Necessity of 5S

Quality Assurance

Productivity
improvement

Quality assurance
Cost reduction
Job satisfaction

Deadline observation Secure production

Happy workplace volume

Workplace improvement

SEIRI SHITSUKE
SEITON SEISOU SEIKETSU
 Definition of 5S
Quality Assurance

(1) SEIRI (Sort)

Distinguishing between necessary and unnecessary things, and getting rid of what you
do not need

(2) SEITON (Set in Order)

The practice of orderly storage so the right item can be picked efficiently (without
waste) at the right time

(3) SEISOU(Shine)
Create a clean worksite without garbage and dust

(4) SEIKETSU(Standardization)
Standardization of best practices

(5) SHITSUKE (Sustain)

The practice of developing customs so that the workplace regulations and rules are
correctly practiced
 Promotion of 5S
Quality Assurance

(1) (2) (3) (4)

SEIRI SEITON SEISOU SEIKETSU
(Standard)
(Sort) (set in order) (Shine) Standardized the
solution
Dispose what is Can retrieve when Make the workplace
not needed required clean

(5)
SHITSUKE
(Discipline)
Develop customs that allow practice of regulations and rules
 Objective of 5S
Quality Assurance

Remove waste
Implement so that ‘waste becomes visible
to facilitate waste removal’

Waste = Current work – money generating work

From current work remove work that does not generate money
 5S that Eliminates Waste
Quality Assurance

Waste (rag) sifting boxes

Clean Dirty A little

Clean Dirty
dirty
objects objects objects objects
objects
“Self-discipline” is the foundation for success of 5S
Quality Assurance

“Self-discipline” supports 5S

Seiso Seiri
(Sort)
(Shine)

Seiketsu Seiton
(Standardization) (Set in order)

Sitsuke (Sustain )
 Heinrich’s Law
Quality Assurance

Accumulation of small
details leads to big
Major accident
success
1 incident

Small scale
accidents
29 incidents
Near miss / startling
incidents
300 incidents
 Bolts Sifting and Sorting
Quality Assurance

Normal 5S

What
Whatvalue
valueisisbeing
beingcreated
created??

Standardization
Standardization

Profitable
Profitable 5S
5S
 SEIRI
Quality Assurance

SEIRI (Sort) refers to:

Distinguishing between necessary things and
unnecessary things and getting rid of what you
do not need

Steps

Stratify Dispose Assign fixed place

 Stratification
Quality Assurance

‘Stratification’ refers to:

Assorting things around oneself into those that are
required and those that are not required

*Other than things used daily are non-required things

*Quantity in excess of what is used daily is non-required

* ‘Leave only this, just in case’ is strictly prohibited
 Action Standards
Quality Assurance

Standards Action

Dispose
Things used approximately once in 6 to 12 months Place far away
Gather and place together at the
Things used approximately once in 1 to 6 months
worksite
Things used once a week Place in vicinity of work

Place so that they are easy to pick

Make it easy to return
Things used daily
Identifiable

Place within arm’s length where

Things used every hour
they can be easily reached
 Categorization of Actions
Quality Assurance

Category Candidate items for actions

Product, in-process product, components, materials,
Damaged products, non-
sub-materials etc. conforming products, rusted
materials etc.

Machinery, jigs, tools, molds etc. Things not planned to be used

Things not used for several years
Old products, components, materials, sub-materials
etc.
Those that have expired
Non-required items
Drawings, documents, magazines, catalogs etc.
Those that have become old
 Assign Fixed Places
Quality Assurance

Assigning fixed places refers to:

Preparing rules and making visible ‘where’ and in
‘what quantity’’ the required things are to be placed

* Decide locations for things that will remain

* Make rules for locations

* Making visible refers to visual management

* Start with what can be done
 Location of things that will remain
Quality Assurance

Location of things that will remain should

consider :
(1) Where it will be used
(2) Where it will be placed
(3) How much it will be placed
(4) How it will be placed
 SEITON
Quality Assurance

SEITON (Set in order) refers to :

Implementing functional storage by deciding correct
placement method and layout so that the required
objects can be quickly used what it is required

Steps

Assign fixed places and

fixed quantity
Make it compact
 Assign fixed places and fixed quantity
Quality Assurance

Assigning fixed places and fixed

quantity :
Refers to facilitating picking and placing and ensuring
zero shortages
* Give priority to use frequency and decide fixed place

* Consider also safety (mainly weight)

-Place heavy objects at a height where they are easy to pick from

* Eliminate labor required for searching and returning

* Decide placing volume bused on usage volume (1 time, 1 day)

 Storage Index
Quality Assurance

Storage index = Steps x Hand operation

frequency

* How many steps does it take to walk to the storage

location?

* How many times is it necessary to move the hand to

grip, transport and place the object for storage?

*The storage coefficient will vary according to holding

method, transporting method and placement method
 Decision standards for fixed positions
Quality Assurance

(1) Where it will be used Clarification of usage objective and place

Near where it will be used so that work can be done

(2) Where it will be placed while walking
Stand-up operations

(3) How much will be placed Maximum, Minimum, Order point

Easy to place, Easy to remove (one-touch

(4) How will it be placed operation)

(5) Indication of placing location Coloring, boundaries

Illustrative indication, component name

(6) Recognize visually indication, Quantity indication

First in- First out, Recognize by observing

(7) Stagnating time is visible placement date

Decide person in-charge of

(8) supervision
Indicate person responsible
Examples of tools sorting (Seiton)
Quality Assurance
 SEISO
Quality Assurance

SEISO (Shine) refers to :

Removal of dirt and by investigating source of dirt
preparing countermeasures

Steps

Take action to prevent dirtiness

Identify source of occurrence
and its occurrence
 Take Preventive Actions
Quality Assurance

Actions to prevent dirtiness and its occurrence

refers to:
countermeasures against source of occurrence
include countermeasures (challenge towards
common sense) for process methods (defects in
processing conditions etc.)

*The basic point is sweeping and cleaning and inspecting

*It is also important to take immediate actions such as placing a cover etc.

* Accumulation of small points will lead to a situation where sweeping is not

required
 SEIKETSU
Quality Assurance

SEIKETSU (Standardization ) refers to:

Standardization of 5S through ‘visual management’

Steps

Make abnormalities visible in

Grasp vital points for management
management points
 Standardization of 5S
Quality Assurance

Clarification of vital points for management

- What are the minute defects
(1) - Basic conditions: Cleanliness, refueling, replace tightly bind fast, dirt,
looseness
- Operating conditions: pressure, temperature, time, flow
volume, weight, Equipment, jigs and tools, sub-materials

Prepare standards for the conditions

(2) - Objectification of judgment standards for normal versus abnormal
- Judgment without using measurement, knowledge, intuition and knack

Judgment standards for abnormalities

(3) - Inspection methods that can be used by anybody
- Methods for actions against abnormalities
 Points for Visual Management
Quality Assurance

(1) Recognize well even from a distance

(2) There are indicators on items to be managed

(3) Whether good or bad is clear, and anybody can point out

(4) Anybody can use, and convenient if used

(5) Anybody can follow and repair quickly

(6) Use of tools leads to neatness

 SITSUKE
Quality Assurance

SITSUKE (Sustain ) refers to:

Preparation of workplace atmosphere where
visual management is properly observed

Steps

Check state of observance of

Innovate to ensure observance
standardization of 5S