Training slides for 5S Awareness & Implementation. (NOT for Practical 5S: Uplift Company Image by Increasing Quality & Productivity Training). This is one day training. Normally conducted on Saturday. To join the training, please send email to training@myanuar.com

1. 5S Awareness & Implementation

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•Name
•Designation
•Experience in 5S

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 Course Outline
1. Introduction to 5S History , Concepts, Benefits
2. Application of 5S
- Seiri (Sort/Structurize)
- Seiton (Set-in-Order/Systemize)
- Seiso (Shine/Sanitize)
- Seiketsu (Standardize)
- Shitsuke (Sustain/Self-Discipline)
3. Tips, Implementation , Examples
4. Practical

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 Course Objectives
At the end of this course, participants will be able to:
• Understand the principles of 5S
• Understand benefits of using 5S & workplace
efficiency
• Implement 5S & maintain it in any organization
• Develop self-directed staff using team-focused
approach.

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 History & Origin
• Henry Ford first perfected flow
production in the early part of
the 20th Century.
• Toyota improved Ford’s design
in the 30s and 40s developing
its LEAN production system to
be more adaptive to needs and
changes.
• It is based on “order &
structure”
• It was required to ensure the
sustainability of the “Visual
Factory” concept.
• Taiichi Ohno created the original
“4S” concept of workplace
organization and visual control at
Toyota during the early 1950’s.
• The concept was further refined
into “5S” during the 1960’s and
1970’s.
• U.S. manufacturers added a sixth
“S” for “safety” during the 1990’s.
• The 5S+1 tools were recently
modified by Gwendolyn Galsworth
to include “Visual Workplace”
disciplines.

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Basic Concept: What is 5S?
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 What is 5S? Basic Concept
• 5S is a workplace organization technique
• It is a way to involve associates in the ownership of
their workspace
• It helps create and maintain the efficiency and
effectiveness of a work area
A system to reduce waste and
optimize productivity

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 What is 5S? Basic Concept. How??
• Maintaining organized work area
• Using visual management

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Seiri Seiton Seiso
Seiketsu Shitsuke

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Sort /
Structurize
Set-in-Order
/
Systematize
Shine /
Sanitize
Standardize
Sustain /
Self-
Discipline

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Sisih Susun Sapu
Seragam
Sentiasa
amal

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 Seiri (Sort / Structurize / Sisih)
 Separating the Needed from the Not-Needed
 Eliminate not-needed items and perform an initial
cleaning
 Establish criteria/handling of items
 Identify not-needed items
 Move not-needed items to holding area
 Conduct a white-elephant sale
 Conduct an initial cleaning

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 Seiton (Systemize / Set in Order / Susun)
 A place for everything and everything in its place,
clean and ready to use
 Arrange workplace for safety and efficiency
 Identify key equipment and supplies
 Determine location for each item
 Outline locations and zones
 Develop shadow boards, label items
 Document layout, equipment, supplies

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 Seiso (Shine / Sanitize / Sapu)
 Cleaning for Inspection
 Perform daily cleaning and inspection to understand work
conditions
 Identify points to check for performance
 Determine acceptable performance
 Determine visual indicators/controls
 Mark equipment/controls
 Conduct daily cleaning/inspections

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 Seiketsu (Standardize / Seragam)
 Developing common methods for consistency
 Make abnormal conditions noticeable and document
agreements
 Document agreements and checks
 Establish/document standard methods across similar
work areas
 Document new standard methods

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 Shitsuke (Sustain / Sentiasa Amal)
 Holding the Gains and Improving
 Maintain the gains from other 5S activities and improve
 Determine 5S Level of Achievement
 Perform routine checks
 Analyze results of routine checks
 Measure progress and plan for continuous
improvement
 Training & communication to all employees to ensure 5S
application – developing good habit to all employees.

