SEIRI (SORT)

Seiri is about organizing and eliminating unnecessary items. Seiri has to do with the
Toyota pillar of “Just-In-Time” (JIT) -- “just what is needed, in the quantity needed, only
when needed”. The red tags campaign is a strategy to identify potentially unnecessary
items in the workplace, evaluate their usefulness and treat them appropriately. We have
to ask (figuratively) the following three questions to any item in the workplace:

 Is this element necessary?

 If necessary, do you need this amount?
 If necessary, must it be located here?

Once we identify these elements, then we take action by:

 Keeping them in a red tags area for a period of time to see if they are necessary.
 Throwing away or discarding them.
 Changing their location.
 Leaving them in the same place.

2. SEITON (SET IN ORDER)

Seiton means setting in order the necessary elements so that they are easy to find and
use by anyone. The concept of Seiton could be summarized in one sentence: a place for
everything and everything in its place. When implementing Seiton make sure you follow
these three steps:

 Step 1. Determining appropriate locations.

 Step 2. Identifying the locations.
 Step 3. Identifying all items and their needed quantity.

. SEISO (SHINE)
Seiso means keeping the work area clean and in good condition for health and safety.
We can implement the third S in 5 steps:

 Step 1: Determining what we are going to clean.

 Step 2: Dividing the workplace in “cleaning areas”, and then assigning people in
charge of those specific areas.
 Step 3: Determining cleaning methods: what, where, who, when and how.
 Step 4: Setting in order the cleaning tools, storing them in places where they are
easy to find, use and return.
 Step 5: The final step is incorporating systemic cleaning inspection.

4. SEIKETSU (STANDARDIZE)
Seiketsu does not refers to an activity, but a state or condition. Seiketsu consist of
building a strong set of procedures to maintain the first 3S. In fact, it is the state that
exists when the first 3S (Seiri, Seiton and Seiso) are properly maintained. When
implementing Seiketsu make sure you follow these three steps:
  Decide who is the person in charge of maintaining the needed conditions to
maintain the first 3S.
 Avoid setbacks by means of integrating daily maintenance.
 Check the level of maintenance.

Seiketsu has also to do with the concept of Visual 5S: everyone should be able to
distinguish between normal and abnormal conditions at a glance.

When the same problem occurs again and again, it’s time to go to the next level:
prevention and root cause analysis:

 Why do we accumulate unnecessary items? (Preventive Organization)

 Why are tools and items not returned to the right place? (Preventive Order)
 Why do floors get dirty again and again? (Preventive Cleaning)

5. SHITSUKE (SUSTAIN)
Shitsuke (sustain and discipline) means turning into a habit the fact of maintaining the
correct procedures. You can use 5S slogans, posters, visual panels, newsletters, and
visiting other departments or companies (benchmarking).

Some final tips to sustain the 5S:

 Train employees.
 Build a team for implementation.
 Assign time and develop a program for implementation
 Provide resources for implementation.
 Recognize and support the implementation by managers and directors.
 Stimulate creativity of all workers, listen to their ideas and allocate resources to
develop those ideas.
 Create tangible and intangible rewards for the effort.

5 things you need to know for a successful implementation:

 When beginning a 5S implementation in your company or organization choose a

reliable, engaged and committed team, and select an easy work area so that you
are able to guarantee success. This will smooth the way for more difficult areas.
 Measure, audit and act. Then measure, audit, and act again and again.
 A two day 5S training workshop is a good way to begin the implementation.
Some managers or directors should participate in the workshop so that operators
see that the company is really committed.
 The 30 seconds test is an easy way to make sure you have done a good job: you
should find any item, tool, information, document, or person in less than 30
seconds.
 Encourage people to be creative: most of the examples in this post had a cost of
zero dollar while achieving thousands of dollars in benefits.

The 5 Characteristics of an Auditor

 Have the Required Experience. Certifications are key academic qualifications

for an auditor. ...
 Ability to Make Independent Decisions. An auditor's decision should not be
wavered or influenced by anyone. ...
 Auditors Have the Ability to Understand Different Business Needs. ...
 Dependable. ...
 Effective Communication Skills.

Seiton means Orderliness. It means setting ever thing in proper order for easy retrieval. It
involves setting in order what is found in Seiri, Straighten and Standardization of it.
Methodology of Seiton: The rack system for easy retrieval.

Methodology of Seiton:
The rack system for easy retrieval.
Bin system for proper identification.

