5S Methodology

Welcome to the
class….
5’s Methodology
Objectives: at the end of the
session student must be
able to:
• Enumerate 5’s Methodology.
• Identify 5’s Methodology.
• Perform 5’s Methodology in
classroom situation.
5S IN MAINTENANCE
What is 5S and why do we

want to do it?
5S
THE SECRET TO
JAPANESE SUCCESS
IDEA BEHIND 5S
In order to achieve high levels of quality,

safety and productivity, workers must
have a conducive working environment
WHAT IS 5S?
• Developed by the Japanese
• Housekeeping System
• Helps Create a Better
Working Environment and a
Consistently High Quality
Process
DISCOVERY OF 5S
• 30 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
DISCOVERY OF 5S
• 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
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
ADVANTAGES OF 5S
• Health and Safety is ensured

• Machine maintenance
• Quality
• Productivity
• Lean Manufacturing
ADVANTAGES OF 5S
• results in a place easier to manage
• smooth working no obstruction
• no deviation, no problems
• because everyone knows where the

things are spposedf to be
ADVANTAGES OF 5S
• TIME SAVING
• QUICK RETRIEVAL
• ACCIDENTS & MISTAKES MINIMIZED
• INCREASES SPACE
• CREATES WORKPLACE OWNERSHIP
ADVANTAGES OF 5S
• FOUNDATION OF ALL QC TOOLS
• CONTINUOUS QUALITY
IMPROVEMENT
• LEAN MANUFACTURING
• KINDERGARTEN OF QUALITY TOOLS
& TECHNIQUES
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)
METHODOLOGY
OF 5S
THE 5S PRINCIPLES
• SEIRI – Organisation/Sort out
• SEITON – Orderliness/Systemize
• SEISO – The Cleaning/Shining
• SEIKETSU – STANDARDIZE
• SHITSUKE - Sustain/Discipline
5S
1. Sort - All unneeded tools, parts
and supplies are removed from the area
2. Set in Order - A place for everything and
everything is in its place
3. Shine - The area is cleaned as the
work is performed
4. Standardize - Cleaning and identification methods are
consistently applied
5. Sustain - 5S is a habit and is
continually improved
Also - Work areas are safe and free of hazardous or
dangerous conditions
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
RED
RED TAG TECHNIQUE TAG
• 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
RED
TAG
For wavering items
• place the suspected items in

the red tag area for one week
• allow the staff to re-evaluate
the needed items
• at the end of week those who
need items should be
returned
ORGANISATION
PRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once per year Throw away

Once per year Store away from
the workplace
Avg. Once per month Store together but

Once per week offline
High Once Per Day Locate at the

workplace
2. ORDERLINESS (SEITON)
• once you have eliminated all

the unneeded items
• now turn to the left over

items
ORDERLINESS(SEITON)
Organise layout of tools and

equipment
 Designated locations
 Use tapes and labels
 Ensure everything is available
as it is needed and at the
“point of use”
ORDERLINESS(SEITON)
Workplace Checkpoints:-
• Positions of aisles and storage places
clearly marked?
• Tools classified and stored by
frequency of use?
• Pallets stacked correctly?
• Safety equipment easily accessible?
• Floors in good condition?
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

SEISO (CLEAN/SHINE)
• Divide areas into zones
• Define responsibilities for cleaning
• Tools and equipment must be owned by

an individual
• Focus on removing the need to clean

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
5. SHITSUKE (SUSTAIN / DISCIPLINE)
• Means inoculate courtesy & good habits

• Driving force behind all 5S
• Deming’s point number 1: Consistentancy of
purpose
• Make it a way of life
• Part of health and safety
• Involve the whole workforce*
• Develop and keep good habits
LITMUS TEST FOR 5S
• 30 second rule
• one must locate the item with in 30
second if 5s is properly implemented
• also applies to the electronic records
retrieval
WHAT U HAVE COME ACROSS
AT THE END OF DAY
Followings can be harnessed form the

5S
1. NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
Cont.
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10.EMPLOYEES MOTIVATED
11.WORKSTATIONS BECOME SPACIOUS
Some 5S Examples
After 5S - Cleaned,
organized and drawers
Before 5S labeled (less time and
frustration hunting)
5S Examples - Sort, Set in Order
See the difference?

1. Sort - All unneeded tools, parts and supplies are removed
from the area
2. Set in Order - A place for everything and everything is
in its place
5S Examples - Shine
3. Shine - The area is cleaned as the work is performed

(best) and\or there is a routine to keep the work area
clean.
The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S
The Good

5S Methodology

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Welcome to the

What is 5S and why do we

In order to achieve high levels of quality,

• Equipments were so clean and

• Operators spend less time looking for items

• Health and Safety is ensured

• because everyone knows where the

• visual control to see the abnormalities

• Remove unnecessary clutter

• All tools, gauges, materials, classified

• Remove items which are broken,

• give staff red labels

• place the suspected items in

Low Less than once per year Throw away

Avg. Once per month Store together but

High Once Per Day Locate at the

• once you have eliminated all

• now turn to the left over

Organise layout of tools and

• Create a spotless workplace

• Identify and eliminate causes of dirt

• Sweep, dust, polish and paint

• Divide areas into zones

• Define responsibilities for cleaning

• Tools and equipment must be owned by

• Focus on removing the need to clean

• Means inoculate courtesy & good habits

Followings can be harnessed form the

See the difference?

3. Shine - The area is cleaned as the work is performed

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