5's' System - NIPURN MEHTA

A
Project Report
On
5 S SYSTEM
AWARENESS, PRACTICES, LIMITATIONS
At
JK Paper Ltd., Songadh
HDFC Bank, Bardoli Branch
ICICI Bank, Bardoli Branch
B.V. Patel Institute of BMC & IT, Gopal Vidyanagar
Submitted To:
Bhulabhai Vanmalibhai Patel Institute of Business

Management, Computer & Information Technology,
Gopal Vidyanagar
Submitted By:
NIPURN MEHTA
TYBBA
06 BBA 34
Acknowledgement
I am greatly thankful to JK Paper Ltd., ICICI Bank, HDFC Bank and B.V.
Patel Institute of BMC & IT for giving me an opportunity to work on this
project at their company.
I wish to express my sincere thanks to Mrs. Poonam Mittal, Director of

Bhulabhai Vanmalibhai Patel Institute of Business Management, Computer &
Information Technology, Gopal Vidyanagar, Tarsadi, was my project guide
and gave me opportunity to do this project report under JK Paper Ltd., ICICI
Bank, HDFC Bank and B.V. Patel Institute of BMC & IT.
I am thankful to my external guides Mr. H.K. Sharma and Mr. V.A Ashtekar
of JK Paper Ltd; Mr. Vipul Modi of HDFC Bank; and Mr. Hemal of ICICI
Bank, without whom this project would not have been completed
successfully.
Last but not least, I thank all those who have helped me directly or indirectly
during the course of this project.
NIPURN MEHTA
06 BBA 34
Declaration
I, Nipurn R. Mehta, student of Bhulabhai Vanmalibhai Patel Institute of

Business Management, Computer, & Information Technology, Gopal
Vidyanagar, hereby declare that this project report has been undertaken as a
part of 6th Semester of Bachelor of Business Administration (BBA) syllabus of
Veer Narmad South Gujarat University, Surat. I declare that this report has
not been submitted to any other university or institute for any other purposes.
Date: Signature
Place: Gopal Vidyanagar
NIPURN MEHTA
PAGE
CH. NO CHAPTER NO
EXECUTIVE SUMMERY 01
SYNOPSIS 03
INTRODUCTION
1 INTRODUCTION OF 5S 04
THEORETICAL FRAME WORK
2 RESEARCH OBJECTIVES 15
3 RESEARCH METHODOLOGY 16
4 LIMITATION OF THE STUDY 21
5 DATA ANALYSIS AND INTERPRETATIONS 22
6 FINDINGS AND CONCLUSIONS 45
7 RECOMMENDATIONS 47
REFERENCES
8 BIBLIOGRAPHY 48
APPENDIX
EXECUTIVE SUMMARY
5S is a method for organizing a workplace, especially a shared workplace

and keeping it organized. 5S is the Japanese concept which collaborates 5
activities; each starts with English letter S and very powerfully denotes the
work place behavior in any Japanese company. 5S stands for SEIRI, SEITON,
SEISO, SEIKETSU and SHITSUKE.
This research project was carried out to check the conceptual awareness,
current standard and problems in implementation of 5S system in the
organizations.
Data were obtained through survey method. Researcher personally contacted

78 respondents who were from executive and manager level staff of JK Paper
Ltd, ICICI Bank, HDFC Bank and B.V. Patel Institute of BMC & IT. Samples
were selected through convenience sampling method. The Likert Scale
questionnaire was used to know actual practices and 5 awareness checking
questions along with one open ended questions was used to find out
implementation problems.
Respondents were asked total 390 questions to check their conceptual

awareness, out of that 43% of questions were not answered, 29% questions
were correctly answered and 28% questions were wrongly answered. But
reason for not answering and wrongly answering was not the unawareness;
rather it was the difficulty to recall the Japanese words of concept.
Respondents were asked 16 Likert scale questions to know about their

practices of 5S. It was found that respondents practice the system on regular
basis, because the average response of respondents falls between always and
often.
1
Prepered By : NIPURN MEHTA
Respondents mostly faced problem of time and less involvement,
commitment and support from subordinates, superiors and peers. Another
major problem for respondents was to sustain the system after
implementation.
It was recommended that training and development sessions and refreshing

sessions should be organized on regular basis, proper motivation should be
given to practice the system on regular basis, and top management should set
examples for employees by practicing and sustaining the system.
Finally, it was concluded that respondents are aware of concept but faces
problems to remember the Japanese terms of concept. They practice the
system due to regular monitoring of top management. They faced problem
like lack of time, lack of commitment and support form subordinates, peer
group and superiors, changing mindset of employees to practice 5S and
problem of sustainability of system.
2
SYNOPSIS
1. Area of Research
JK Paper Ltd., Songadh
ICICI Bank, Bardoli Branch
HDFC Bank, Bardoli Branch
B. V. Patel Institute of Business Management, Computer & Information
Technology
2. Research Topic
5S System Awareness, Practices, Limitations
3. Objective of Research
To check awareness of employees, lecturers and students regarding
5S.
To know actual application of 5S.
To check current standard of 5S practiced in organization.
To find out problems in implementation of 5S system
4. Research Methodology
Research Design
Descriptive Research Design
Sources of Data collection
Secondary Data
Websites
Books
Material given by JK Paper Ltd.
Primary Data
Questionnaire
Sample Size
78 Respondents
3
1. INTRODUCTION
1. Introduction of 5S
5S is a method for organizing a workplace, especially a shared workplace