Benefits of Seiton:
Standardization of workplace.
Easy retrieval of whatever is necessary.
Easy identification.
Cleaning up a work station or shop floor is easier after the tools have been stored
properly

Benefits of 5S
You can understand how beneficial 5S can be with the organized structure of the workplace that
is continually sustained. However, to further understand the benefits in detail, here is a short list.
 Quality – With the implementation of 5S, there is a designated place for everything that is
needed, and all the items fit into their own space, thereby minimizing mistakes and errors in
getting hold of the needed item. This in turn reduces wastage of time, and also improves the
quality of work.
 Productivity – 5S helps in eliminating waste in terms of items, tools, machinery, and
equipment; and in turn systems, processes, time, and efforts. All of this subsequently results
in improved productivity, increased uptime, and higher efficiency.
 Safety – With the removal of clutter, it is obvious that any and all kinds of hazardous and
dangerous conditions will become visible. This will help to deal with them and avoid, or at
least reduce, any kinds of accidents or negative incidents to occur.
 Employee morale – Involving all the employees in the processes of 5S also allows their
inputs and suggestions for further improvement of the workplace and its processes and
maintenance. This involvement boosts their employee morale and motivates them to work
better, thus further enhancing the productivity in the workplace.
 Company image – Finally, with all of the above achieved that includes quality,
productivity, safety, employee morale, and an organized workplace, a better image of the
organization is generated, which results in better business and growth.
rinciples of 5S
The five main principles of 5S are Sort, Set in order, Shine, Standardize, and Sustain. With the
implementation of these five principles, any kind of wastage, inefficiency, and unsafe conditions
are brought to knowledge, which can then be dealt with.
 Sort – This includes identifying all the necessary items in the workplace, and removing all
the unnecessary ones.
 Set in order – Once the necessary items are identified, they are labeled, colour coded,
and well organized in the right places.
 Shine – This process involves the cleaning up of the workplace thoroughly.
 Standardize – This step makes sure that all the team members are trained on the above
three steps and know how to perform them with consistency.
 Sustain – Here, a monitoring system is set up to observe that the organized and
standardized workplace is being continually maintained.
5S is a process that delivers outstanding results in the areas of quality, productivity, cost,
efficiency, and safety. 5S also helps in boosting staff morale and improving the company’s
image. The process involves cleaning away the workplace to get rid of clutter and unused items,
tools, and machinery, and putting everything that is important in the right place. However, this is
not a one-time process. The constant cleaning and the process of putting stuff in the right place
needs to be consistently maintained so that the main goal of 5S, which is to achieve higher goals
of work improvement, can be achieved.ss

Disadvantages of using the 5S method:

The major problems with 5S appear when it is not properly
understood, used, or implemented.

1 Misunderstanding of what 5S accomplishes

2 Resistance to change ·
3 Not addressing problems in the workplace ·
4 Lack of management support

dvantages of 5S System
Benefits of 5-S system are as follows,

1. Reduction in errors/defects due to standardized

procedures.
2. Consistent and improved quality.
3. Higher productivity.
4. Lesser accidents.
5. Higher morale of employees.
6. Gets to work in a clean, organized, and clutter-free
workplace.
7. Lesser time to retrieve things when required.
8. More useable space.
9. Reduction in machine downtime.

5S Action List
Therefore, in order to ensure 5S gets into the blood of the
organization, the following action list needs to be put into
place.
 a. Arrange employees training in 5S technique and
provide pamphlets / easy to read booklets on 5S
practices to all employees.
b. Practice pick up components/papers/rubbish
and promote friendly competition & competitive
benchmarking among the departments for 5S.
c. Observe paper destruction day (say 15th/16th
day of the month following each quarter.
d. Conduct fire drills and practice dealing with
emergencies.
e. Replace equipment after its economic retentive
period.
f. Work together on specific 5S projects.
g. Insist that employees attend works in uniform
and wear safety shoes.
h. Set aside a short period (say 10 minutes)
when everyone must concentrate on 5S (e.g. one
day to ensure everything in place, another day to
ensure there is no oil or
air leaks.
i. Mark 5 minutes at the beginning or end of the
day to practice 5S.
j. Use visuals to draw attention to 5-S non-
conformances and achievements over the period
and to create a competitive point.
k. Audit 5-S housekeeping and follow-up on non-
conformances.
l. Display correct work instructions in the shop
and offices and ensure employees perform work
according to the laid down standard operation
procedures

5. Shitsuke (Sustain)

 Shitsuke means self-discipline. It denotes

commitment to maintain orderliness and to practice the
first 4S as a way of life. The emphasis of shitsuke is the
elimination of the bad habits and constant practice of the
 good ones. Once a true shitsuke is achieved, the
personnel voluntarily observe cleanliness and orderliness
at all times, without having to be reminded by the
management. One must train oneself to keep the 4S
principles and realize that by following the 5S, ultimately
the work will become easier.
 Shitsuke is the most difficult ‘S’ to implement and
achieve. Since human nature is to resist change, many
organization returns to the status quo (i.e. end up with a
dirty cluttered shop) a few weeks following the
implementation of 5S.

