Module 4-5S

Draw 5S Plan

lay out

Explain 5s

elements to

all staff

Select the

Task force

members

5S Implementation Process

5S Roll Out

Step 1:

Sorting out

carry out

workshop

Revamp-

Major 5S

Step 2:

Set in order

Step 3:

Shine

Scan the

Premises

Step 5:

Self

Discipline

Step 4:

Standardize

5S step 3 implementation

Shine (Seiso)

Adopt cleaning as a daily activity and as a part

of inspection. Clean the workplace before

starting of the job and before closing the job.

Put aside 10 or 15 minutes for the same

activity per day.

Clean and inspect defined areas, workplace,

machines and other items.

Cleaning indirectly helps to check or inspect

each and every part and place. Hence, it should

be a habit.

Take remedial action to prevent re-occurrence.

Schedule as needed paint coating on buildings,

floors, machinery and equipment, during non

productive times

SEISO (SHINE)

Find ways to prevent dirt and

contamination.

Sweeping checklists are applied

throughout the day for each of the

common areas

Safety inspections are performed on a

regularly scheduled basis

Workers should be responsible to clean

the machines, tools, work benches in

their individual workplace.

Sweepers should be responsible for the

common areas outside and inside the

premises

Oily floors are a common

problem created by:

Oil leaking from engines,

transmissions and brake

systems and spoiling the floor

Keeping the transmission and other parts on the

floor, spilling the oil.

Draining the oil into a pan, spilling it on the floor.

Carrying the oil pan to a waste oil drum and

carelessly emptying it in the drum.

Note the condition of floor in the photograph.

Use 5 Whys or cause-and-effect methods to find

the root causes of slippery floor and take

appropriate corrective and preventive action.

WHY 1

Used Engine oil is

Emptied in a drum

manually causing

it to spill on the

floor

Ask "WHY" five times - get to the root

cause of why the working bays get dirty

Proper oil collector

is not used for

draining the oil.

WHY 2

While carrying it to

the drum, oil spills

all over the place.

WHY 3

The oil drum is

located at a long

distance

WHY 4

Manual transportation

of the used

engine oil is the main

cause of oil Spilling on

the floors

WHY 5

Root

cause

Conclusion: The used oil should not be transported

manually to the waste oil drum

Air line to

oil drain

trolley

pump

Oil drain trolley with

evacuation pump

A

B

c

Method of preventing oil

spillage on the ground

Waste oil tank located

outside the working

area(hidden from view)

PVC

/FRP

WASTE

OIL

TANK

Waste oil sucked by the

purchaser’s tanker

Making use of the root cause analysis, the task force

came up with the above solution to prevent oil spillage.

Floor rubber mats can be laid under the car

lift to prevent leaking engine and

transmission oils spoiling the floor. There is

no special rubber quality required, local

grades of thick rubber sheets would be ok.

The rubber sheet can be washed with a

chemical or detergent frequently.

5S Step 4 implementation

SEIKETSU(STANDARDIZE)

Wake up Sleeping Beauty !!!!

SEIKETSU (Standardize)

•Establish standards.

Develop visual controls to

expose abnormality.

•integrate with daily work

management.

•Prevent deterioration

using 5W & 1H strategy.

Standards improve reliability and consistency.

Actions items

1. Take “before” photographs.(See module 2 for

before photos)

2. Check that the first three S’s are

implemented properly.

3. All team activity documents/check lists

should be publicly displayed on a 5S board.

4. Establish the routines and standard

practices for regularly and systematically

repeating the first three S’s.

5. Create procedures and forms for regularly

evaluating the status of the first three S’s.

6. Standardize red tag procedures and holding

area rules (see Seiri).

7. Standardize procedures for creating shadow

boards, position lines, and labeling of all items

(see Seiton).

8. Standardize cleaning schedules using the “5S

Owner Check Sheets” (see Seiso).

9. Standardize “single-point lessons” for

documenting and communicating 5S procedures

and improvements in workplace and equipment.

10. Create a maintenance system for

housekeeping. Make a schedule for cleaning of

the workplace. A common approach is to ask a

cross-functional team to do it.

11. Inter-departmental competition is an effective

means of sustaining and enhancing interest in 5S.

12. Assign responsibility to individuals for a work

area and machinery.

Check out

Kaizen suggestion form.xlsx

13. Regular inspection/audit and

evaluation by a special team (including

senior management persons) to be

continued.

14. Instead of criticizing poor cases,

praise and commend good practices or

good performers.

15. Take “after” photographs and post

them on the 5S board(s).

16. Complete evaluation using 5S levels of

implementation with the facility manager

or the authorized persons in the

organization

5S activity Board

•Create an environment

through slogans, posters

and other visuals

•Set an example, from a

habit.

•Conduct audits to evaluate

approach and results.

Recognize 5S achievements

5. SHITSUKE (SELF DISCIPLINE)

Action speaks louder than the words

March04 audit.xls

Fix up a day when your workshop staff

takes a break from the usual boring schedule.

Announce at least 3 winners who have

scored maximum points in the 5S audit.

Distribute T shirts or badges to winners.