Total Quality Management
Week # 11
5S
Prepared by: Khalid Dahleez
Faculty of Commerce – the Islamic University of Gaza
This material was collected from different sources
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WHAT IS 5S?
 IN ORDER TO ACHIEVE HIGH LEVELS OF
QUALITY, SAFETY,AND PRODUCTIVITY,
WORKERS MUST HAVE A CONDUCIVE
WORKING ENVIRONMENT
 Developed by the Japanese
 Housekeeping System
 Helps Create a Better Working Environment
and a Consistently High Quality Process
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What is 5S?
 An easy definition is: Finding a place for
everything and putting everything in its place.
 5S is also the foundation for Continual
Improvement (CI) and Lean implementation.
It’s the elimination of waste Everywhere – while
adding customer value…
It’s a mindset & commitment to achieve a totally
waste-free operation that’s focused on your
customer’s success… achieved by simplifying and
continuously improving all processes
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5S stands for 5 initials of the following
Japanese words:
1.
2.
3.
4.
5.
Sei-ri
Sei-ton
Sei-so
Sei-ke-tsu
Shi-tsu-ke
5S
(Organization)
(Neatness)
(Cleaning)
(Standardization)
(Self-discipline)
ONCSS
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3
THE 5S PRINCIPLES
 SEIRI – Organisation/Sort out
 SEITON – Orderliness/Systemize
 SEISO – The Cleaning/Shining
 SEIKETSU – STANDARDIZE
 SHITSUKE - Sustain/Discipline
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DISCOVERY OF 5S
 Thirty years ago researchers started studying
the secret of success of Japanese
manufacturing companies
 5S turned out to be the most impressive
"secret"
 The factories were so well organized that
abnormal situations were readily apparent
 Equipments were so clean and well
maintained that any problem such as a loose
bolt or leaking oil could be easily seen
 This passion of cleanliness and orderliness
became a hallmark of Japanese organizations
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Seiri = Organization (SORT)
means we remove all items from the workplace that are
not needed for current production (parts, tools,
equipment, etc).
• Industrial definition: To distinguish between necessary things
and unnecessary things, and getting rid of what you do not
need.
• Dictionary definition: To put things in
order (or organize them) according to
a specific rule or principle.
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1. ORGANISATION(SEIRI)
 Decide what you need
 Remove unnecessary clutter
 All tools, gauges, materials, classified and
then stored
 Remove items which are broken, unusable
or only occasionally used
 Key Words:
1. Classification management (Necessary &
unnecessary things)
2. Red tag movement
3. For unnecessary things, find their true
causes.
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Why is my desk getting
messy?
Necessary
Not necessary
now, but maybe
in the future
Unnecessary
Every item on my desk belongs to the gray circle
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Do you throw these things away?
Not necessary
now, but maybe
in the future
It works!
It has a value!
It’s still new!
It’s usable!
It looks nice!
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RED
TAG
RED TAG TECHNIQUE
 GIVE STAFF RED LABELS
 ASK STAFF TO GO THROUGH EVERY
ITEM IN THE WORK PLACE
 ASK IF NEEDED & THOSE THAT ARE
NEEDED,IN WHAT QUANTITY
 NOT NEEDED (RED TAG IT )
 STORE IN THE RED TAG AREA
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RED
TAG
For wavering items
 PLACE THE SUSPECTED ITEMS IN
THE RED TAG AREA FOR ONE WEEK
 ALLOW THE STAFF TO REEVALUATE
THE NEEDED ITEMS
 AT THE END OF WEEK THOSE WHO
NEED ITEMS SHOULD BE RETURNED
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Typical Seiri Activities
1. Eliminate defects and breakage
2. Organize the warehouse
Before
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After
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T. Sugiyama “The 5S Approach to Improvement” PHP, 1995
Seiton = Neatness - Orderliness - Set in Order
Dictionary definition: Establishing a neat layout so that you
can always get just as much of what you need when
you need it.
Industrial definition: It is a way of eliminating search.
ONCE YOU HAVE ELIMINATED ALL
THE UNNEEDED ITEMS
NOW TURN TO THE LEFT OVER
ITEMS
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Question When you ask someone to bring a hammer,
how long can you wait without getting mad?
How long is your patience?
5 minutes? 2 minutes??
or
5 seconds???
Organise layout of tools and equipment:
1.Designated locations
2.Use tapes and labels
3.Ensure everything is available as it is needed and
at the “point of use”
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30 Second Rule
Workplace Checkpoints:1. Positions of aisles and
storage places clearly
marked?
2. Tools classified and stored by
frequency of use?
3. Pallets stacked correctly?
4. Safety equipment easily
accessible?
5. Floors in good condition?
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Key Words & Typical Activities
Key Words:
Design an efficient layout (Functional storage)
Eliminate search (Less search)
Everything should have a name.
(A place for everything and everything in its place)
Typical Seiton Activities:
Stripes on files
First in, first out
Easy to read notices
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3. SEISO (CLEAN/SHINE)
 Create a spotless workplace
 Identify and eliminate causes of dirt and grime –
remove the need to clean
 Sweep, dust, polish and paint
• SHINE means we sweep floors, scrub machines, apply a
fresh coat of paint, and then we KEEP it that way. This
way, everything will be in top working condition so that it
may be used when it is needed.
• It also means preventive maintenance.
