SEMINAR ON

5’S’ Program on Work place Organization

&Standardization

PRESENTED BY-
AMIT SHUKLA
USN- 1DS04ME009
DEPARTMENT OF MECHANICAL ENGG.
DAYANADA SAGAR COLLEGE OF ENGG.
BANGALORE-78.
 An Ancient Prayer

From the cowardice,

That Makes us,
Shrink from the Truth ;
From the laxness,
That Keeps us ,
Content with Half Truth ;
From the Arrogance,
That Makes us Believe,
That We know All truth ;
O’ My Lord,
Deliver Us.
 How Adults Learn & Retain…

• 20% of what they hear

• 30% of what they see
• 50% of what they hear and see +
• 70% of what they hear, see and say
+ +
• 90% of what they hear, see, say and do

+ + +
 But First...
Death by
Initiative

This is NOT a new initiative!

It is NOT a new way A New

of doing business! Way of

Doing
Business!

It is merely doing what we already

do, but doing it BETTER!
Characteristics of PokaYoke Devices

 Simple and cheap

 Part of the process, permitting 100% inspection

 Placed close to where the mistakes occur,

providing quick feedback.

 Designed to stop a particular mistake

 A detection device cannot provide a complete

error proof solution

 Necessary and not a sufficient solution.

5 ‘S’ is Coming
Join The Run

Join the Run

What is 5’S’ ? A basic, fundamental,
systematic approach for
productivity, quality and
safety improvement in all
types of businesses.
The Five S program focuses
on having visual order,
organization, cleanliness
and standardization. The
results you can expect from
a Five S program are:
improved profitability,
efficiency, service and
safety.
The precipices underlying a
Five S program at first
appear to be simple,
obvious common sense.
And they are. But until the
advent of Five S programs
many businesses ignored
these basic principles.
What is 1’S’ ? This is step 1 in a Five S
program:

"Sorting" means to sort

through everything in each
work area. Keep only what is
necessary. Materials, tools,
equipment and supplies that
are not frequently used
should be moved to a
separate, common storage
area. Items that are not used
should be discarded.
Avoid keeping things around
just because they might be
used, someday.

Sorting is the first step in

making a work area tidy. It
makes it easier to find the
things you need and frees up
additional space.
The Principle involved is Sort
In – Sort Out .
 1 ‘S’ – Sort
All Tools,pins,screws, are lying – Tools placed - After Sorting
before Sorting

Plug pins placed - After Sorting

Pins & screws placed - After Sorting

Mixed items - Before Sorting Items arranged - After Sorting

Sorting : Remove the Unneeded items, Rearrange /Regroup

the Needed Items as per Predefined Categories

Sort In - Sort Out

How is Keep the wanted things & remove the
unwanted things using Red Tag
1’S’ Procedure .
carried
Red Tags Procedure :
out ?
Reason Red Tag Procedure is first step of sort
Item Name: 1.Obsolete
2.Not needed now activity. All items at the work place are
(once/year) critically analysed for their use &
Quantity:
3. Not reqd in the qty availability at work place. All unneeded
stored items & those in excess of their normal
Reason for red tag 4.Not reqd in that area use are removed to a remote area marked
5.Defective/ scrap
as Red Tag Holding Area. The idea of this
6.Use not known
activity is to keep only those items in that
Identified by: Disposal
1.Discard area which are relevant & required in
2.Return relevant quantities. All items shifted to
Date:
3.Sell red tag area carry a red tag which is filled
4.Move to separate with, quantity, reason for red tag, tagged
storage area by, date of tagging, reason for tagging
5.Rework
disposal proposal & action by, review
Disposal
ActionBy: date & status of disposal. Each tag is
DateReview/ allotted a unique S. No. Also there is an
Disposed action plan updated with every addition to
Red-tag file no. red tag area to ensure that items don’t lie
there indefinitely, but are disposed at
appropriate times.
What are benefits Creation of space is single
of 1’S’ ? biggest advantage of 1’S’
Generally if you are facing
problem of lack of space, go
for 1’S’ & space problem is
eliminated.
Sometimes one gets
surprised with the amount of
space released as a result of
1’S’ activity.
The other advantage is
money released due to sale
of unwanted items lying
unattended for long times.

When should be
1’S’ activity 1’S’ Being the first the step
started ? of 5’S’ program should be
starting point.
Where is 1’S’ 1’S’ is useful in factories
useful ? work areas , offices &
homes alike.
Housewives find it
maximum useful. Even
Municipal corporations
are getting their staff
trained in steps of 5’S’ as
they realize immense
benefits of it.

The space generated &

money released are
What are the
the success
success
indicators of indicators.
1’S’?
 Seiri – Sorting Out
How often do you
Storage location
need them?

Always Close

Necessary items Sometimes A little far away

Seldom but can't

Separate
throw away

SEIRI Action

Immediate Throw away

throw-away quickly

Unnecessary
Resale value? Try to sell
items

Is disposal Minimize cost of

expensive? disposal
What is 2’S’ ? 2s stands for Set in
order
The Principle involved is
’Place for everything &
Everything in place’

When is 2’S’ 2’S’ Activity is started

Activity started? immediately after 1’S’.
This sequence has to be
followed strictly.
How is 2’S’ 2’S’ activity is carried out
activity carried making use of lines ,
labels & signage.
out ?
Lines Standard colour &
widths are used for
marking locations
 Seiton – Set In Order
Is the matl Storage location
Identified?

Is the limits set? As per prodn req

Is the limits set?

