Necessity of 5S

Quality Assurance

Productivity
improvement
Quality assurance
Cost reduction
Deadline observation

Job satisfaction

Happy workplace

Secure production
volume

Workplace improvement

SHITSUKE

SEIRI
SEITON

SEISOU

SEIKETSU

Definition of 5S
Quality Assurance

(1) SEIRI (Sort)

Distinguishing between necessary and unnecessary things, and getting rid of what you
do not need

(2) SEITON (Set in Order)

The practice of orderly storage so the right item can be picked efficiently (without
waste) at the right time

(3) SEISOU(Shine)
Create a clean worksite without garbage and dust

(4) SEIKETSU(Standardization)
Standardization of best practices

(5) SHITSUKE (Sustain)

The practice of developing customs so that the workplace regulations and rules are
correctly practiced

Promotion of 5S
Quality Assurance

(1)
SEIRI

(2)
SEITON

(Sort)

(set in order)

Dispose what is
not needed

Can retrieve when

required

(3)
SEISOU
(Shine)

(4)
SEIKETSU
(Standard)
Standardized the
solution

Make the workplace

clean

(5)
SHITSUKE
(Discipline)
Develop customs that allow practice of regulations and rules

Objective of 5S
Quality Assurance

Remove waste
Implement so that waste becomes visible
to facilitate waste removal
Waste = Current work money generating work
From current work remove work that does not generate money

5S that Eliminates Waste

Quality Assurance

Waste (rag) sifting boxes

Clean

Dirty

objects

objects

Clean
objects

A little
dirty
objects

Dirty
objects

Self-discipline is the foundation for success of 5S

Quality Assurance

Self-discipline supports 5S
Seiso
(Shine)

Seiri
(Sort)

Seiketsu

Seiton

(Standardization)

(Set in order)

Sitsuke (Sustain )

Heinrichs Law
Quality Assurance

Major accident
1 incident
Small scale
accidents
29 incidents
Near miss / startling
incidents
300 incidents

Accumulation of small
details leads to big
success

Bolts Sifting and Sorting

Quality Assurance

Normal 5S

What
Whatvalue
valueisisbeing
beingcreated
created??

Standardization
Standardization

Profitable
Profitable 5S
5S

SEIRI
Quality Assurance

SEIRI (Sort) refers to:

Distinguishing between necessary things and
unnecessary things and getting rid of what you
do not need
Steps

Stratify

Dispose

Assign fixed place

Stratification
Quality Assurance

Stratification refers to:

Assorting things around oneself into those that are
required and those that are not required
*Other than things used daily are non-required things
*Quantity in excess of what is used daily is non-required
* Leave only this, just in case is strictly prohibited

Action Standards
Quality Assurance

Standards

Action
Dispose

Things used approximately once in 6 to 12 months

Place far away

Things used approximately once in 1 to 6 months

Gather and place together at the

worksite

Things used once a week

Place in vicinity of work

Things used daily

Things used every hour

Place so that they are easy to pick

Make it easy to return
Identifiable

Place within arms length where

they can be easily reached

Categorization of Actions
Quality Assurance

Category
Product, in-process product, components, materials,
sub-materials etc.

Machinery, jigs, tools, molds etc.

Old products, components, materials, sub-materials
etc.
Drawings, documents, magazines, catalogs etc.

Candidate items for actions

Damaged products, nonconforming products, rusted
materials etc.
Things not planned to be used
Things not used for several years
Those that have expired
Non-required items
Those that have become old

Assign Fixed Places

Quality Assurance

Assigning fixed places refers to:

Preparing rules and making visible where and in
what quantity the required things are to be placed

* Decide locations for things that will remain

* Make rules for locations
* Making visible refers to visual management
* Start with what can be done

Location of things that will remain

Quality Assurance

Location of things that will remain should

consider :
(1) Where it will be used
(2) Where it will be placed
(3) How much it will be placed
(4) How it will be placed

SEITON
Quality Assurance

SEITON (Set in order) refers to :

Implementing functional storage by deciding correct
placement method and layout so that the required
objects can be quickly used what it is required

Steps

Assign fixed places and

fixed quantity

Make it compact

Assign fixed places and fixed quantity

Quality Assurance

Assigning fixed places and fixed

quantity :
Refers to facilitating picking and placing and ensuring
zero shortages
* Give priority to use frequency and decide fixed place
* Consider also safety (mainly weight)
-Place heavy objects at a height where they are easy to pick from
* Eliminate labor required for searching and returning
* Decide placing volume bused on usage volume (1 time, 1 day)

Storage Index
Quality Assurance

Storage index = Steps x Hand operation

frequency
* How many steps does it take to walk to the storage

location?
* How many times is it necessary to move the hand to
grip, transport and place the object for storage?
*The storage coefficient will vary according to holding
method, transporting method and placement method

Decision standards for fixed positions

Quality Assurance

(1)

Where it will be used

Clarification of usage objective and place

(2)

Where it will be placed

Near where it will be used so that work can be done

while walking
Stand-up operations

(3)

How much will be placed

Maximum, Minimum, Order point

(4)

How will it be placed

Easy to place, Easy to remove (one-touch

operation)

(5)

Indication of placing location

Coloring, boundaries

(6)

Recognize visually

Illustrative indication, component name

indication, Quantity indication

(7)

Stagnating time is visible

First in- First out, Recognize by observing

placement date

(8)

Decide person in-charge of

supervision

Indicate person responsible

Examples of tools sorting (Seiton)

Quality Assurance

SEISO
Quality Assurance

SEISO (Shine) refers to :

Removal of dirt and by investigating source of dirt
preparing countermeasures

Steps

Identify source of occurrence

Take action to prevent dirtiness

and its occurrence

Take Preventive Actions

Quality Assurance

Actions to prevent dirtiness and its occurrence

refers to:
countermeasures against source of occurrence
include
countermeasures
(challenge
towards
common sense) for process methods (defects in
processing conditions etc.)
*The basic point is sweeping and cleaning and inspecting
*It is also important to take immediate actions such as placing a cover etc.
* Accumulation of small points will lead to a situation where sweeping is not
required

SEIKETSU
Quality Assurance

SEIKETSU (Standardization ) refers to:

Standardization of 5S through visual management

Steps

Grasp vital points for management

Make abnormalities visible in

management points

Standardization of 5S
Quality Assurance

Clarification of vital points for management

- What are the minute defects
- Basic conditions: Cleanliness, refueling, replace tightly bind fast, dirt,
looseness
- Operating conditions: pressure, temperature, time, flow
volume, weight, Equipment, jigs and tools, sub-materials

(1)

(2)

(3)

Prepare standards for the conditions

-

Objectification of judgment standards for normal versus abnormal

Judgment without using measurement, knowledge, intuition and knack

Judgment standards for abnormalities

-

Inspection methods that can be used by anybody

Methods for actions against abnormalities

Points for Visual Management

Quality Assurance

(1)

Recognize well even from a distance

(2)

There are indicators on items to be managed

(3)

Whether good or bad is clear, and anybody can point out

(4)

Anybody can use, and convenient if used

(5)

Anybody can follow and repair quickly

(6)

Use of tools leads to neatness

SITSUKE
Quality Assurance

SITSUKE (Sustain ) refers to:

Preparation of workplace atmosphere where
visual management is properly observed

Steps
Check state of observance of
standardization of 5S

Innovate to ensure observance