5S Best Practice

© CII-AVANTHA Centre for Competitiveness for SMEs
Training Program on
Mfg. Excellence
Via
5S
© Confederation of Indian Industry

CII-AVANTHA Centre for Competitiveness for SMEs
What is manufacturing excellence all about ?
3
What is manufacturing excellence all about ?
PEOPLE
and
SYSTEMS
Too many parameters to work upon ? 4

Indian Manufacturing ( Journey so far )
50 Years Lean
IPS
manufacturing
Introduced
JIT
See through
layouts
Flow
Manufacturin
Product g
Layouts
10 Years 5 Years
Department
Process
wise Layouts
Layouts
1950 1960 1970 1990 2000 2005 2010 2015
50 Years • Years
15 Customer Satisfaction & Loyalty
Price = Cost + Profit Cost = Selling
• Price
Growth- Profit
in Sales & Profitability
Producer driven manufacturing Customer driven manufacturing
• Employee Satisfaction & Loyalty
1950s
Department-wise
layout
1960s
Process
wise layout
1970s
Product
Wise
layout
1990s
Flow Mfg.
2000
See-
Through
layout
2005
Introduced
JIT
Production
system
Indian Manufacturing ( Future )
2015-2020 Next Generation

??????? Manufacturing
will go through
a major change
Indian Manufacturing ( Challenges )
• Redefining QCD
• TEI ( Total Employee Involvement )
• Systems And Practices
• Green manufacturing
- Global warming
- 95 % + Recyclability for all product content
- Entire supply chain should be Green
Indian Manufacturing ( Next )
•Today’s Concepts are no longer valid
•Need to graduate to next levels
Let us understand….
THEN , NOW & NEXT

Next Generation Manufacturing

THEN NOW NEXT
No concepts ADVANCE
1S,2S
Of 5 S 5S
Job Education &

Instruction OJT
Training
Leveraging IT
Manual IT ( MRP ) for Mfg.
Design

THEN NOW NEXT
Supervisors Improvement
Facilitators
( Chasers ) Engineers
TEI ( Total
--------
EI ( Employee Employee
Involvement) Involvement)
----- EMS GO Green


THEN NOW NEXT
“Q” by “Q” by Integrated
QA/QC
judgment systems Management
Integrated
Comfort Target Inventory
Procurement Procurement Management
Must be State of the art
Basic Welfare
Welfare Satisfactory
Facilities Facilities
facilities

THEN NOW NEXT
Focused
Evolved Material “Q” Improvement
Handling Material Material Handling
Handling
Personality Quality System SOP Based
Based System Certification Standardization
Innovation
Improvement KAIZEN based
based
Sporadic Improvement
Improvement
What is 5S ?
Cleaning
To create a safe working culture

To produce good quality products
To reduce Non Value Added Activity
What is 5S ?
• A Five S program is usually a part of, and
the key component of Visual Factory
(Workplace) Management (VFM). And 5s
and VFM are both a part of Kaizen -- a
system of continual improvement -- which
is a component of lean manufacturing.

Why 5S
Ultimate Goal Better Tomorrow for Everyone
Intermediate Effective Use Resources

Goal Efficiency Improvement
Economic Operation
J T
Approach T T
I Q
& Method P Q
T C
M M
Foundation 5S
5 S FOUNDATION FOR PRODUCTIVITY IMPROVEMENT
Elements of 5S
• Seiri — Sort
• Seiton — Set in Order
• Seiso — Shine
• Seiketsu — Standardise
• Shitsuke — Sustain

STEP 1
SEIRI
SORT

CII-AVANTHA Centre for Competitiveness
Step 1 - SEIRI
Definition
Seiri means that
You remove all items from the workplace

that are not needed for current production
/ operations

Step 1 - SEIRI
Why ?
• The factory becomes extremely crowded and hard to work in.
• Lockers, shelves and cabinets for storage get in the way of

communication
• Time is wasted in tools, parts searching
• Excess Stock hide production problems
• Unneeded items and equipment make it harder to improve process

flow
Done with the objective of saving
and recovering space

Step 1 - SEIRI
Steps to doing SEIRI

S.No What to do Who does it
1. Identify the coordinator CEO
2. Identify the zones Coordinator
3. Identify the Zonal coordinator CEO/Co-ordinator
4. Identify the Red tag holding area Co-ordinator
5. Define the Red Tag Co-ordinator
6. Establish Criteria for red tag CEO/Co-ordinator
7. Establish frequency for doing red tag CEO/ Co-ordinator
7. Do the red tag All persons
8. Identify the Review Committee CEO
9. Review the Red Tagged Items Review Committee
Step 1 - SEIRI
ZONES
• The company to be divided into several
small zones to include every inch of space
in the company (incl Work area, office
area, Security cabin, canteen, toilets,
garden, etc)
• Each zone to have a zonal coordinator