(like a shop floor or an office space), and keeping it organized. It's
sometimes referred to as a housekeeping methodology; however this
characterization can be misleading, as workplace organization goes
beyond housekeeping. The 5S system is a series of activities designed to
improve workplace organization and standardization.
It is believed that good housekeeping and workplace organization are

directly linked to achieve discipline in manufacturing. If production
control, maintenance, quality assurance, or layout are not properly done,
for e.g. then the problem will easily appear a bad housekeeping and
workplace organization will not result in better compliance to schedule,
fewer machine breakdown, lower defect rates and prompt exposure of
problem areas.
When these practices are coordinated a truly first- class manufacturing

operation is achieved. A general attitude of cooperation is established so
that people practice good housekeeping not only in their own areas, but
also to help in other areas.
5S is a concept which collaborates 5 activities; each starts with the English

letter 'S' and very powerfully denotes the work place behavior in any
Japanese company. Many companies in the world have adopted and
practices 5S and undoubtedly they do perform better. Boeing, HP, Boise
Cascade, Tecumseh are some of the well know companies who practice
5S philosophy. Statistics show that 5S improved their productivity and
performance in many ways and put them ahead of their competitors. It is
4
not always the technical edge that makes companies shine; it is these
subtle practices and disciplines that make the difference.
The 5S are five Japanese words:
1. SEIRI (Sort)
2. SEITON (Set In Order)
3. SEISO (Shine)
4. SEIKETSU (Standardize)
5. SHITSUKE (Sustain)
This basic philosophy is applied in unique ways for many different

situations such as: to improve or design workstations, to improve overall
plant organizations, to improve plant safety, to create visual aids, to
standardize systems across work areas so employees can help each other
out easier, and to increase efficiency and quality.
1. SEIRI (Sort) - Remove all Unneeded Items
This is organizing things that you require and disposing of things that you
do not need any more. Seiri means tidiness, organization. Seiri refers to the
practice of sorting through all the tools, materials, etc., in the work area
and keeping only essential items. Everything else is stored or discarded.
This leads to fewer hazards and less clutter to interfere with productive
work.
Sort is a process of removing every non essential item from the workplace.
This task is not always simple, as work areas have had years to build up
items that arent necessary for completing the job. Examples of items that
need sorted are extra tables, benches, cabinets, tools, inventory, cleaning
supplies, rags, and documents. All of these extra items just get in the way
of efficient production.
5
Advantages of Sorting:
Task Simplification
Effective use of Space
Careful purchase of Items
2. SEITON (Set In Order) - Set Limits and Create Temporary Location

Indicators
Once things are sorted they should be kept in designated places to retrieve
later for use. This is called Seiton, which means storing the things chosen
as required, in a dedicated place. Seiton mean orderliness. It focuses on the
need for an orderly workplace. Tools, equipment, and materials must be
systematically arranged for the easiest and most efficient access. There
must be a place for everything, and everything must be in its place. The
standard in industry is you should find a tool/material within 20 seconds
or less, to be productive. Search a tool / material for hours, and you are
gone, and will lose your vital time in work.
Set in Order is the process of organizing the remaining items after the
sort process is completed. For example, all tools used in a setup on a
machine should be placed as close as possible to where they will be used.
There should be a place for everything and everything should always be in
its place unless it is being used.
Objective:
To retrieve things in 30 seconds as well as return the things to the

same place quickly
To Avoid accidents, embarrassment
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Steps:
1. Identify proper place for each and every Item

2. The correct place, position for item must be chosen according to how
the work is being performed and who will use it.
3. Label and mark locations of things with stickers, markers, etc for easy
identification
4. After use put the things back at the respective place for safekeeping.
5. Keep items required frequently near your work place/area.
Advantage:
Workflow becomes efficient and effective
3. SEISO (Shine) - Clean Everything, Use Cleaning as Inspection
This means cleanliness. At the end of your shift clean the machineries,
tools for future usage. Seiso indicates the need to keep the workplace clean
as well as neat. Cleaning in Japanese companies is a daily activity. At the
end of each shift, the work area is cleaned up and everything is restored to
its place.
It is the process of cleaning the work area and any machinery or

equipment in it. The ideal lean manufacturing implementation is to keep
the equipment in the same or better shape than when it was delivered.
Prior to lean manufacturing, many companies allowed their machinery to
deteriorate over time. Lean Manufacturing, employing the concepts of 5S,
TPM (Total Productive Maintenance), and Kaizen, keeps machinery
producing the same way or better than the day it was received, even after
many years of use.
Steps:
1. Clean the things regularly

2. Put aside 3 minutes every day to clean your workplace
3. Regularly clean machines and tools which you use
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4. Never throw anything around or dirty any place. Dont assume that
someone else will clean it for you.
5. Use right material for cleaning
6. Find the root-cause and eliminate
7. Clean even the less noticed places
8. Everyone should see the work place through the eyes of a visitor
9. In organization cleaning involves delegating individual areas of
responsibility.
Advantages:
Clean workplace
Machines and tools have longer life
Less breakdown of machine
Less frustration
4. SEIKETSU (Standardize) - Implement Visual Displays and Controls
This means following a particular standard. This allows for control and
consistency. Basic housekeeping standards apply everywhere in the
facility. Everyone knows exactly what his or her responsibilities are.
Housekeeping duties are part of regular work routines. 10-15 minutes
before and after the work shift, dedicated for only 5S, as an industry
standard.
Standardize is the process of making the first three Ss a habit. Many

companies have went through cleaning and organizing systems over the
years only to see it slip away back to an unorganized facility. Standardize
is one of the most important of the 5S system. For example, if a machine is
to be wiped clean at the end of a shift, it should be done every single day
without fail.
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Steps:
1. Create a maintenance system for housekeeping
2. Hold interdepartmental competitors for housekeeping. This will
increase the awareness of the condition of the workplace.
3. Look for unsafe areas and rectify them. This includes loose wiring
naked wires, spillage etc.
4. Allow your employee to participate in development of standards.
5. Decorate your workplace so that it is enjoyable for you and others.
6. Follow first 3 S practices regularly.
Requirements
Top management support and involvement

Certification of inspections using labels, tags etc.
Danger warning marks and signs
Color coding of files, pipes and containers
Responsibility labels
Directional marking on pipes
5 S museum photo now and before.
5. SHITSUKE (Sustain) - Keep in Place Through Training and Total

Employee Involvement
This refers to workplace discipline. Shitsuke means sustaining discipline.