Definition: Eliminating trash, filth, and foreign
matters for a cleaner workplace. Cleaning as
a form of inspection.
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Key Words:
Keep things clean + Inspection
(Caring attitude)
1. Divide areas into zones
2. Define responsibilities for cleaning
3. Tools and equipment must be owned by
an individual
4. Focus on removing the need to clean
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Cleanliness is a big business today.
Sanitation engineers
Laundry
Dry cleaner
Janitor
Garbage collector
Pollution control operator
Clean-room designer
One-third (1/3) or one-fourth (1/4) of the total
investment amount is used for cleanliness.
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4. SEIKETSU (STANDARDISE)
 Generate a maintenance system for the
first three
 Develop procedures, schedules, practices
 Continue to assess the use and disposal of
items
 Regularly audit using checklists and
measures of housekeeping
 Real challenge is to keep it clean
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Seiketsu = Standardization
Definition:
SEIRI
SEITON
Keeping things organized, neat,
and clean, even in personal and
environment aspects.
SEISO
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Seiketsu = Standardization
GAP
Ideal State
Current State
1.Define an ideal state
2.Standardize the solution (5S standardization)
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Typical Seiketsu Activities
1. Make quality manual
2. Directional markings
3. Color-coded pipes
• STANDARDIZATION happens when the first three S’s
are properly implemented and maintained.
• It means that racking, paint colors, labeling, operational
layouts are designed in a standard fashion.
• Everything will be in place so everyone will know exactly
what they are responsible for; and, exactly when, where,
and, how to do it.
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5. SHITSUKE (SUSTAIN / DISCIPLINE)
 Means inoculate courtesy & good habits
 Driving force behind all 5S
 Deming’s point number 1: Constancy of
purpose
 Make it a way of life
 Part of health and safety
 Involve the whole workforce*
 Develop and keep good habits
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Shitsuke = Self-discipline
Definition:
Doing the right things
as a matter of course.
We SORT areas. We SET IN ORDER work places. We
SHINE areas. With STANDARDIZATION it is easy to
identify anything out of place.
SUSTAIN is different: It isn’t a single separate activity; We
SUSTAIN when we have developed habits of always using
the first 4 S’s together on a daily basis.
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Key Words & Typical Activities
1.
Habit formation (Make it a habit)
2.
Create a disciplined workplace
Typical Shitsuke Activities
1. Wear your safety shoes
2. Exercise time
3. No smoking at workplace
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WHAT U HAVE COME ACROSS
Followings can be harnessed form the 5S
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
NEAT & CLEAN WORKPLACE
SMOOTH WORKING
NO OBSTRUCTION
SAFETY INCREASES
PRODUCTIVITY IMPROVES
QUALITY IMPROVES
WASTAGE DECREASE
MACHINE MAINTENANCE
VISUAL CONTROL SYSTEM
EMPLOYEES MOTIVATED
WORKSTATIONS BECOME SPACIOUS
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5 S’s
Sort
Clear out rarely used
Items by Red Tagging
Sustain
Use Regular Management
Audits to Stay Disciplined
Eliminate
Waste
Straighten
Organize and Label a
Place for Everything
Standardise
Create Rules to Sustain
the first 3 5’S
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Shine
Clean It
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When Does 5S Happen?
ALL THE TIME!! 5S is a mindset and a
culture. The 5S’s are a part of each
Associate’s workday. There will also be
CI Events and WPO (WorkPlace
Organization) Events. In an Event,
Associates are taught how to
implement the principles of Continual
Improvement.
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How is 5S Implemented?



By the associates! Who has a better idea
to make our jobs easier than us? Our
management is committed to improving
how we work.
We want to work smarter, not harder.
Along the way, support will come from
EVERYONE.
We will teach the 5S process, and together
we will implement it and make it work.
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ADVANTAGES OF 5S
 If tools and materials are conveniently located in
uncluttered work areas
 Operators spend less time looking for items
 This leads to higher workstation efficiency, a
fundamental goal in mass production
 A clean and tidy workplace leads to greater well being
and increased motivation
 Company image improves
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ADVANTAGES OF 5S
 Health and Safety is ensured
 Machine maintenance
 Quality
 Productivity






Lean Manufacturing
TIME SAVING
QUICK RETRIEVAL
ACCIDENTS & MISTAKES MINIMIZED
INCREASES SPACE
CREATES WORKPLACE OWNERSHIP
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ADVANTAGES OF 5S
 RESULTS IN A PLACE EASIER TO MANAGE
 SMOOTH WORKING
NO
OBSTRUCTION
 NO DEVIATION, NO PROBLEMS
 B/C EVERYONE KNOWS WHERE THE
THINGS ARE SPPOSEDF TO BE
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ADVANTAGES OF 5S
 FOUNDATION OF ALL QC TOOLS
 CONTINUOUS QUALITY
IMPROVEMENT
 LEAN MANUFACTURING
 KINDERGARTEN OF QUALITY TOOLS
& TECHNIQUES
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ADVANTAGES OF 5S
 VISUAL MANAGEMENT SYSTEM
 VISUAL CONTROL TO SEE THE
ABNORMALITIES
 SIMPLE SIGNALS THAT PROVIDE AN
UNDERSTANDING OF THE CONDITION(
NORMAL/ ABNORMAL)
 A LOOK AT THE PROCESS REVEALS ITS
DIRECTION (RIGHT/WRONG)
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