5S5S-- 5 PILLARS OF 5 PILLARS OF

VISUAL WORK PLACEVISUAL WORK PLACE

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VISUAL WORK PLACEVISUAL WORK PLACE

5S5S-- 5 PILLARS OF VISUAL WORK 5 PILLARS OF VISUAL WORK PLACEPLACE

� THE FIRST PILLER: Seiri means -ORGANISATION

--THE RED-TAG STRATEGY

� THE SECOND PILLAR: Seiton means- ORDERLINESS

--THE SIGN BOARD STRATEGY

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--THE SIGN BOARD STRATEGY

� THE THIRD PILLAR : Seiso means-CLEANLINESS

� THE FOURTH PILLAR :Seiketsu means- STANDARISED

CLEANUP

� THE FIFTH PILLAR : Shitsuke means-DISCIPLINE

WHY ARE THE 5S NECESSARY?

�Changing business environment

---competition is growing harsher every year.

---demands more sophisticated products at lower cost.

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OBSTACLES:

Old beliefs, Old concepts, Old customs and Old habits

ARE DEEP ROOTED AND NOT EASY TO UPROOT OR

REPLACE

Old Belief

�House Keeping should be done by Housewives

at home, and by Cleaners and Sweepers at

work.

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�Why must we implement the 5S’s?

�We do not understand why 5S’s are necessary?

�They contribute to FAT in the companies.

�Every ounce of this FAT is pure waste

5S’s IMPLEMENTATION REDUCES THE FAT

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5S’s IMPLEMENTATION REDUCES THE FAT

(WASTE) SIGNIFICANTLY AND IMPROVES THE

CORPORATE HEALTH.

� Waste arising from unneeded desk supplies (too many

pens, pencils, erasers, etc.)

� Waste arising from unneeded allocation of space and

equipment.

� Wasteful motion in searching, side-stepping, etc.

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� Wasteful motion in searching, side-stepping, etc.

� Non-value added actions-picking up, putting down,

counting, etc

� Waste arising from Errors and Defects upsetting the

deliveries

Work is more efficient in waste-free office

5 S

�Similar to taking Bath.

�Why we take Bath everyday?

�People practice 5S in their personal lives without

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�People practice 5S in their personal lives without

even noticing it.

�Daily routine of Bathing, Dental care and so on

are personal hygiene type of 5S implementation

in daily life.

CASE STUDIES

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CASE STUDIES

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Pallet Shortage

Received request to order more Pallets

A. Identified 300 Red-Tag.

B. 300 Pallet shortage was converted into 300 pallet surplus.

C. One third of inventory was eliminated

� Inventory that time forgotRed-Tag strategy revealed some parts inventory in the

ware house that had set for 20 years, without anyone

noticing it.

� Window-less WallFirst darkness was created by closing the window with

empty boxes and then extra Fluorescent Lamps were

installed to overcome the darkness

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installed to overcome the darkness

� The Rowboat FactoryFilth generated during manufacturing in the Die-Cast

Factory was neither prevented nor cleaned periodically.

Boots were sanctioned to the people to walk around the

place more easily .Boot clad workers might let conditions

slide until the water get knee-high and may ask for

Rowboats.

� Using a wide room

The need for two extra floor to accommodate office staff

evaporated with the implementation of Red-Tag strategy

(Removal of unwanted items).

� A Tale of Needless Suffering

Assistants have to put useless overtime efforts for the

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misplaced report.

� When Reference Material Becomes Immaterial

Reports no longer needed continue to be generated and

distributed.

RESISTANCE TO THE 5S’S

� What’s so great about Organization and

Orderliness?

� Why should I, the President, Be 5S

Chairman?

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Chairman?

� Why clean when it just gets dirty again?

� Implementing O & O will not boost output.

�My Filing System is in a Mess – but I know

my way

�5S’s and Related Improvements are Just for

the Factory.

�We’re Too Busy to Spend Time on O and O

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�Who Are They to Tell Me What to do?

�We Don’t Need the 5S’s–

We’re Making Enough Money, So Just Let Us

Do Our work.

�These types of resistance occur at every factory

and at every office in the early stages of 5S

implementation.

�If we ignore such resistance and force the 5S

implementation, the result will be nothing more

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implementation, the result will be nothing more

than superficial improvements.

We must get everyone to truly understand how

necessary the 5S’s are while incorporating 5S

implementation into ongoing improvement activities.

BENEFITS:

�A neat and clean factory or office will have higher

output (productivity).

�A neat and clean factory or office will produce fewer

defects/ mistakes

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defects/ mistakes

�A neat and clean factory or office will meet

deadlines better.

IMPLEMENTATION OF THE 5S’S BRINGS MANY

DIRECT & INDIRECT BENEFITS.

Benefits From Six Zero’s

1. Zero Changeover Time from one Job to another Bring

Operations Diversification

2. Zero Defects / Errors Bring Higher Quality

3. Zero Waste Brings Lower Costs

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4. Zero Delays Bring Reliable Deliveries

5. Zero Complaints Bring Greater Confidence & Trust

6. Zero Red Ink (Zero unwanted items at work place)

Brings Corporate Growth

5 PILLARS OF 5 S:

1.Organization, 2.Orderliness,3.Cleanliness,4.Standardized

cleanup,5.Discipline

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5.Discipline

Pillar 1: ORGANIZATION

� Keep only what is needed, only in the quantity needed and only when it is needed

� Remove from workplace all items that are

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� Remove from workplace all items that are not needed for current operation- Use Red Tag

Offices are full of items that are not required. They Create Problems and Create Waste

Places to look for unneeded Items

� Back of drawers in individual employees’ desk

� Center and right top drawers to find unneeded writing supplies.