Step 1 - SEIRI
Red Tag Holding Area

Red tag Holding area
This is an area set aside for use in storing red tagged
items that need further evaluation
(Why- It gives you a safety net between first questioning whether something is
needed, and actually getting rid of it)
Types of Red Tag Holding Area

Local Red Tag area – The Dept / Zones / Area can have individual red
tag area to avoid mix up of items with other areas
Central Red Tag Area – Later it would be better to have a central red
tag area for disposal

Step 1 - SEIRI
RED TAG
Red Tag can be a paper tag with the
following information
What is the item?

How much Quantity?
Why is it removed out (damaged,
excess, etc)?
What is approx value?
Section from where the item is
removed?
Establish the frequency of

doing red tag

Step 1 - SEIRI
Criteria for Red Tag

• Every person asks to all the items around his / her workplace
– Is this item needed ?
– If it is needed, is it needed in this quantity?
– If it is needed, is it required very frequently?
If Answer is “NO”
REMOVE FROM WORKPLACE

RED TAG CAMPAIGN
Unused Machines & Parts

Red tag Campaign
18/7/2011 12/08/2011
5th Red tag campaign 6 Feb 2012
12/8/2011 18/7/2011
18/7/2011
Red Tag Item kept in designated Red Tag Area
@Confederation of Indian Industry 33
Step 1 - SEIRI
Review the Red Tagged Items

• The review team would consist of senior members who
can take decisions on disposal, it must include personal
buying new items
– First a “purchase ban” on all items red tagged till inventory lasts
– Review the items accordingly
• Keep the item where it is

• Move the items to a new location
• Store the item away from the work area
• Hold the item in the local red tag area for evaluation
• Disposal of the item

Best
Best Shining
Shining
Example
Example : :
Only
Only 1S
1S
Before
35
Best Shining
Example :
Only 1S
After
36
Machine Shop Space Released Over the period
July-2011
12 Feb-2012
1 July-2012
Management Action on Red Tags
Step 1-
Red Tag Analysis
Creating Pie Chart of Red Tag Analysis
CEO Review
For all 7 Categories of Red Tag action plan for top 3-4 components
Item Freq. of Responsibility Action Creation of

Description Review on Red New
Tags Standard

Management Action on Red Tags
Step 2-
PDCA of Red Tag
Step 3-
SOP to be developed
Step 4-
Monitoring of Results

1S - Sorting out
Nothing on the floor and gangways
Before
After

BEFORE AFTER
OBSTRUCTION IN AISLE
CON ROD HONING SPM
BEFORE AFTER
DRESSING IMPROVED : EXTRA CABLES REMOVED.

CABLE TRAY MADE VERTICAL SO THAT DUST WILL NOT ACCUMULATE ON TRAYS.
CON ROD HONING SPM
BEFORE AFTER
METALLIC PANEL REMOVED FOR EASE OF INSPECTION BY THE OPERATOR DURING

ROUTINE DAILY CLEANING ACTIVITY.
METALLIC JUNCTION BOXES REPLACED WITH CLEANER/SMALLER PLASTIC BOXES
(QUANITY OF BOXES REDUCED FROM 4 TO 2 BY RE-ROUTINGOF CABLES)
6th MRM
Best Before - After Photograph: Only WPP Improvement
Before After
Date : 10.01.2012 Date :14.02.2012

Open land creating dust to floor Lawn to avoid dust
PROBLEM inside the factory IMPROVED
6th MRM 44
17th Feb 2012
Glimpses of the Garden
flowers in bloom Garden at ETP

Classify clearly the items into necessary and
unnecessary items, then dispose of unnecessary items
Do not leave SEIRI half done. All of the unnecessary

items should be discarded.
Not
Necessary
Not
Necessary
STEP 2
SEITON
SET IN ORDER

