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Quality Improvements



1950 1960 1970 1980

1. 5S Principles
 Elimination of waste
 Every body is involved,
Co-operative effort
 Attack root cause
 Human being is fallible
2. Objectives
 Improve housekeeping
 Make every individual
responsible for housekeeping
 Beautify by simple means
 Productivity improvement by
saving time, space etc.
3. 5 S’ s
• Seiri - Sorting
• Seiton - Systematic arrangement
• Seiso - Cleaning
Inspection while cleaning
• Seiketsu - Standardization
• Shitsuke - Self Discipline
If we do not do 5S, we can’t do any
other work efficiently. They are
features which are common to all
places and are the indicators of
how well an organization is

Its an additional burden. Too busy to do 5S


Why clean it? It will get dirty again

We cannot change the existing setup.

More work pressure – No time for these things

5S means cleaning up the desk

SEIRI = Sorting – Just in Case to
Meaning Distinguish between necessary and
unnecessary items and eliminate the unnecessary items

Activity: Establish a criteria for eliminating

unwanted items. - Eliminate unwanted items either by
disposing them or by relocating them.

Success Area saved or percentage of space available

SEIRI = Sorting – Fight with
SEIRI = Sorting 3 Categories

√ - Item Required
X – Item Not Required
?– Undecided
Move to Red Tag Holding Area
Seiri = Sorting What is unnecessary

1. Item is not needed

2. Item is needed however quantity in stock is more
than what is needed for consumption in near
3. Item is needed but once in a blue-moon

4. Contingency Parts
Critically decide the quantity of contingency
parts to be retained and criteria for such parts

Frequency of use Storage Method

*Things you have not used Throw them out
in the past one year
*Things you have used once Store at distance OR
in the last 6-12 months Keep in store
*Things you have used only Store it in central place

once in the last 2-6 months in your zone


*Things used more than once Store it in central place


a month in your zone


HIGH *Things used once a week Store near the workplace

*Things used daily or hourly Store near the workplace
Seiri = Sorting Identifying unnecessary

1. Parts & Work in Process (WIP)

• Things fallen back behind the machine or rolled under it
• Broken / some items inside the machine
• Things under the racks/ platform
• Extra WIP
• Stock of rejected items
• Items accumulated over period for rework
• Material awaiting disposal decision
• Material brought for some trial, still lying even after trial
• Small qty of material no longer in use

Seiri = Sorting Identifying unnecessary

2. Tools, Toolings, Measuring devices

• Old jigs, tools not in use are lying
• Modified tools, tooling for trial, are lying after trial
• Worn out items like bushes, liners, toggles etc. lying
• Broken tools, bits, etc. may be lying
• Measuring equipment not required for the operation
being performed, is lying
3. Contingency Parts
• Many times storage place for contingency parts become
a last refuge for broken parts, surplus items and things
nobody is likely to use
Seiri = Sorting Identifying unnecessary

4. Shelves and Lockers

• Shelves and lockers tends to collect things that nobody
ever uses, like surplus, broken items, used tea-cups etc.
5. Passages and Corners
•WIP material waiting for decision or dispatch
• Dust, material not required seem to gather in corner
6. Besides Pillars and under the stairs
• These places tends to collect junk, spittoon etc.
7. Walls and Bulletin Boards
• Old out dated notices which have lost their relevance
• Posters or bulletins on wall
• Dust, remains of torn notices, cell tape pieces Contd..
Seiri = Sorting Identifying unnecessary

8.Floor, Pits, Partitions

• Defective parts
• Protection caps, shoe covers
• Packing material, stickers, barcodes, cut-leads
• Hardware items, small items, runners, plastic granules
• Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
• Many unwanted, outdated, temporary files pile up
•Old dated mails still remaining in inbox and sent items
•Deleted mails not being purged when closed
•Recycle bin not emptied
Seiri = Sorting TAGGING

TAG No ______________ Date _________

ITEM NAME________________ QTY ______

Tag Created By: _________________________________


Reason: ________________________________________


Decision Date: ___________ Decision By: __________

To Scrap To Reuse after Salvage To Dispose

Seiri = Sorting Improvement methods

1. Flow Process Chart (Procedural Analysis)

Drawing a process flow chart for the system
eg. How to make and use category wise grouping