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unneeded writing supplies.� Disorganized paper piles on desktops,

Card board boxes kept under the desk� Lockers, shelves and cabinets to find

unneeded papers, and files.

Red Tag

� An effective tool for implementation of organization (First Pillar)

� Popular even in Korea and France

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� Differentiate between what is needed and what is not.

� Aimed at conquering an enemy known as waste

Today with Information Explosion people produce vast amounts of information through computers, photocopiers,

and Fax

Best approach--

to find ways to Prevent unneeded information

Yr. Company No. of employees

Discard amount(Tons)

Discard amount/Employee(Kg)

78 TDK 600 100 166

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unneeded information being collected or produced in the first place

78 TDK 600 100 166

80 KawasakiSteel Corp

1600 170 106

82 Mitsui. Eng.

1300 140 106

83 Taiso Marine

1300 210 161

Criteria for discarding a document

� Ask- Whether this document has been used in the last month?

� Answer—No� Ask- Whether this document will be needed

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� Ask- Whether this document will be needed during the year end?

� Answer- No� Ask- Is this document is at least two years old?� Answer- Yes� Document in question is no longer needed and

can safely be discarded

Transfer of documents to remote storage

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Pillar 2: ORDERLINESS

• It is standardizing the arrangement of needed items for easy retrieval and use

• It is labeling to make their storage easily understood by anyone.

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understood by anyone.

• It is always implemented with its partner organization

USE SIGNBOARD STRATEGY

SIGNBOARD STRATEGY

• A tool that makes orderliness a more visual process

• A method clearly indicating where (location),

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• A method clearly indicating where (location), what (items) and how many are stored.

• It helps faster & easy retrieval of items by anyone

Implementation steps

• Determine locations- decide where to place needed items

• Put frequently used items as close as

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possible to the user for easy access.

• Indicate locations--Make & post Signboards that clearly indicate item names and self name/no. where items will be kept.

Problems avoided by implementing orderliness

� Motion waste� Searching waste� Human energy waste

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� Human energy waste� Inventory waste� Defective Product waste� Waste of unsafe condition

Pillar 3: CLEANLINESS

� It means that keep everything swept and clean.

� It emphasizes removal of dirt, grime and dust from the work place

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from the work place

� It turns the workplace into clean, bright place where people will enjoy working

� It keeps everything in top and ready to use condition.

� Cleanliness & bathing are important for physical & mental health

� Would you consider bathing once a year-No

� Cleaning in office should happen on a daily basis

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basis

� It is difficult to start the day with fresh ideas when one’s desk is littered with eraser bits, useless papers, and leftover work from the previous day.

Pillar 4: STANDARDIZED CLEANUP

� It means that Organization, Orderliness, and Cleanliness are maintained.

� It relates most strongly with cleanliness.

� It is the condition that exist after Cleanliness is

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� It is the condition that exist after Cleanliness is practiced for sometime.

� Basic purpose of Standardized Cleanup is to prevent setbacks.

� To help make maintaining the first three S’s a daily habit

Problems from non-implementation

� Conditions revert to previous undesirable levels

� Piles of unneeded items lie scattered

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� Piles of unneeded items lie scattered around workplace at the end of the day

� Office people start accumulating more stationery supplies than they need

Pillar 5: DISCIPLINE

� It means always following specified and standardizedprocedures .

� Without discipline 5S will not last long.

� Managers who do not accept responsibility for maintaining

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the 5S’s are not entitled to complain for their subordinates not practicing 5S’s.

� Discipline is not to be taken lightly. It is, in fact, a pivotalfactor for the implementation of 5S,s.

5S Introduction Steps

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Step 1: ESTABLISHING THE 5S PROMOTION

ORGANIZATION

5S Promotion Organization

Chairman: MD

5S Council

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5S Leader: Head Admin.

5S Patrol Team 5S Team 5S Team

5S Council

Step 6: EVALUATION AND FOLLOW- UP

� 5S conditions are like a stretched rubber-band. Once

released, it return to its original shape.

� 5S will collapse or broken down due to lack of evaluation

and follow up.

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� 5S evaluation can be conducted by 5S patrols during

routine inspection.

� External evaluations are also important

� Strongest force in maintaining 5S conditions is discipline

(the fifth pillar). It prevents 5S breakdowns.

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EIGHT TIPS FOR ESTABLISHING THE 5S

Tip #1 The president must take ultimate responsibil ity.• Don’t place this responsibility with subordinates.

Tip #2 Every 5S policy decision requires company authorization.• Informal, improvised 5S policymaking does not work.

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Tip #3 Promote company wide participation .• 5S introduction does not work when only some

employees get involved.

Tip #4 Explain the 5S’s until everyone understands them .• Thorough 5S implementation requires thorough

understanding.

Tip #5 Be persistent and meticulous .• Don’t give up on something just because it is

difficult.

Tip #6 Be quick and ruthless when red-tagging andmaking signboards.• Long, drawn-out red-tagging and signboard

strategies die of inertia.

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strategies die of inertia.

Tip #7 Have the president participate in 5S patrols .• Top managers are especially needed when a 5S

patrol discovers mistakes made by middle managers.

Tip #8 The 5S’s are the company’s road to survival.• Without them, there is little hope for improvement