Step 2 - SEITON
Definition
Seiton means that
You arrange needed items so that they are easy to

to use and label them so that anyone can find
them and put them away

Step 2 - SEITON
Why ?
SEITON is important because it helps eliminate many
kinds of waste in the workplace
– Motion Waste – Person sent to find cart searched full
factory
– Searching Waste – No one can find the key to the tool
cabinet
– Waste of Human Energy – Frustrated worker gives up
searching for template after two hours
– Waste of Excess Inventory – Desk drawers are full of
papers and stationary supplies
– Waste of defective products – Items not kept back in
the same location so worker picks up wrong piece for
assembly
– Waste of unsafe condition – Boxes of material kept in
the walkway, causing someone to trip and get injured
Steps to do SEITON
Step A – Deciding Appropriate location
1. Principles of Storing jigs, tools, dies to eliminate waste
2. Principles of motion economy to eliminate waste
3. 5 S Map to decide location
Step B – Identifying location

1. Signboard Strategy
2. Painting Strategy
3. Colour coding Strategy
4. Outlining strategy
Step 2 - SEITON
Deciding Appropriate location

5 S Map to decide locations
Steps in making a 5 S Map
1. Make a floor plan or area diagram of the study area
2. Draw arrows in process flow sequence. For every operation there
is one arrow.
3. Search for areas of waste based on principles shown earlier.
4. Make new 5 S map. Draw arrows again. (Use several iterations till
most efficient one is reached)
5. Find out the feasibility and time period to make the layout change
6. Implement the new layout by moving parts, tools, machines etc.
7. Continue to further improve the layout

Step 2 - SEITON
BEFORE
OUT
Deburring Cleaning
Grinder Grinder IN
Loader
#2 #1
Heat
Roller
treatment

Step 2 - SEITON
AFTER
Roller
Grinder Heat
#2 treatment
3 4
5
2
Grinder
Cleaning
#1
1 6
Loader Deburring
IN OUT

Step 2 - SEITON
Identifying location
Signboard Strategy
The signboard strategy uses signboards to identify

what, where and how many.
Location indicators (where does the item go)
Item indicators (what item goes here)
Amount indicators (how many items go here)

Signboard
Work Instructions Displayed Near Eye Sight
Operator Can’t read the work inst. easily Operator read the work inst. easily
BEFORE AFTER
Good working environment (contd..)
Visual office
57
Step 2 - SEITON
Painting Strategy
The Painting Strategy is a method for
identifying locations on floors and walkways
Factors to keep in mind while using painting strategy
– U-shaped cell designs are more efficient than straight
production lines
– In process inventory should be positioned carefully for best
process flow
– Floors should be leveled or repaired before painting
– Walkways should allow for safety and smooth flow esp at
the turns
– Divider lines should be 2 or 4 inch wide
– Paint color MUST be standardized. Colors should be bright
Good working environment Via 2S
Clean and Visual factory
59
Color coding Strategy
Color coding strategy can be use to indicate which
items is used for which part
Examples
– Different colors can be allotted to different oils and the oil
bath to be marked the color of the type of oil to be used
– If certain items are used for making the same part then the
items can be color coded the same color and kept in a
location having the same color.
– Inventory levels can be color coded to indicate the critical,
designed, reorder and excess levels

Step 2 - SEITON

Inventory Control for Spares

Step 2 - SEITON
Outlining Strategy
Outlining is a method to show which jigs and tools

are stored where.
Outlining means drawing outlines of jigs and tools

in their proper locations

Step 2 - SEITON
SHADOW BOARDS FOR GAUGES

Step 2 - SEITON
Outlining Strategy in Drawer

Place necessary items at proper position
for practical usage and clearly indicate the contents
so that everyone can understand.
ＢＣ
ＡＤ

STEP 3
SEISO
SHINE

Step 3 - SEISO
Definition
Seiso means that
You need to keep everything swept and

clean
This is done with the objective of inspecting for

problems and taking faster corrective actions

Step 3 - SEISO
Steps to do SEISO
Determine Shine targets
• Storage space, Equipment or Empty Space
Determine Shine assignments
• Divide job based on area of cleaning
• Divide job based on time of cleaning
Determine Shine Methods
• Choose the right tools
• Shining should take 5 minutes
• How much to shine should be defined
Prepare tools
• Keep tools near location of shine
Start to Shine
• Clean thoroughly

Step 3 - SEISO
3S

Step 3 - SEISO
SPIC & SPAN
If there’s Lesser No. of Items
there is Lesser to Clean
• One is Best
– One page memo
– One day Processing
– One location Files
– One copy Filing
• Reduce no of Tools
– Reduce no. of bolt sizes
– Use of winged nuts
– Consolidate kinds of oil
– Combine various tools into one
– Any others...
3S - Shine Equipment
Shine road Shine lawn
Shine training hall Shine shop floor