2. Operational Analysis
Preparing the sequence of operations for system
eg. How to perform Seiri (sorting)

3. Check List
A check sheet is used to decide what sort of main system
and sub system are necessary.
POINTS 5 4 3 2 1

1 Is there any UNWANTED item present in area

2 Is there any item more than required

3 Is there any item on different location

4 Is there proper Red Tag Area identified

5 Is the list of all items in Red Tag Area available

6 Is there any classification done for Wanted items

7 Is there any item not used for more than a year

8 Is there criteria present to eliminate unnecessary items

9 Is there any unwanted dirt/dust present

10 Is there any leakage present (Air, Water, Oil or Material)

11 Is there any defective item present or Unsafe item in the area

12 Is there any spilled item on the floor

13 Are all Equipments, Jigs & Machines working OK

14 Is there minimum 20 % storage free space available

15 Are People working in the area aware about 1 - S



Seiri = Sorting Dealing with papers

How to reduce papers on

your table ?
1. Make a single pile of papers
2. Go through them and sort in
following categories
a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information
Seiri = Sorting Dealing with papers

How to reduce papers on

your table ?

4 D Principle

SEITION = Systematic Arrangement

Meaning To determine type of storage and layout that

will ensure easy accessibility for everyone .

Activity - Functional storage

- Creating place for everything and putting
everything in its place

Success - Time saved in searching (30 sec to locate an item)

Indicator - Time saved in material handling
SEITION = Systematic Arrangement
In short, SEITION means PEEP

Place for Everything

Everything in its place
Seiton = Systematic Arrangement

How to achieve Systematic Arrangement

Decide where things belong

Decide how things should be put away

Obey the Put away rules

Seiton = Systematic Arrangement

ow to achieve Systematic Arrangement ?

ecide where things belong
Standardize Nomenclature
Determine an analytical method of storage
ecide how things should be put away
Name & locations to everything. Label both ite
and location
- Store material functionally
- Prevent mistakes with coding by shapes & co

Seiton = Systematic Arrangement

w to achieve Systematic Arrangement ?

cide how things should be put away
ollow first in first out rule
If two identical items are to be located, then s
them separately, color code them.

bey the rules

ut the things back to their location after
their use
Seiton = Systematic Arrangement


1 ) Signboards

2) Color codes

3) Outline markings

4) Labels
Seiton = Systematic Arrangement


Seiton = Systematic Arrangement

Usage • Store frequently used

near the workplace and
Weight &• Heavy at some
material should be stored
Shape of the lower levels/layers
Place directly on the material
handling device for ease of

Functional Storage
Seiton = Systematic Arrangement

• Same category of
material may be
stored in one location.
Eg. Fasteners, Seals ,
Operation resistors
• All items required for an
Wise operation may be stored in one
Eg. Allen key, spanner etc hand
tools required for setting m

Functional Storage
Seiton = Systematic Arrangement

tlining and Placement Marks

Mark boundaries of dept., aisles, Machines
Follow straight line, right angle rule
Nothing shall be kept outside the boundaries
ands and shelves
eep only required number of stands and shelv
Standardize height, size
Provide casters where necessary so that it can
Seiton = Systematic Arrangement

res and Ducts

olor code
When there are multiple connections - bundle
wires, label them and make sure that they are
straight line /right angle and firmly anchored
achine-tools & Tools
ut the tools in the order you need them
Location of the tool should be such that it can
put away with one hand
Try to eliminate some hand tools by permanen
attaching it to the bolt head
Seiton = Systematic Arrangement

des, Dies, Other important consumables

tore them in the protected place
Maintain these things regularly by applying ru
preventive, oiling etc.
P- Work In Process
esignate a place for each component/part
Decide on how much quantity to be stored
Ensure that there is no damage to good part
during transit, they do not get rusty and they
not mislabeled
Seiton = Systematic Arrangement

s & Lubricants
Reduce number of oils used (Standardize)
Color code for oil
Safety aspects - fire prevention, pollution, lea
trumentation & Measuring Devices
abel them, show direction of flow
SEISO = Cleaning
Meaning Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection

Activity - Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning inspection

Success - Reduction in machine down time

Indicator - Reduction in no. of accidents
Seiso = Cleaning

• Here cleaning means more than just keeping

things clean. Cleaning should be viewed as a
form of Visual Inspection

• Preventive measures should be taken to tackle

problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated
Seiso = Cleaning

Various Minor Defects

= Trash = Dirt =Knocking
= Loose parts = Leaks =Scattering
=Skips =Curvature =Abrasion
=Rust =Scratches =Eccentricity
=Lurching =Abnormal =Vibration
=Abnormal =Heat =Abnormal
Sounds smells
=Faded color =Hisses - Cracks
Seiso = Cleaning

5 Minutes Every day for cleaning

• Devote 5 minutes everyday for cleaning your
work area

• Participation of everyone is required

• Attack hard to clean places regularly

Seiso = Cleaning

Cleaning-Inspection points for most

Grime, clogging, dust balls, rust,
Cleaning leakage etc.