This refers to maintaining standards and keeping the facility in safe and
efficient order day after day, year after year. This is most important in the
sense that whatever we learnt in earlier 4 S's should be practiced in true
spirit throughout the year. This should become a discipline it its own way.
It refers to maintaining and reviewing standards. Once the previous 4S's

have been established, they become the new way to operate. Maintain the
focus on this new way of operating, and do not allow a gradual decline
back to the old ways of operating. However, when an issue arises such as
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a suggested improvement, a new way of working, a new tool or a new
output requirement, then a review of the first 4S's is appropriate.
Requirements
Retrain from tendency to return to the status and the comfort-zone

of the old way of doing things
Follow office disciplines and decorum
Maintain good habits
Maintain courtesy and manners with subordinates
The 5 Ss are about doing the basics. They provide a foundation on which to
build other quality activities. With a tidy, disciplined environment, you can
see many of the things which need further attention. Companies that live in
chaos, no matter how fashionable it is these days, spend a lot of time in
unproductive activities. This is not to say that chaos does not have its place
in creative situations where you want to think out of the box, chaos can be a
welcome friend. But the truth of most companies is that a very large
proportion of activities could benefit from more control rather than more
chaos.
Implementing the 5 Ss requires full co-operation of all involved. This in itself

is an amazingly powerful activity. When people realize that these simple
activities have such power, and that by implementing them well, the
workplace becomes a more pleasant place, the principles will get more
enthusiastically embraced.
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Benefits of 5S System:
o Improve quality
o Achieve work standardization
o Decrease changeover time
o Improve safety
o Reduce storage costs
o Reduce cycle time
o Reduce machine down time
o Boost employee morale as well as work environment
o Simplifies work environment
o Not only improves physical environment but, improves thinking
process as well.
o Reduces waste
o Reduces non-valued activities
o Reduces stress
o Enhances image and create positive impression on others
2. Theoretical framework
2.1 Behavior
Behavior is defined as a 'stimulus - response dyad, which means
that a given point of time, under given circumstances, a particular
stimulus causes a particular response.
In other words behavior is an outward physical expression of a
particular state of mind i.e. what a person does. Thus, behavior is an
observable and measurable activity of human beings.
Behavior is caused, motivated and goal oriented. It is often affected
by subconscious motives of needs, i.e. certain internal forces, propel
a person to behave. Behavior is thus, the result of total effect of
individual and situational variables.
Behavior is therefore a persons externally visible, measurable and
perceptible action and performance.
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Features of Behavior:
Behavior is a caused, orderly and a systematic activity.
Behavior can be understood easily if causes behind it can be
analyzed.
Behavior can be controlled by manipulating the causes.
Behavior is caused by the influence of external and internal factors.
Behavior is autonomous.
Behavior affects others behavior and also gets affected by others.
Behavior is predictable but accuracy is limited.
Determinants of Behavior
Behavior is determined by attitude, personality, perception,

motivation, abilities, self-concept, socio-cultural set up, reference
group, needs and situation.
2.2 Attitude
An attitude is defined as learned predisposition to respond in a

constantly favorable or unfavorable manner with respect to a given
object.
According to Thrustone, Attitude refers to, The sum total of a
mans inclinations and feelings, prejudice or bias, preconceived
notions, ideas, fears, threats and convictions about any specific
topic. Attitude is inclination to behave in a particular way.
Ways to change Attitude
Some of the ways to change attitudes are given below.

Providing required information additional information helps to
change attitude.
Use of fear A moderate level of fear threats makes one aware of
the situation and brings change.
12
Influence of peers and friends Peers and friends are liked,
confided in and trusted, hence one listens to them and changes the
attitude.
Involvement approach when individuals are actually involved in
a particular situation their dissatisfaction lowers and attitude
changes.
Using change techniques effectively for example Oral techniques
should be used when it can be said with positive, effective tone
with sufficient logic and evidences to support the argument.
2.3 Perception
Perception is the selection and organization of environmental
stimuli to provide meaningful experiences for the receiver.
Perception involves searching for, obtaining and processing
information in the mind. It represents the psychological process
whereby people take information from the environment and make
sense of their world.
Perception is the unique way each person sees and interprets

things. Point of view is perception. Perception discriminates the
understanding of one person from another. Different people attach
different meaning to the same stimulus and these results in
differences in behavior.
Perception is the process of selecting, organizing and interpreting

or attaching meaning to events happening in the environment.
2.4 Communication
According to Keith Davis, Communication means the transfer of

information and understanding from one person to another person.
It is way of reaching other with facts, ideas, thoughts and values. It
is a bridge a person can cross safely the river of misunderstanding
that sometimes separate people.
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2.5 Control
Control helps to check the errors and to take the corrective action so
that deviations from standards are minimized and stated goals of
the organization are achieved in desired manner.
Control is a foreseeing action whereas earlier concept of control was

used only when errors were detected. Control in management
means setting standards, measuring actual performance and taking
corrective action. Thus, control comprises these three main
activities.
According to Harold Koontz, Controlling is the measurement and

correction of performance in order to make sure that enterprise
objectives and the plans devised to attain them are accomplished.
In 5 S System also control is important because, after

implementation of the system, monitoring the implementation and
keeping proper control over employees is necessary.
2.6 Leadership
A simple definition of leadership is that leadership is the art of

motivating a group of people to act towards achieving a common
goal.
A leader should be able to motivate the followers to practice the 5S

system. If he fails to do so, the implementation of system can ot be
done properly and habits of practicing 5S could not be cultivated.
14
2. RESEARCH OBJECTIVES
1. To check awareness of employees, lecturers and students

regarding 5S.
2. To know actual application of 5S.
3. To check current standard of 5S practiced in organization.
4. To find out problems in implementation of 5S system.
15
3. RESEARCH METHODOLOGY
Rationale behind Study
In the era of liberalization, competition is increasing day by day. To