Methodology of Shitsuke (Sustain)

1. Monitor the refined methods consistently.

2. Maintain the defined methods for continuous
improvement.
3. Establish norms and follow them.
4. Keep repeating the 1 to 4 ‘S’

Benefits of Shitsuke (Sustain)

1. Discipline in the system.

2. Waste reduction.
3. High morale.
4. Neat and cleanliness.
5. Easier to work.
6. Lesser stress at work.

 Seiketshu is repeatedly following of “Seiri”, “Seiton”

and “Seiso”, developing and implementing standard
operating procedures and maintaining safe and hygienic
conditions at work leading to serene atmosphere.
Seiketshu embraces both personal cleanliness and that of
the work environment.
 It emphasis on 5-S standardization and visual
management. Standardization ensures that all
 assignments are absolutely clear and there is no
undefined area. Visual management ensures that
communication is simple and effective. Together, they
(i.e. standardization
and visual management) provide an effective way of
continuous improvement.
Guidelines

 Make standards obvious from a distance.

 Necessary information is located on or near the
process it relates to.
 Everyone can understand the standards.
 Visuals created: Checklists, Labels, Material
placements, Safety Equipment labeled and accessible,
Gauge limits are labeled.
 Establish and implement areas of standardization-
Documents, instructions, labels, signage, Material
handling, color codes, Review cycles, Also, standardize
the work itself, How is the work process done properly in
this area?, Create/revise Standard Work, Post-it
prominently in the work area.
The activities necessary to implement Seiketsu in the
organization are:

1. Mark aisles of sufficient width and ensure that

they are free from obstruction.
2. Standardize best practices in your work areas
and implement them as effective work standards.
3. Create as many visual control system as
possible such as:
– OK/Rejection.
– Reworks stickers/labels.
– “Danger zones” marks on meters and switches.
– Warning signs and marks (e.g. no smoking
warning sign in paint area)
– Fire extinguishers and exit signs.
 4. Display department/office labels and
nameplates. Ensure proper ventilation and
exhaust.
5. Introduce color for easy and faster
identification (color codes as shown in above).
6. Place first aid boxes and fire extinguishers at
suitable locations and display location maps for
fire extinguishers at strategic places.

2. Seiton ( Set in order)

 Seiton means systematic, orderly, efficient, and

effective arrangement of items in use.
2.

Set in Order:

Review the process flow in the area.

 Flow Process Chart.

 30-second storage and retrieval.
Motion Study Analysis.

 Position things to promote good posture and safe

lifting/retrieval.
 Minimize body motions and travel
Establish a layout proposal to optimize a safe workspace:

 Safety concerns all addressed

 Material flows
 Tools accessible
 Safety covers in place
 Anti-fatigue mats
 Defined and straight aisles
Create the Visual Workplace
 Tools labeled and/or outlined &Visual indicators
 Material placement markers or outlines on the floor
Benefits of Seiton:

1. Easy retrieval of materials.

2. Time taken to search is minimized.

3. Unnecessary purchase is avoided.

4. Categorize files, mails, papers, etc. based on
specific criterion viz. subject/title;
project; customer/supplier/department/usage.
5. Compartmentalize cabinets/drawers/shelves/desks.
6. Determine the quantity of each item and plan
storage according to pre-fixed quantity.
7. Plan storage to ensure easy retrievability (within
pre-set target time).
8. Color code items for easy identification.
9. Keep files/binders vertically and not laid out.
10. Plan storage of compact disks to prevent them
from getting scratched.
11. Install visual control for the replenishment of
stocks and checking missing items.
12. Observe a ‘Paper destruction day’ once every
quarter of the year.

 What items are to be stored?

 Where should the items be stored?
 What quantity of the items is generally required to be
stored?
 Are there any special storage requirements?
 How often the items are to be stored or retrieved?
 Therefore, section means, “to arrange correctly
following the correct method of doing activities and
making thorough preparation so that the activities can be
performed even if they occur abruptly.”
 Since arranging correctly is a natural follow up activity
after segregation, seiri and seiton are often used and
practiced together. Some areas which often needs
attention are unlabeled tool cribs, cluttered shelves./
lockers, office files, and things lying on the shop floor.
I. BENEFITS OF 5S • 5S will improve work efficiency, safety and also improves
productivity.
II. • A clean and organised workplace is safer. It decreases the possibility of
injuries occurring. • Increase product quality and process quality.
III. • 5S will motivate and involve your employees.
IV. • 5S will organize your whole organisation as well as workplace.
V. • 5S will remove clutter from workspace.

4.1 Lack of Top Management Commitment

4.2 Financial Constraints

4.3 Lack of Awareness of 5S

4.4 Lack of Strategic Planning of 5S

4.5 Lack of Employee Commitment

4.6 Resistance to Change and Adoption

Lack of Cooperation/Teamwork

Lack of Education and Training

9 Lack of Motivation

Inability to Change Organisational Culture

Non – Clarity of Organisation Policy and 5S Programme

Lack of Communication

No Proper Vision and Mission

4 Lack of Leadership

5 Conflict with Other Quality Management System