs, fixtures,
•Dusty walls, roofs ,Littered Floor,
untidy
•Outside of the factory
Office
•Dusty table
•Dirty Office equipments
Type writers,
Computers,
•Dirty windows
•Dust in hidden places etc
Home
•Dirty furniture & floor
•Dusty window
•Dusty book shelves
•Dusty floor, cobwebs, fans
Consequence of not
practicing SEISO
• Most machines are affected by dust and
dirt. Their performance may go down,
they may wear out faster. The costs Can
be huge.
• Cleaning reveals many potential
equipment problems which may
otherwise get overlooked.
Consequence of not
practicing SEISO
• Dust and dirt on products, materials,
packing boxes will almost certainly affect
either their performance quality and in
the least their aesthetic quality.
• A dusty and dirty place is unpleasant to
work in.
SEIKETSU: CLEANLINESS
Washing, with a strong overtone of
keeping things disinfected as well as
free of hazardous Chemicals.
Some authors call this step standardizing.
But Standardizing should be common
to each of the 5-s.
Factor floor
•Handling hazardous Chemicals
Control of fumes,
•Hazardous, Dust etc.
•Disinfecting personal Hygiene.
Office
•Pest control.
•Personal hygiene
Home
•Pest control
•Personal hygiene
Consequence of not practicing
SEIKETSU
1. Good health and safety require the
practice of Seiketsu (it does not cover all
safety and health aspects but is basic to
it).
2. Hazardous chemicals, dusty chemicals,
fumes etc. can make it a dangerous
place to work in unless controlled
Consequence of not practicing
SEIKETSU
3. Washing thoroughly cleans a place
and makes the work place pleasant so
an unwashed work place can become
unpleasant.
4. Personal hygiene is also essential for a
healthy workforce.
SHITSUKE: DICIPLINE
Discipline, especially with regard
to safety rules and punctuality
SHITSUKE: DICIPLINE
5-S means everything is in its place.
People must also be in their place, at
the right time, in the right attire, It is
Management’s responsibility to train
people to practice 5-s with discipline, to
acquire the habit and to keep it.
Consequence of not practicing
SHITSUKE
1. If management is not disciplined , then
employees would not be either and the
first 4-S would backslide.
2. Without acquiring the 5-S habits, it is
difficult to maintain good 5-S.
Consequence of not practicing
SHITSUKE
3. Lack of shitsuke means not following
standards. Not only 5-S but all activities
relating to safety and quality will also
be affected.
5-s House Keeping
Training on 5S must be with the aid
of visual charts and display.
That is the way to ensure that the
message is understood and stays clear.
It is also easier to train new or
Transferred employees.
The charts and displays reinforce the
usage continuously and enable us to form
habits/Until 5-S Become a habit, the
battle is not won.
5-S HOUSE KEEPING
IMPORTANCE OF 5S
A Clean workplace is high in P roductivity
A clean workplace produces high Q uality
A clean workplace keeps C ost down
A clean workplace ensures
D elivery on time
A clean workplace is
to work
afe
S for people
A clean workplace is high in
orale
M