survive in this cut-throat competition one needs to be systemized, whether
it is organization or an individual. Systemization is for:
Quality Improvement
Overall work cost reduction
Work Efficiency
Deciding work priority
As a matter of preference, everybody desires to work in fresh, clean, safe

and well functioning workplace.
A cluttered work area undoubtedly mirror the kind of attitude and

mindset of workers, as well as managers, have in giving importance to
their jobs.
On the other hand, a clean and tidy environment reflects how the
employees care about their jobs and work hard with due concern and
consideration.
5S System is all about systemizing oneself as well as organization. Many

of organizations in India such as HP Technologies, Boeing, HP, Boise
Cascade, Tecumseh, etc. have adopted 5S system and practices 5S and
undoubtedly they are performing better.
16
Problem Definition
Awareness regarding 5S system, actual habits of practicing 5S
system and Implementation problems faced by people in
implementing 5S system.
Need and significance of 5S
Improve quality
Achieve work standardization
Decrease changeover time
Improve safety
Reduce storage costs
Reduce cycle time
Reduce machine down time
Boost employee morale as well as work environment
Simplifies work environment
Not only improves physical environment but, improves thinking
process as well.
Reduces waste
Reduces non-valued activities
Reduces stress
Enhances image and create positive impression on others
17
Utility of the Research
1. The research will find out the problems faced by people in
implementing 5S system and by thereby help the researcher in

practicing the system for his own cause.
2. The research will help the organizations where the research has been
carried out for knowing the awareness level for 5S of the employees
in the organizations. As research will also find out actual habits of
employees in implementing the 5S system and problems faced by the
employees in implementation; organizations can better manage and
implement the system with ruling out the problems face in
implementation.
3. The research will also help other organizations who practice 5S
system in knowing various implementation problems faced by

employees.
4. The research will also help each and every respondent to know their
habits of practicing 5S system.

5. The research will help any other researcher who wants to undertake
similar research.
Objectives
1. To check awareness of employees, lecturers and students regarding
5S.
2. To know actual application of 5S after implementation.
3. To check current standard of 5S practiced in organization.
4. To find out problems in implementation of 5S system.
18
Data Sources
There are two types of sources of data
1. Primary Data Sources

2. Secondary Data Sources
The researcher has used both primary and secondary data. The primary
data is collected for the specific purpose of a specific inquiry of study.
Such data is original in character and is generated through survey.
The researcher is interested in knowing the conceptual awareness of

people regarding 5 S, actual habits of implementation 5S and problems
faced by people in practicing 5S. The descriptive research design focuses
on how to collect primary data.
The researcher has collected the primary data by survey method because
the analysis of the topic is mainly based on questionnaire.
Secondary data is collected through books, search on internet.
Research Instrument
As the sources of collecting data were primary, data has been obtained
through survey method. The Likert scale questionnaire was used.
Researcher contacted each respondent personally and questionnaire was
filled by them.
Geographical Scope
Managers and executive level personnel of JK Paper Limited, Unit:
Central Pulp Mills at Fort Songadh.
Manager and Executives of ICICI Bank at Bardoli.
Manager and executives of HDFC Bank at Bardoli.
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Students of TYBBA of B.V. Patel Institute of Business Management,
Computer and Information Technology, Tarsadi who attended seminar
on 5S in February 2008.
Director and lecturers of B.V. Patel Institute of Business Management,
Computer and Information Technology, Tarsadi.
Sampling Plan
When only few representative items of a population are selected and data
are collected only from these items or respondents, then such method is
known as sampling.
Sample Size
Here, a sample size of 78 respondents is taken for the research purpose.
Sampling Method
The researcher used non-probability/convenience sampling method for

research.
Sampling Unit
Sampling unit means a specific group which we are going to select for the
research. The sampling units are Executives and Managerial level
personnel, Director, lecturer and students of the college who implement or
practice 5S system.
Processing and analysis of data
After collecting the data from the survey, the data was edited, tabulated
and arranged in a meaningful pattern. The data was then presented in the
form of tables and charts.
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4. LIMITATIONS OF STUDY
1. Non Response Error

Non-response error occurs when the respondent does not pay attention
over the questionnaire and as a result does not give response for a
particular question.
Non response error has occurred, when the respondents have to
answer for the awareness checking questions. They knew the concept
but they did not know the name of each S of 5S.
2. Lack of Knowledge of the concept in new recruitees.
Many respondents from JK Paper Ltd were new in the organization
and as they didnt attend any training and development session of 5S
there were some problems in their practice. As it is in the policy of JK
Paper Ltd. to practice 5S system, they were practicing it in a very
limited way without fully comprehending the concept.
3. There were less number of executive level staff in ICICI Bank and
HDFC Bank. Hence adequate number of questionnaire could not be
filled.
4. In B.V. Patel Institute of Business Management, Computer &
information Technology, there has not been organized any training
session on 5S since last one year, many of the respondents had
forgotten the terms but they practice it.
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5. DATA ANALYSIS AND
INTERPRETATION
AWARENESS CHECKING
78 respondents were asked for their conceptual awareness about 5 S

Each respondent was asked 5 questions having two options, viz. True
and False.
So, 78 respondents were asked total 390 questions. Out of that
respondents gave their answer for 222 questions and remaining 168
questions were left unanswered.
A tabular representation along with graph, of above data is given below:
Responded Not responded

222 168
No Response
43%
Responded
57%
Responded
No Response
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Out of 222 responses, 113 answers given by respondents were correct and rest
109 answers were wrong (Incorrect)
Correct Answer Wrong Answer

