5S Methodology

What is 5S?

5S is a system for organizing spaces so work can be performed efficiently, effectively, and safely by eliminating the waste. This system focuses on putting everything in right place and keeping the workplace clean, which makes it easier for people to do their jobs without wasting time or risking injury.

The 5S comes from five Japanese terms:

-          Seiri (Sort)

-          Seiton (Set in Order)

-          Seiso (Shine)

-          Seiketsu (Standardize)

-          Shitsuke (Sustain)

The Origin of 5S:

5S began as part of the Toyota Production System (TPS) in the early and mid-20th century. This aims to increase the value of products or services for customers. This is often accomplished by finding and eliminating waste from production processes.

 

Benefits of 5S

-          Higher Quality

-          Increased Productivity

-          Reduced Costs

-          Safe work Environment

-          Employee Satisfaction

What are the 5S’s?

Let’s take a closer look at each part of 5S.

1S-Sort (Seiri):

   - Sorting Means sort everything what we need and what we don’t need.

   - Items that are not used should be removed or recycled and keep only what is actually required every day.

   - Instruments, Materials, Unidentified items or any things that hasn’t been used recently but might be needed in future shift this to separate area called Quarantine Area or Red Tag Area.

   - Only items that are required should remain in workspace and for that Whole team should spend a few hours going through the entire area like Cabins, Machine area etc.

   - Sorting Steps Cleaning  >  Classification  >  Assign the Responsibility  >  Shifting unwanted items to Quarantine /Red Tag Area  >  Recycling the things in Red Tag Area

Sorting of unwanted items

2S-Set in Order (Seiton):

 - Set in Order is for organizing the items at workplace. 

 - Arrange all the required items for economy movement based on frequency of use.

 - Several things are used together then store them together like welding machine and welding rods.

 - Identify all the items and mark identification symbols on them for easy handling and storage to identified location after use. 

 - Frequently used items should be kept nearer to user.

Arrange accoridng to category

3S-Shine (Seiso):

- After Set in Order, the workplace need regular cleaning so shine is used for regular cleaning of workplace and equipment.

- Cleanliness creates better working environment, increase customer satisfaction, reduce accidents and makes defects easier to detect.E

- Very workplace should have a person or group assigned to clean the area. Area ownership is best way to assign the responsibility.

- Cleaning is an ongoing process and should have questions like who’s responsible for cleaning? When and how it will be done? Which tools require? Etc.

Regular cleaning of workplace and equipments

4S-Standardize (Seiketsu):

- Standardize means documenting all necessary activities. In that we can turn Good Practices into Good Habits.

 - By developing standards for process all person knows what to do, how to do, when to do and where to do. It will help them to remember the new standards and encourage them to do the same.

 - We can use symbols, labels banners for standardization.

 - Standardization done by using Flow charts, Audits, sign boards etc.

standardization by using daily practice

5S-Sustain (Shitsuke):

 - Sustain means keeping 5S running smoothly but also of keeping everyone in the organization involved.

 - Keep a record of progress with evaluation, communications, and trainings.

 - We can sustain commitment by conducting inspection on random basis, Establishing proper communication from top to bottom and bottom to top management, Providing training to employee and by conducting promotional events in factory.