Is the area marked? On floor or stand

Is the rejects area Defect fact cards 

INPUT/OUTPUT MTLSM marked separately? 3W 1E cards

Does it follow
Six freedom rules
storage freedom ?
SET IN ORDER Storage location
items

Is the items labeled? As per operation

labeled requirement

TOOLS/GUAGES Is the area marked ? On floor or stand

Is it close at hand? On a template

Labels Labels of standard
fonts & sizes are
used to mark
locations,
equipments,bins
& containers.

Signage Fire extinguishers,

exit ways are
marked using
standard symbols.
What is Time for
benefit of searching
2’S’ ? Before After tools , items
files etc is
eliminated to
zero.
What is 3’S’ Stands for shine.
3’S’? The principle involved is
‘cleaning with meaning’
Cleaning methods should
address questions like what is
being cleaned, where is it
being cleaned, how is it being
cleaned, who will clean &
when will it be done.
The cleaning schedule should
include walls, floor, roof etc.
Locations for cleaning
material must be marked & 2s
for cleaning material should
not be ignored.
Abnormalities like loose
wires, leakages must be
tagged promptly.
Cleanliness is also helpful to
notice damages on equipment
such as leaks, breakage and
misalignment.
 Seiso- Shine
Is what to clean Cleaning Check list
identified?

Is the frequency set As per process req

Is the limits set?

Is the method clear

As per the area

Who is to clean? Daily/weekly

CALENDAR

Recording with
Tags/Register
meaning ?
SHINE Storage location
items

Is the items labeled? As per operation

labeled req

MATERIALS Is the area marked ? On floor or wall

Is it close at hand? In a stand

What are the 3’S provides safe,
immaculate & pleasant
benefits of 3’S’
surroundings.
activity? It is very important to
boost the morale of
working people

Clean thoroughly
the workplace inside
out. Roofs,
How is 3’S’ Equipments , floor.
activity done? Start from the top &
come down
gradually.
3’S’ Prepare the
S.N What When How Who
o cleaning check-
lists & follow
Floor Shift Start & End Floor Mops Sweeper &
1 Cleaning Whenever there Brooms certified them.
is spillage. by SIC

Machine Shift Start & End Waste MC

2 cleaning Whenever there Cloth & Operator
is spillage. Solvent

Wall 1st Day of Brooms Sweeper &

3 Cleaning with certified
Month
from Dust extended by SIC
& Cobwebs handles

Work Shift Start & End Waste M/C

4 Tables Whenever there Cloth & Operator
is spillage. Solvent
What is 4’S’? 4’S’ stands for standardization of 1’S’, 2’S’
& 3’S’.
The Principle involved is standardisation of
above 3s i.e. defining clearly what is
required level to be achieved.
The workplace must have display of
required standards. Area map. Audit
sheets, work instructions,Do’s & Don’ts in
that workplace.history cards for
equipments, COT checklists, Safety check
lists, production performance graphs,
Quality performance graphs, planned
maintenance records, OEE graphs,
improvement tracking graphs.

When is 4’S’ 4’S’ is carried out after completing 3’S’

activity.
carried out?
It is important to follow the sequence as
bypassing the steps can lead to no benefit
of any step.
The idea is workplace should speak itself
giving an idea about state of affairs in the
shop.
 Seiketsu - Standardise
Prepare a list of all standards that needs to be located in
the work area
this will include, area map, 5 S audit sheet

PICTORIAL WORK INSTRUCTIONS FOR-OPERATION & DO'S and DONT'S

SMED, AM-COT, SAFETY POINTS
HISTORY CARD
PLANNED MAINTENANCE-RECORD AND PLANS
CURRENT PERFORMANCE GRAPHS/TRENDS-
PRODUCTION INFORMATION AS OF CURRENT
OUTPUT PERFORMANCE
QUALITY PERFORMANCE
OEE
IMPROVEMENT'S TRACKING GRAPHS/CHARTS
SKILL LEVEL
ANY OTHER INFO THAT MAY BE REQUIRED FROM TIME TO TIME
Audit both the area and equipment for all the above work
instructions and usage- no ncr's
What is 5’S’ 5’S’ stab\nds for sustain.
activity ? Sustain activity is carried
out using following
steps :
Train all operators in
observing SOPs &
Red Tag Procedures.
Place of neat storage of
personal items.
Process owners carry out
Daily Audit & 5’S’
Teams meet once a week.
Recognition for Best Area
as a rolling trophy.
How is 5’S’ Sustaining is done
activity done through Audits &
? Training
 5 ‘S’ Sustain
Action Plan

S.No. Action Who Target Date

Conclusions:

 Think simple

 Think specific

 Think attributes

 Think early

 Think responsive

 Think reuse
REFERENCES
1. Besterfield, D.H., 2001. Quality Control, 7th edition, New Jersey: Prentice
Hall International.

2. Straker, D., 1995. A Toolbook for Quality Improvement and problem Solving,
New York: Prentice Hall.

3. Turner, W.C., Mize, J.H., Case, K.E. and Nazametz, J.W., 1993. Introduction
to Industrial and Systems Engineering, New Jersey: Prentice Hall
International.

4. Shigeo, S., 1986. Zero Quality Control: Source Inspection and the Poka
Yoke
System, Massachusetts and Norwalk: Productivity Press Cambridge.

5. Shigeo, S., 1988. Poka Yoke: Improving Product Quality by Preventing

Defects, Massachusetts and Norwalk: Productivity Press Cambridge.

6. Woo, C.C., 2007. Microcontroller Based Motorized Cleaner, Faculty of

Electrical Engineering, Universiti Teknologi Malaysia, Unpublished
Thank you