113 109
49%
51%
Correct Answer
Wrong Answer
Interpretation:
From the above two graphs it can be concluded that the ratio of response and
non-response is quite same. Here 57% of the questions were answered by the
respondents and rest 43% of the questions were not answered by the
respondents. As per the observation of the researcher, the reason for not
answering the questions was not the unawareness of the concept rather, it
was the difficulty faced by respondents, to recall the Japanese words of the
concept.
Out of 222 respondents who responded, 51% gave correct answer and
remaining 49% responded wrong answers. Here too, reason for giving
incorrect answer was the difficulty to recall the Japanese words of the
concept.
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ACTUAL HABIT AND CURRENT STANDARDS
1. You organize things that you require.
Parameter No. of Responses out of 78 Percentage (%)
Always 48 62
Often 23 29
Sometimes 6 8
Seldom/rarely 1 1
Never 0 0
1% 0%
8%
Always
29% Often
62% Sometimes
Seldom/Rarely
Never
(A) H0: Respondents always organize things that they require.
Standard Significance
Respondents Mean tcal ttab HO:
Deviation Level
78 1.49 0.69 6.27 1.96 Rejected 95%
Here HO is rejected that means, Respondents do not organize things

always.
(B) H0: Respondents often organize things that they require.
Respondents Mean tcal ttab H0:
Deviation Level
78 1.49 0.69 6.53 1.96 Rejected 95%
Here H0 is rejected that means, Respondents does not organize things

often
From above analysis, it can be concluded that the response of respondents

falls between always and often. So respondents usually organize things.
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2. You dispose off things that you do not require.

Always 35 45
Often 22 28
Sometimes 13 17
Seldom/rarely 7 9
Never 1 1
1%
9%
Always
17% 45%
Often
Sometimes
28% Seldom/Rarely
Never
H0: Respondents often dispose off things that they do not require.
Deviation Level
78 1.94 1.04 0.51 1.96 Accepted 95%
Here, H0 is accepted. Hence it was found that respondents often dispose

off unneeded things from the workplace.
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3. You think twice about need for item before recommending its
Purchase.
Parameter No. of Responses out of 78 Percentage
Always 52 67
Often 21 27
Sometimes 4 5
Seldom/rarely 0 0
Never 1 1
5% 0% 1%
Always
27%
Often
67% Sometimes
Seldom/Rarely
Never
(A) H0: Respondents always think twice about need for item before
recommending its purchase.
Deviation Level
78 1.42 0.71 5.22 1.96 Rejected 95%
Here H0 is rejected, it was found that Respondents always twice about

need for item before recommending its purchase
(B) H0: Respondents often think twice about need for item before
recommending its purchase.
Deviation Level
78 1.42 0.71 7.21 1.96 Rejected 95%
Here H1is rejected; hence here too it was found that respondents often
think about need for item before recommending its purchase.
So, from above analysis, respondents generally think twice about need for
item before recommending its purchase.
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4. You make effective use of space at workplace.
No. of Responses
Parameter Percentage (%)
out of 78
Always 51 66
Often 19 24
Sometimes 7 9
Seldom/rarely 1 1
Never 0 0
1% 0%
9%
Always
24%
Often
66% Sometimes
Seldom/Rarely
Never
(A) HO: Respondents always make effective use of space at workplace.
Deviation Level
78 1.46 0.71 5.72 1.96 Rejected 95%
Here H0 is rejected; hence Respondents dont always make effective use

of space at their workplace.
(B) H0: Respondents always make effective use of space at workplace.
Deviation Level
78 1.46 0.71 5.72 1.96 Rejected 95%
H1 is rejected; so Respondents dont often make effective use of space

at their workplace.
So from above analysis it can be concluded that, respondents generally make

effective use of space at workplace.
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5. You have specified place to put each and every item.
Response No. of Responses out of 78 Percentage (%)
Always 41 53
Often 22 28
Sometimes 11 14
Seldom/rarely 4 5
Never 0 0
0%
5%
14% Always
Often
53%
28% Sometimes
Seldom/Rarely
Never
(A) HO: Respondents always have specified place to put each and every
item.
Deviation Level
78 1.72 0.89 7.14 1.96 Rejected 95%
Here, H0 is rejected; so it can be said that respondents do not always

have specified place to put each and every item.
(B) H0: Respondents often have specified place to put each and every
item.
Deviation Level
78 1.72 0.89 2.78 1.96 Rejected 95%
H0 is rejected; so it was found that respondents do not often have

specified place to put each and every item.
So, it can be concluded that, respondents usually have specified place to put
each and every item.
28
6. You constantly label and mark locations of things with
stickers and markers for easy identification.
No. of Responses
Response Percentage
out of 78
Always 33 42
Often 18 23
Sometimes 16 21
Seldom/rarely 7 9
Never 4 5
9% 5%
Always
42%
21% Often
Sometimes
23% Seldom/Rarely
Never
H0: Respondents often label and mark locations for easy identification.
Deviation Level
78 2.12 1.2 0.88 1.96 Accepted 95%
Here H0 is accepted, so it can be directly said that respondents often label and
mark locations of things with stickers and markers for easy identification.
29
7. After use you put the things back at its respective place.
Always 49 58
Often 22 12
Sometimes 3 16
Seldom/rarely 3 8
Never 1 6
8% 6%
Always
16%
Often
58% Sometimes
12%
Seldom/Rarely
Never
(A) HO: After use Respondents always put things back to its respective
place.
Deviation Level
78 1.53 0.84 5.57 1.96 Rejected 95%
Here H0 is rejected, so it cant be said that after use respondents put

things to its respective place.
(B) H0: After use respondents often put things back to its respective
place.
Deviation Level
78 1.53 0.84 4.94 1.96 Rejected 95%
H1 is rejected; so it was found that respondents dont often put things

back to its respective place.
So it can be concluded that respondents usually put their things back at its
respective place after use.
30
8. You keep items required frequently near your
workplace/area.
Always 42 54
Often 31 40
Sometimes 2 2
Seldom/rarely 1 1
Never 2 3
2% 1% 3%
Always
Often
40%
54% Sometimes
Seldom/Rarely
Never
(A) H0: Respondents always keep items required frequently near their
workplace.
Deviation Level
78 1.59 0.82 6.35 1.96 Rejected 95%
Here hypothesis is rejected so it can be said that, respondents dont

always keep required things near their workplace.
(B) H0: Respondents often keep items required frequently near their
workplace.
Deviation Level
78 1.59 0.82 4.42 1.96 Rejected 95%
Here also H0 is rejected. Hence Respondents dont often keep required

frequently near their workplace.
Hence, it was found that respondents generally keep items required

frequently near their workplace.
31
9. You give at least 3 minutes every day to clean your workplace.

