2 Principle of 5 S5S Philosophy focuses on effective work place organization, simplifies work environment, reduces waste while improving quality and safety.There is no hope for efficiency or quality improvement with dirty work place, waste of time and scrap.Developed in Japan, this method assume no effective and quality job can be done without clean and safe environment and without behavioral rules.The 5S allow to set up a well adapted and functional work environment, ruled by simple yet effective rules.5S deployment is to be done in a logical and progressive way. The 3 first S are shop floor actions, while the 2 lasts are sustaining and progress actions.Apparently simple, the 5S are a consistent and powerful set. Their correct deployment allows change and progress far beyond just perform cleaning (or order the cleaning to be done).5S are the solid base, the foundation on which to build continuous improvement, install lean manufacturing tools and methods. They are also an effective lever for change management and empowerment.It is recommended to start implementing 5S in a well chosen pilot workshop or pilot process, and spread to the others step by step
3 Five S Seiri Seiton Seiso Seiketsu Shitsuke The five S stand for the five first letters of these Japanese words:SeiriSeitonSeisoSeiketsuShitsuke
4 Meaning Seiri Sorting Out Seiton Systematic Arrangement Seiso Spic and Span (Shine)Seiketsu StandardizingShitsuke Self-discipline (Sustain)
5 5S – SORTThe first stage of 5S is to organize the work area, leaving only the tools and materials necessary to perform daily activities.When “sorting” is well implemented, communication between workers is improved and product quality and productivity are increased.Sorting, keep the necessary in work area, dispose or keep in a distant storage area less frequently used items, unneeded items are discarded.Seiri fights the habit to keep things because they may be useful someday. Seiri helps to keep work area tidy, improves searching and fetching efficiency, and generally clears much space. Seiri is also excellent way to gain valuable floor space and eliminate old broken tools, obsolete jigs and fixtures, scrap and excess raw material.
6 5S – SET IN ORDERThe second stage of 5S involves the orderly arrangement of needed items so they are easy to use and accessible for “anyone” to find. Orderliness eliminates waste in production and clerical activities.Systematic arrangement for the most efficient and effective retrieval. A good example of Seiton is the tool panel. Effective Seiton can be achieved by painting floors to visualize the dirt, outlining work areas and locations, shadow tool boards. For improving changeover time with SMED or reduce machine downtime through Total Productive Maintenance (TPM) it is necessary to have tools at hand. So a specific mobile tool cart was designed. An other example of Seiton are "broom carts". As cleaning is a major part of 5S we custom made carts to hold brooms, mops and buckets. Several carts have specific locations and all employees can find them.
7 5S – SHINEThe third stage of 5S is keeping everything clean and swept. This maintains a safer work area and problem areas are quickly identified.An important part of “shining” is “Mess Prevention.” In other words, don’t allow litter, scrap, shavings, cuttings, etc., to land on the floor in the first place.Cleaning. After the first thorough cleaning when implementing 5S, daily follow-up cleaning is necessary in order to sustain this improvement. Cleanliness is also helpful to notice damages on equipment such as leaks, breakage and misalignment. These minor damages, if left unattended, could lead to equipment failure and loss of production. Regular cleaning is a type of inspection. Seiso is an important part of basic TPM; Total Productive Maintenance and Safety matter through cleanliness is obvious.
8 Benefits of 5S Shine Eliminate spring cleaning Incorporate cleaning into daily routineMaintain clean and ready-to-use equipment
9 Benefits of 5S Shine Define shine target Identify shine methods Implement standardized cleanupMake “Shine” a natural part of your work day
10 5S – STANDARDIZEThe fourth stage of 5S involves creating a consistent approach for carrying out tasks and procedures. Orderliness is the core of “standardization” and is maintained by Visual Controls.Standardizing. Once the first three S have been implemented, it should be set as a standard so to keep these good practice work area. Without it, the situation will deteriorate right back to old habits. Have an easy-to-follow standards and develop a structure to support it. Allow employees to join the development of such standards.The 3 first S are often executed by order. Seiketsu helps to turn it into natural, standard behavior.
11 Visual Benefits of Standardize Signboard strategySignboard usesPainting strategyShadow boardingColor-coding strategyStandardize “Best Methods” across the organization
12 5S – SUSTAINThis last stage of 5S is the discipline and commitment of all other stages.Without “sustaining”, your workplace can easily revert back to being dirty and chaotic..Finally, to keep first 4 S alive, it is necessary to keep educating people maintaining standards. By setting up a formal system; with display of results, follow-up, the now complete 5S get insured to live, and be expanded beyond their initial limits, in an ongoing improvement way; the Kaizen way.
13 Keep The First 4s AliveThat is why it is so crucial for your team to be empowered to improve and maintain their workplace. When employees take pride in their work and workplace it can lead to greater job satisfaction and higher productivityThe effect of continuous improvement leads to less waste, better quality and faster lead times.