No oil, Low oil, leakage, filter clogging,

Oils dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
Seiso = Cleaning

Cleaning-Inspection points for most

Loose bolts, welding detachment,
Tightening loose parts, vibration or bumping
noise, friction

Heat Oil tanks, motors, heater, axles, control

panels, washing/ cleaning water,
bearing, wiring etc.
Seiso = Cleaning

Cleaning-Inspection points for most

Breakage, cracks, dent on sliding
Breakage, parts, handle has come off, broken
Cracks switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.
Seiso = Cleaning

Function wise Cleaning check list of

Compressed Air lines, air valves,
Pneumatics connections, meters, filters,
reservoirs etc.

Hydraulic oil tank, oil valves,

Hydraulics filters, pumps, hoses, gauges,
cylinders etc.
Seiso = Cleaning

Function wise Cleaning check list of


Mech & Motor fan, fan belt, couplings,

Joints, pulleys, chains, pump
Power Train
bearings etc.

Control panel, lamps, light, switch,

Electrical sensors, wiring, ducts, fuses etc.
Seiso = Cleaning

Function wise Cleaning check list of


Tools, fixtures, gauges, dies,

Toolings measuring instruments, etc.

Equipment Furnaces, rollers, chutes,

Specific CNC machines, etc.
SEIKETSU = Standardization
Meaning Setting up standards / Norms for a neat, clean,
workplace and details of how to maintain the
norm (Procedure)

Activity - Innovative visual management

- Color coding
- Early detection of problem and early action

Success Increase in 5S indicator

SEIKETSU = Standardization
Tools used for analysis :
Seiketsu = Standardization

• Regularizing 5S activities so that

abnormalities are revealed

•Make it easy for everyone to identify

the state of normal or abnormal

• For maintaining previous 3S, deploy

visual management
Seiketsu = Standardization

• It has been estimated by scientific

study that 60% of all human activities
starts with sight

• 5S is easy to do once.It is consistency

that is difficult. That is why Visual
Management is so important, so that
everybody will know that there is
some problem.Visual Management
Seiketsu = Standardization

What visual control communicates ?

It grabs one or more of our senses in

order to

• Alert us to an abnormality
• Help us recover quickly
• Promote adherence and prevention
• Enable successful self management
Seiketsu = Standardization

Some methods for visual communication

⇒ Color coding
⇒ Use of Labels
⇒ Danger alerts
⇒ Indication where things should be put
⇒ Directional arrows/ marks
⇒ Transparent covers
⇒ Performance indicators
Seiketsu = Standardization

Some methods for visual communication

⇒ Precision management labels
⇒ Inspection labels
⇒ Temperature labels
⇒ Responsibility photos
Seiketsu = Standardization

Points to remember in making visual c

control tools
1. Make them easy to see from
2. Put the display on the things
3. Everyone can tell what is right and
what is wrong
4. Anybody can follow them and make
necessary corrections easily
5. Work place should look brighter &
Seiketsu = Standardization

Some everyday visual management

♦ Traffic signal
♦ Zebra crossing
♦ In car - Petrol indicator
- Speed indicator
♦ Direction arrows
♦ Electric danger sign
♦ Toilet
Seiketsu = Standardization

Some visual communication signs

SHITSUKE = Self Discipline
Meaning Every one sticks to the rule and makes it a habit

Activity - Participation of everyone in developing good

- Regular audits and aiming for higher level

Success High employee morale

Indicator Involvement of all people
SHITSUKE = Self Discipline
Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.
Shitsuke = Self Discipline

We need everyone to maintain 5S


To maintain DISCIPLINE, we need

to practice and repeat until it
becomes a way of life.

Discipline is the Core of 5S

Shitsuke = Self Discipline

Discipline means making a steady

habit of properly maintaining
correct procedure.

Time and effort involved in

establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.
Shitsuke = Self Discipline Pledge

It shall be my constant effort to

maintain my workplace in good
order by
 Assigning a place for everything
& keeping everything in its place
 Sorting out unwanted material
periodically & discarding them
 Keeping my work area neat &
clean everyday
Machine building Bay
Heat Treatment Area
Heat Treatment Area
Machine Shop
End of the
presentation &
Beginning of 5S