Always 43 55
Often 10 13
Sometimes 13 17
Seldom/rarely 7 9
Never 2 6
9% 6%
Always
17% Often
55%
Sometimes
13%
Seldom/Rarely
Never
H0: Respondents often give at least 3 minutes every day to clean their
workplace.
Deviation Level
78 1.99 1.29 0.07 1.96 Accepted 95%
Here H0 is accepted; hence it can be concluded that Respondents always

give at least 3 minutes every day to clean their workplace.
32
10. You throw things and assume that someone will clean it up
for you.
Always 2 3
Often 5 6
Sometimes 7 9
Seldom/rarely 12 15
Never 52 67
3%
6%
9% Always
15% Often
67% Sometimes
Seldom/Rarely
Never
(A) H0: Respondents never throw things and assume that someone will
clean it up for you.
Deviation Level
78 4.37 1.05 5.3 1.96 Rejected 95%
Hypothesis is rejected, so respondents throw things and assume

that someone will clean it up for them.
(B) H0: Respondents rarely throw things and assume that someone will
clean it up for them.
Deviation Level
78 4.37 1.05 3.11 1.96 Rejected 95%
Here Hypothesis is rejected so respondents often throw things and assume

that someone will clean it up for them.
From above calculation it can be said that, the result falls between never and
rarely. So respondents generally dont throw things.
33
11. You feel frustrated because you cannot find things quickly
when needed.
Always 9 12
Often 15 19
Sometimes 24 31
Seldom/rarely 16 20
Never 14 18
18% 12%
Always
19%
Often
20%
Sometimes
31% Seldom/Rarely
Never
H0: Respondents sometimes feel frustrated because they cannot find

things quickly when needed.
Deviation Level
78 3.14 1.25 0.99 1.96 Accepted 95%
Here H0 is accepted, therefore it can be said that respondents sometimes feel

frustrated because they cannot find things quickly when needed.
34
12. You make efforts and notice unsafe areas, practice equipment
etc.
Always 23 30
Often 32 54
Sometimes 12 15
Seldom/rarely 1 1
Never 0 0
1% 0%
15% 30% Always

Often
Sometimes
54% Seldom/Rarely
Never
HO: Respondents often make efforts and notice unsafe areas.
Deviation Level
78 1.88 0.7 1.51 1.96 Accepted 95%
Hence H0 is accepted here it was found that respondents often make efforts to
notice unsafe areas.
35
13. Employees are allowed to participate in development of
standards.
Always 46 59
Often 22 28
Sometimes 8 10
Seldom/rarely 0 0
Never 2 3
0% 3%
10% Always
28% Often
59% Sometimes
Seldom/Rarely
Never
(A) HO: Employees are always allowed to participate in development of

standards.
Deviation Level
78 1.59 0.87 5.99 1.96 Rejected 95%
As H0 is rejected, it cant be directly said that employees are always

allowed to participate in development of standard.
(B) H0: Employees are often allowed to participate in development of
standards.
Deviation Level
78 1.59 0.87 4.16 1.96 Rejected 95%
As H0 is rejected, it cant be directly said that employees are often

allowed to participate in development of standard.
From above calculation it can be concluded that respondents are generally

allowed to participate in development of standards.
36
14. You get required support and involvement from your seniors.
Always 43 55
Often 18 23
Sometimes 9 11
Seldom/rarely 2 3
Never 6 8
3%
8%
11% Always
Often
55%
23% Sometimes
Seldom/Rarely
Never
H0: Respondents always get required support and involvement from

seniors
Deviation Level
78 1.85 1.2 1.1 1.96 Accepted 95%
Here H 0 is accepted; therefore it can be said that respondents always get

required support and involvement from seniors.
37
15. You have regular audit system for housekeeping.
Always 35 45
Often 24 31
Sometimes 10 13
Seldom/rarely 6 7
Never 3 4
4%
7%
Always
13% 45%
Often
Sometimes
31%
Seldom/Rarely
Never
H0: Organizations always have regular audit system for housekeeping
Deviation Level
78 1.95 1.11 0.04 1.96 Accepted 95%
As hypothesis is accepted, it can be concluded that organizations always have

regular audit system for housekeeping
38
16. You follow rules and regulations by practicing 5S and Set
examples for others.
Always 36 46
Often 26 33
Sometimes 11 14
Seldom/rarely 2 3
Never 3 4
3% 4%
14% Always
46%
Often
Sometimes
33%
Seldom/Rarely
Never
H0: Respondents always follow rules and regulations by practicing 5S

and Set examples for others.
Deviation Level
78 1.85 1.01 1.31 1.96 Accepted 95%
Hence it was found that respondents always follow rules and regulations by
practicing 5S and Set examples for others.
39
Apart from all above analysis, to know about overall implementation
standard of 5'S', mean of the responses were taken as base and a line chart as
shown below was drawn.
3
Mean Value of Responses
2
2.12
1.94 1.99 1.95
1.86 1.88 1.85 1.85
1.72
1.49 1.53 1.59 1.59
1.42 1.46 Mean Value
1 of Responses
0.67
0
Que. Que. Que. Que. Que. Que. Que. Que. Que. Que. Que. Que. Que. Que. Que. Que.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
As mean of most responses is between 0 and 1, i.e. always and often, finally it
can be concluded that the implementation is done properly and 5S is
regularly practiced in all four organizations.
40
PROBLEMS IN IMPLEMENTATION
Problems in Implementation Frequency

