5S KAIZEN

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5S KAIZEN

What is

5S

By:PAWAN

5S stands for 5 initials of the following Japanese words:

1. 2. 3. 4. 5.
By:PAWAN

Sei-ri (Organization) Sei-ton (Neatness) Sei-so (Cleaning) Sei-ke-tsu (Standardization) Shi-tsu-ke (Self-discipline)

5S

ONCSS
1

International 5S
5 Steps for improvement

KAIZEN
By:PAWAN

Sei-ri

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Seiri

Seiri = Organization
Dictionary definition:

To put things in order (or organize them) according to a specific rule or principle. Industrial definition:

To distinguish between necessary things and unnecessary things, and getting rid of what you do not need.

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Why is my desk getting messy?

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Solution

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Red tag movement

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Red tag movement

At the beginning of each month, put a red tag on every item. During the month, remove the red tag when item is used. At the end of the month, decide whether the item with the tag is necessary or not.
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Wooden Pallet

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Key Words:

1. Classification management
(Necessary & unnecessary things)

2. Red tag movement For unnecessary things, find their true causes.
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Typical Seiri Activities

1. Eliminate defects and breakage 2. Organize the warehouse

Before
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After

Sei-ton
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Sei-ri Sei-ton

Seiri Seiton

Seiton = Neatness
Dictionary definition:

Establishing a neat layout so that you can always get just as much of what you need when you need it. Industrial definition:

It is a way of eliminating search.

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Question
When you ask someone to bring a hammer, how long can you wait without getting mad? How long is your patience?
5 minutes? 2 minutes?? or 5 seconds???

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30 Second Rule
Tool Box

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By:PAWAN

30 Second Rule

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Key Words:

1.Design an efficient layout.

(Functional storage)

2.Eliminate search
(Less search)

Everything should have a name.

(A place for everything and everything in its place)

Reserved seats
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Typical Seiton Activities

1. Stripes on files 2. First in, first out 3. Easy to read notices

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Before

After

Posters of Seiri

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Posters of Seiton

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Sei-ton
Seiri Seiton Seiso
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Sei-ri Sei-ton Sei-so

Seiso = Cleaning
Definition:

Eliminating trash, filth, and foreign matters for a cleaner workplace. Cleaning as a form of inspection.

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Key Words:

Keep things clean

+ Inspection
(Caring attitude)

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Cleanliness is a big business today.

Sanitation engineers Laundry Dry cleaner Janitor Garbage collector Pollution control operator Clean-room designer One-third (1/3) or one-fourth (1/4) of the total investment amount is used for cleanliness. 1
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Typical Seiso Activities

1. Quick 5S drill 2. Sparkling clean campaign 3. Everybody is a janitor
Broom Dust pan Mop
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Sei-ke-tsu

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Sei-ke-tsu Sei-ton
Seiri Seiton Seiso Seiketsu
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Sei-ri Sei-ton Sei-so Sei-ke-tsu

Seiketsu = Standardization
Definition:
SEIRI SEITON

Keeping things organized, neat, and clean, even in personal and environment aspects.
SEISO

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What is Problem ?
Problem is something like ----.

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Charles H. Kepner Benjamin B. Tregoe

The New Rational Manager Princeton Research Press, Shinkanrisha no Handanryoku (Japanese Edition), 1985

GAP Ideal State

Current State

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Key Words:

1. Define an ideal state 2. Standardize the solution

(5S standardization)

Documentation (ISO 9000)

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By:PAWAN

Kathmandu, NEPAL

Streets in Kathmandu

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Typical Seiketsu Activities

1. Make quality manual 2. Directional markings 3. Color-coded pipes

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Before

After

Shi-tsu-ke Sei-ke-tsu Sei-ton

Seiri By:PAWAN
5

Sei-ri Sei-ton Sei-so Sei-ke-tsu Shi-tsu-ke Seiton Seiso Seiketsu Shitsuke

Shitsuke = Self-discipline
Definition:

Doing the right things as a matter of course.

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ATA Boiler Company

(at a suburb of Rio de Janeiro)

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Morning exercise

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Key Words:

1. Habit formation
(Make it a habit)

2. Create a disciplined workplace

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Typical Shitsuke Activities

1. Wear your safety shoes 2. Exercise time 3. No smoking at workplace

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5S in Colombo

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Exercise

Establish a clean-up time every day. SEISO Eliminate oil leakage. SEIRI Make a reserved seat for each tool. SEITON Paint yellow lines at workplace. SEIKETSU Wear safety badge this week. SHITSUKE
SEIRI SEITON SEISO SEIKETSU SHITSUKE
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Exercise

Remove expired materials. SEIRI Display names of tools on the shelf. SEITON Force workers to greet each other. SHITSUKE Prepare a manual of the work. SEIKETSU Clean up a hidden place. SEISO
SEIRI SEITON SEISO SEIKETSU SHITSUKE
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Posters of 5S

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Nepal

Thailand

Posters of 5S

SEIRI SEITON SHITSUKE

SEISO
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SEIKETSU

Nepal

Benefits of 5S

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National Productivity Board, Singapore

Why not start 5S today?

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