STEP 4
SEIKETSU
STANDARDISE

Step 4- SEIKETSU
Definition
Seiketsu means that
You need to create a consistent way of

doing tasks and procedures.
This is done with the objective of ensuring

that the condition does not deteriorate back to
the condition it was before implementing 1S,
2S and 3 S.
Step 4- SEIKETSU
Steps to do SEIKETSU
Step A : Making it a habit

– Decide who is responsible for 3 S activities
– Integrate 3S duties into regular work duties
– Check on how well 3S conditions are being maintained
Step B : Prevention
– Prevent unneeded items from accumulating
– Prevent from having to put back things

Some evidence of standardized work areas
•Clear, shiny aisle ways

•Color coded areas
•Slogans, banners
•No work-in-process ( WIP )

•One-Piece Flow
•Standardized Work Sheets

STEP 5
SHITSUKE
SUSTAIN

Step 5 - SUSTAIN
Definition
Sustain (Shitsuke) means that
You need to make a habit of properly maintaining
correct procedures of 1S, 2S, 3S & 4S.

Step 5 - SUSTAIN
HOW to implement 5th S
Awareness - All need to understand what 5S is about
Time - Time has to be allocated to do the 5S
Structure - A Structure has to be formulated on how and when
5S activities will be done
Support - Management support needed in acknowledgement,
leadership and resources.
Management must lead by example
Rewards and recognition - Efforts need to be recognized
Satisfaction and Excitement - This needs to be shared in
the entire organization

Step 5 - SUSTAIN
Tools and Techniques for 5th S

5S Slogans
5S Posters/ Stickers
5S Photo Exhibits
5S Newsletters
5S BADGES AND BUTTONS
5S MINI SLOGAN SIGNS
5S Maps
5S Pocket manuals
5S Department tours
5S Competitions
Step 5 - SUSTAIN
CRITICAL FACTORS/STEPS IN
IMPLEMENTING 5S
Top Management commitment
Leadership by location head
Awareness Training Programme for all
employees (concepts, rules, steps, benefits)
Launching of 5S programme, promotion
through badges, posters, booklets, banners
Allocation of funds
Identification of 5S areas

Step 5 - SUSTAIN
5S In The Office
Step 5 - SUSTAIN
5S On The Plant Floor

Think...


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© CII-AVANTHA Centre for Competitiveness for SMEs

© Confederation of Indian Industry

Too many parameters to work upon ? 4

1950 1960 1970 1990 2000 2005 2010 2015

2015-2020 Next Generation

THEN , NOW & NEXT

Indian Manufacturing ( Next )

Job Education &

Indian Manufacturing ( Next )

----- EMS GO Green

Indian Manufacturing ( Next )

Indian Manufacturing ( Next )

To create a safe working culture

© Confederation of Indian Industry

Intermediate Effective Use Resources

• Seiton — Set in Order

© Confederation of Indian Industry

© Confederation of Indian Industry

You remove all items from the workplace

© Confederation of Indian Industry

• Lockers, shelves and cabinets for storage get in the way of

• Time is wasted in tools, parts searching

• Excess Stock hide production problems

• Unneeded items and equipment make it harder to improve process

© Confederation of Indian Industry

Steps to doing SEIRI

© Confederation of Indian Industry

Red Tag Holding Area

Types of Red Tag Holding Area

© Confederation of Indian Industry

What is the item?

Establish the frequency of

© Confederation of Indian Industry

Criteria for Red Tag

– Is this item needed ?

– If it is needed, is it needed in this quantity?

– If it is needed, is it required very frequently?

© Confederation of Indian Industry

Unused Machines & Parts

5th Red tag campaign 6 Feb 2012

Review the Red Tagged Items

– Review the items accordingly

• Keep the item where it is

© Confederation of Indian Industry

Item Freq. of Responsibility Action Creation of

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

DRESSING IMPROVED : EXTRA CABLES REMOVED.

METALLIC PANEL REMOVED FOR EASE OF INSPECTION BY THE OPERATOR DURING

Best Before - After Photograph: Only WPP Improvement

Date : 10.01.2012 Date :14.02.2012

flowers in bloom Garden at ETP

Do not leave SEIRI half done. All of the unnecessary

© Confederation of Indian Industry

Seiton means that

You arrange needed items so that they are easy to

© Confederation of Indian Industry

Step B – Identifying location

Deciding Appropriate location