Less Knowledge 8
Less Involvement/ support/commitment 17
Sustainability 13
Time related problems 18
Lack of resources 4
Changing Mindset is Difficult 4
Lack of Space 4
No Problems 10
No Answer 14
Others 10
18
16
14
Responses
12
10
17 18
8
13 14
6
10 10
4 8
2 4 4 4
Problems in Implementation
41
SUMMARY CHART FOR AWARENESS
CHECKING QUESTIONS
Findings (%)
Question Asked Options
Correct Wrong Did not
Answers Answers Answer
SEITON stands for removing
all unneeded items from True/False 23 35 42
workplace
SEISO stands for process of
organizing the remaining items True/False 23 37 40
after sort process
SHITSUKE stands for cleaning
True/False 28 28 44
the work areas
SEIKETSU stands for
True/False 42 13 45
standardizing process
SEIRI stands for maintaining
True/False 28 27 45
and reviewing standards
42
SUMMARY CHART FOR HABIT &
PRACTICE CHECKING QUESTIONS
Response (%)
Question Findings
Always Often Sometimes Rarely Never
You organize things Organize

62 29 8 1 0
that you require. things usually
You dispose off things
Dispose off
that you do not 45 28 17 9 1
things often
require.
You think twice about Generally
need for item before think twice
67 27 5 0 1
recommending its before
Purchase. purchase
You make effective Generally make
use of space at 66 24 9 1 0 effective use of
workplace. space
You have specified
Usually have
place to put each and 53 28 14 5 0
specified place
every item.
You constantly label
and mark locations of Often mark
things with stickers 42 23 21 9 5 locations of
and markers for easy things
identification.
After use you put the Usually put
things back at its 63 28 4 4 1 things back at
respective place. its place
You keep items
Usually keep
required frequently
54 40 2.5 1 2.5 items requires
near your
near
workplace/area.
You give at least 3 often gives
minutes everyday to 55 13 17 9 6 time to clean
clean your workplace. desk
You throw things and
assume that someone Rarely throw
3 6 9 15 67
will clean it up for things
you.
You feel frustrated
because you cannot Sometimes
11 19 31 21 18
find things quickly feels frustrated
when needed.
43
You make efforts and
Often make
notice unsafe areas,
30 54 15 1 0 efforts and notice
practice equipment
unsafe areas
etc.
Employees are
Allowed often
allowed to participate
59 28 10 0 3 to participate
in development of
in development
standards.
You get required
support and Generally gets
55 23 12 3 8
involvement from support
your seniors.
You have regular
Often have
audit system for 45 31 13 7 4
regular audit
housekeeping.
You follow rules and
often follow
regulations by
46 33 14 3 4 rules and set
practicing 5S and Set
examples
examples for others.
44
6. FINDINGS & CONCLUSION
FINDINGS
1. For awareness checking questions, out of 390 questions asked to 78
respondents, 43% questions were not answered, 39% questions were
answered correctly and remaining 28% were wrongly answered.
2. 62% of respondents always organize things that they require and 29%
respondents often organize things that they require.
3. 45% of respondents always dispose off unneeded things and 285
respondents dispose unneeded things often.
4. 67% respondents always think before purchase and 27% thinks often
before purchase.
5. 66% respondents always make effective use of space at workplace and
24% uses space often.
6. 53% respondents have specified place to put things.
7. 42% respondents constantly mark locations and things with markers
and stickers for easy identification
8. 58% respondents put things back to its respective place after use.
9. 54% respondents always keeps required items near them and 40%
respondents often put frequently needed items near them.
10. 55% respondents clean their workplace everyday.
11. Only 3% respondents throw things here and there and assume that
someone else would clean it for them.
12. 12% respondents get frustrated when cant find things when needed.
13. Only 305 respondents try to notice unsafe areas at workplace.
14. 59% employees are allowed to participate in development of
standards.
15. 55% respondents get support and involve from their seniors
16. 45% respondents are audited regularly for proper housekeeping
17. Only 46% respondents follow rules and regulations of 5S.
45
CONCLUSION
Banks
1. Employees of banks are not much aware of the system as Japanese

names of concept make it difficult to remember it. But they practice the
system and are habitual to it.
2. Due to lack of time to executives they sometimes faced problems in
practice it.
College
1. Due to lack of constant reminder sessions, lecturers and students have

forgotten the terms of concept.
2. Lecturers practice the system but not on continuous basis. They face
the problem of sustainability of system.
3. Only few respondents practice the concept on regular basis, but they
dont get required support form subordinates, peer group and
students.
JK Paper Ltd
1. Employees of JK Paper Ltd. have better conceptual awareness about

5S compared to college and banks, but they were in problem when
asked for proper terminologies of the concept.
2. As 5S system is the part of Total Productive Maintenance Policy (TPM
Policy) of JK Paper Ltd., they have special department for TPM and
regular practice of 5S is done under constant the monitoring of DGM
of TPM.
3. As JK Paper is located in rural area, (Gunesda Village, Songadh)
workers are less educated and less committed and supportive. Hence
executives face problems to change the mindset of such workers and
make them understand the concept is also challenging for them.
46
7. RECOMMENDATION
1. Successful implementation of 5'S' system comes through regular practice.

These things, if not practiced regularly, people forget. So constant and
regular reminders in the form of training & development sessions and
refreshing courses should be organized.
2. Proper motivation should be given to people for practicing practice the
system.
3. It should practice on the regular basis.
4. People should made conceptually aware of the system
5. Top management personnel should set examples for their subordinates
and thus make them practice the system in correct method.
6. Audit on regular basis should be done to make sure that system is
practiced in correct manner
7. To improve co-ordination between top level and bottom level staff and to
increase involvement of employees, team building sessions should be
organized so that employees understand each other well and it helps in
practicing 5S.
8. Lower level workers should be illustrated the benefits of 5S system in
their day to day functioning.
47
8. REFERENCES
BIBLIOGRAPHY
1. Handouts given by external guide
2. Handouts given by internal guide
Websites
3. http://shabbarsuterwala.blogspot.com/2008/05/5s-philosophy-of-
japanese-for-business.html - 22 Jan., 2009. 12:22 am
4. http://www.emsstrategies.com/newsletter110103.htm - 22 Jan 2009.
12:23 am
5. https://www.amazines.com/article_detail.cfm?articleid=475771
22 Jan 2009. 12:25 am
6. http://www.themanagementor.com/EnlightenmentorAreas/mfg/QM/
basics5s.htm
7. http://www.tenstep.fr/01_Publique/90.3_EspaceDeLaQualite/Anglais
/700TheBasicsOfThe5SPractice.pdf
48
APPENDIX
Questionnaire
Topic: 5S System Awareness, Practices, Limitations
Dear Sir/Madam,
I, Nipurn Mehta, am a student of Final Year BBA of B.V. Patel Institute of