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 Summary
 5S is a continuous program focuses on organization,
cleanliness, and standardization to improve profitability,
efficiency, service and safety

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Benefits
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 Safety
 Organized & clean- easy to spot hazards
 Visual indicators alarm people of hazardous situations
 Healthier workplace
 Quality Improvement
 Reduce contamination / deterioration
 No short cuts - right tools available
 Visual management - easy detection
 Not cluttered - minimize damage
 Improving Process Efficiency
 Items for work are easily located,
 Don’t waste time searching,
 Improve work flow

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 Reduce Cost
 Efficient use of space, reduce footage
 Reduce downtime
 Damage prevention
 Waste reduction
 Employee Motivation
 Organized & clean workplace,
 Availability of tools,
 Helps workers do job well
 Pride & ownership
 Improve work culture
 Positive image to customers

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Key for Success
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 Management’s visual commitment & example
 Employees
 Active 5S champions & committee
 Training, education, promotion
 Communication
 Plan & do, review & action
 Recognition & reward
 Part of daily operation plan
 Immediate feedback
 Challenge the situation
 No shame & blame

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Implementation
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24. 5S Implementation
Sort / Structurize / Sisih

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 Objectives
 Making work area organized
 Free up space
 Easy to FIND the things you need

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Set up Steering Committee
(Sponsor ,Chairman)
Plan schedule
budget &
programme
Define boundaries of
layouts, Area champions
or Owner
Communication &
Publicity,
Awareness & Training
Assign Steering
committee member to
1 or more areas
Optional:
Temp Red Tag Area

27. Area 1 Area 2
Area 3 Area 4
5S Awareness & Implementation
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Select zone
Involve the
workers &
supervision of
area
Move items
to temp red
tag area
RED TAG it
& Fill Log
Identify unwanted
or misplaced or
unknown items or
not used daily
Take before
picture
Take
picture
Evaluation

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RED TAG
Date
Name Signature
Item
Action required

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 Evaluation for Disposition
 Return to home
 Find a home for it
 Scrap it ( sell or throw )
 Recycle, reuse, rework, repair
Who
decides?

31. 5S Implementation
Set in Order / Systemize

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 Physical lines on the floor to identify
work areas, storage areas, finished product
areas, etc
 Put shadows on tools boards, making it easy to
quickly see where each tools belongs
 Provide shelves, cabinets, tool trolleys
 Label name of items for easy identification
 Provide location map

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Before After

37. 5S Implementation
Shine / Sanitize / Sapu

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 Do a one time clean up – floors, machines, shelves,
tools, storage boxes (repaint ,replace, refurbish if
necessary)
 Identify & report specific source of dirt, filth, leak, spill.
Eliminate it!
 Identify & report damages, broken parts, rusted supports,
racings, exposed wires, missing nuts & bolts expired
item, potential hazards and problems

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 Create a spotless workplace
 Identify and eliminate causes of dirt and grime –
remove the need to clean
 Sweep, dust, polish and paint
 Divide areas into zones
 Define responsibilities for cleaning
 Tools and equipment must be owned by an
individual
 Focus on removing the need to clean

41. 5S Implementation
Standardize - Develop process structure to support new
practices

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 Generate a maintenance system for the first three
 Develop procedures, schedules, practices
 Continue to assess the use and disposal of items
 Regularly audit using checklists and measures of
housekeeping
 Real challenge is to keep it clean

43. 5S Implementation
Sustain - Holding the Gains and Improving

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 Means inoculate courtesy & good habits
 Driving force behind all 5S
 Deming’s point number 1: Constancy of purpose
 Make it a way of life
 Part of health and safety
 Involve the whole workforce*
 Develop and keep good habits
 Requires discipline & effort
 Carrot versus stick, Motivation & competition
 Train & coach
 Resources
 Audits
 Improve
 Communication board

45. 5S Implementation
Examples

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49. 5S Awareness & Implementation
Kick Start Exercise on Actual Worksite
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