Business Management, Computer and Information Technology, Gopal
Vidyanagar. I have undertaken research project entitled 5S System
Awareness, Practices, Limitations as a part of my curriculum in the 6th Sem. I
request you to spare sometime to consider the following questionnaire. As the
intention of this project is purely academic, all information provided by you will
be kept strictly confidential. Be as truthful as you can.
Thank you for your co-operation.
Personal Profile
Name:
Designation:
Organization:
State True or False:
SEITON stands for removing all unneeded items from

workplace TRUE/ FALSE
SEISO stands for process of organizing the remaining items after
sort process TRUE/ FALSE
SHITSUKE stands for cleaning the work areas TRUE/ FALSE

SEIKETSU stands for standardizing process TRUE/ FALSE
SEIRI stands for maintaining and reviewing standards TRUE/FALSE
49
A = Always
O = Often
? = Sometimes
S = Seldom/rarely/not often
N = Never
1. You organize things that you require. A O ? S N
2. You dispose off things that you do not require. A O ? S N

3. You think twice about need for item before
A O ? S N
recommending its Purchase.
4. You make effective use of space at workplace. A O ? S N
5. You have specified place to put each and every
A O ? S N
item.
6. You constantly label and mark locations of
things with stickers and markers for easy A O ? S N
identification.
7. After use you put the things back at its
A O ? S N
respective place.
8. You keep items required frequently near your
A O ? S N
workplace/area.
9. You give at least 3 minutes everyday to clean
A O ? S N
your workplace.
10. You throw things and assume that someone will
A O ? S N
clean it up for you.
11. You feel frustrated because you cannot find
A O ? S N
things quickly when needed.
12. You make efforts and notice unsafe areas,
A O ? S N
practice equipment etc.
13. Employees are allowed to participate in
A O ? S N
development of standards.
14. You get required support and involvement from
A O ? S N
your seniors.
15. You have regular audit system for housekeeping. A O ? S N
16. You follow rules and regulations by practicing
A O ? S N
5S and Set examples for others.
What problems you face in implementing 5S System?
50

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A

JK Paper Ltd., Songadh

HDFC Bank, Bardoli Branch

ICICI Bank, Bardoli Branch

B.V. Patel Institute of BMC & IT, Gopal Vidyanagar

Bhulabhai Vanmalibhai Patel Institute of Business

I wish to express my sincere thanks to Mrs. Poonam Mittal, Director of

I, Nipurn R. Mehta, student of Bhulabhai Vanmalibhai Patel Institute of

THEORETICAL FRAME WORK

4 LIMITATION OF THE STUDY 21

5 DATA ANALYSIS AND INTERPRETATIONS 22

6 FINDINGS AND CONCLUSIONS 45

5S is a method for organizing a workplace, especially a shared workplace

Data were obtained through survey method. Researcher personally contacted

Respondents were asked total 390 questions to check their conceptual

Respondents were asked 16 Likert scale questions to know about their

It was recommended that training and development sessions and refreshing

5S is a method for organizing a workplace, especially a shared workplace

It is believed that good housekeeping and workplace organization are

When these practices are coordinated a truly first- class manufacturing

5S is a concept which collaborates 5 activities; each starts with the English

The 5S are five Japanese words:

This basic philosophy is applied in unique ways for many different

1. SEIRI (Sort) - Remove all Unneeded Items

2. SEITON (Set In Order) - Set Limits and Create Temporary Location

To retrieve things in 30 seconds as well as return the things to the

1. Identify proper place for each and every Item

It is the process of cleaning the work area and any machinery or

1. Clean the things regularly

4. SEIKETSU (Standardize) - Implement Visual Displays and Controls

Standardize is the process of making the first three Ss a habit. Many

Top management support and involvement

5. SHITSUKE (Sustain) - Keep in Place Through Training and Total

This refers to workplace discipline. Shitsuke means sustaining discipline.

It refers to maintaining and reviewing standards. Once the previous 4S's

Retrain from tendency to return to the status and the comfort-zone

Implementing the 5 Ss requires full co-operation of all involved. This in itself

Behavior is determined by attitude, personality, perception,

An attitude is defined as learned predisposition to respond in a

Ways to change Attitude

Some of the ways to change attitudes are given below.

Perception is the unique way each person sees and interprets

Perception is the process of selecting, organizing and interpreting

According to Keith Davis, Communication means the transfer of

Control is a foreseeing action whereas earlier concept of control was

According to Harold Koontz, Controlling is the measurement and

In 5 S System also control is important because, after

A simple definition of leadership is that leadership is the art of

A leader should be able to motivate the followers to practice the 5S

1. To check awareness of employees, lecturers and students

Rationale behind Study

In the era of liberalization, competition is increasing day by day. To

As a matter of preference, everybody desires to work in fresh, clean, safe

A cluttered work area undoubtedly mirror the kind of attitude and

5S System is all about systemizing oneself as well as organization. Many

Need and significance of 5S

implementing 5S system and by thereby help the researcher in

system in knowing various implementation problems faced by

habits of practicing 5S system.

There are two types of sources of data

1. Primary Data Sources

The researcher is interested in knowing the conceptual awareness of

Secondary data is collected through books, search on internet.

Here, a sample size of 78 respondents is taken for the research purpose.

5's' System - NIPURN MEHTA

5's' System - NIPURN MEHTA