5S Housekeeping

2008-12-08T05:52:00.000-08:00

For everything you wanted to know on building leadership and management, refer Shyam Bhatawdekar’s website: http://shyam.bhatawdekar.com

(Refer our High Quality Management Encyclopedia “Management Universe” at: http://management-universe.blogspot.com/)

We advise you also to read other related topics of Japanese Management Systems at URLs given below:

(A to Z of Quality Techniques) http://a-z-quality-techniques.blogspot.com/
(Total Quality Management- TQM) http://total-quality-concept.blogspot.com/
(Total Productive Maintenance- TPM) http://total-productive-maintenance.blogspot.com/
(Quality Function Deployment- QFD and House of Quality) http://quality-function-deployment.blogspot.com/
(Quality Gurus) http://quality-gurus.blogspot.com/
(Cost of Quality- COQ) http://cost-of-quality.blogspot.com/
(Kaizen) http://kaizen-improvement.blogspot.com/
(Gemba Kaizen) http://gemba-kaizen-improvement.blogspot.com/
(Quality Circles) http://quality-circles.blogspot.com/
(Quality Circles History) http://quality-circles-history.blogspot.com/
(Just in Time Management- JIT) http://just-in-time-management.blogspot.com/

5S Housekeeping Is Fundamental

(For 5S Housekeeping at homes, refer: (Housekeeping at Home) http://5s-housekeeping-home.blogspot.com/)

5S Housekeeping is fundamental for enhancing the value for the customer
5S Housekeeping is the foundation for all the organizational systems/processes
which, in turn, enhance value to customers

5S Housekeeping: A Glance

Since early 80’s in Japan
Pioneer- Toyota, Japan
Systematic approach to good housekeeping
People oriented approach: every individual can contribute to improve his workplace
Practice oriented approach: cleaner, better, effective and safer workplace
5S stands for the five good housekeeping principles

Vision

To keep both one’s external and internal house in order, develop a sensitivity for one’s surroundings and a concern for the environment at large
A systematic and rational approach to workplace organization and methodical housekeeping with a sense of purpose

Advantages

Workplace becomes cleaner and better organized.
Shop floor and office operations become easier and safer.
Results are visible to everyone- insiders and outsiders. Problems detected fast.
Visibility gives rise to further improvements. Increased number of suggestions.
People are disciplined.
It instills pride among people.
Happier employees with high morale and greater employee involvement.
Better use of floor space.
Less work in progress and inventories. Less time in material handling.
Retrieval time minimized. Better flow of work. More time for improvement activities.
Low machine breakdown rate. Low down time. Better preventive maintenance.
Low accident rate.
High yield of materials.
High and consistent product quality. Low overall cost.
Company image enhances and generates more business.

Elements of 5S

5S comprises 5 simple steps:

Seiri: Sorting out. Remove unnecessary items as appropriate
Seiton: Systematic arrangement. Prefix a place for every thing and put every thing in place (Read the article titled Be Tidy and Get Back Your Lost One Third of Life at http://wow-idea.blogspot.com/)
Seiso: Spic and span. Cleaning not for beautification alone but with a sense of purpose.
Seiketsu: Serene atmosphere/sanitizing. Environmental cleanliness.
Standardization. Develop standards/evaluation criteria.
Shitsuke: Self discipline/training. Create awareness of all 4Ss and train to implement.

You may also refer: http://5s-housekeeping-home.blogspot.com/

Steps to Implement the 5 Elements of 5S

Seiri

•Classification- sort out
•Elimination- remove unnecessary items as appropriate
•Storage- frequent use/rare use items
- close location/distant location
- identification of items
•Fix responsibilities and share responsibilities
•Monitor progress

Rough Criteria for Seiri

•Not used for a year- Check and throw
•Used only once in last 6 to 12 months- Store at a distance
•Used only once in last 1 to 6 months- Store at a central place in the work area
•Used weekly/hourly/daily- Store near work site

Seiri: Obstacles

•Seiri is not as easy to practice as it seems
•It is wasteful to throw things away
•We might possibly use them later
•It was so much trouble for me to make these things
•I know it is not used but it is in good condition, let it be there
•I want every thing here. I may use these any time, I can’t tell when. So don’t remove any thing
•If you think it is “such a waste to throw it away”, we can’t get started

Seiton

(Read the article tiltled Be Tidy and Get Back Your Lost One Third of Life at http://wow-idea.blogspot.com/)

•Ensure rational layout of machines, equipment, cabinets
•Place frequently used items at the point of use
•Prefix a place for every thing and put every thing in place
•Use labels, color codes to identify
•Use index for files, records and drawings
•Plan storage with easy irretrievability
•Mixed up items in cabinets should be organized
•Make cabinets, shelves, racks self explanatory through identification aids
•Have visual controls for checking missing items

Seiso

•Develop standards of cleaning
•Clean up work place, machines and tools after use
•Clean up supply line (no leakage, blockage, clogging with oil/dirt
•Assign responsibilities and schedules for cleaning
•Clean waste bins at end of shift/day
•Clean light bulbs, fans, shades, reflectors
•Pay special attention to scrap yard, gardens, godowns
•Scrap and chips from machines could fall directly in to collecting bins

Seiketsu

•Identify 5 S areas
•Develop standards/evaluation criteria with workmen (SOP’s and housekeeping standards)
•Establish checking procedure 5W + 1H
•Establish feedback procedure 5W + 1H
•Wear neat and clean uniform
•Wear protective clothing
•Provide adequate lighting, ventilation, exhaust
•Check electrical wiring, cables, switches
•Maintain sanitary/hygienic conditions in wash rooms, locker rooms, canteen and kitchen
•Earmark smoking and eating areas
•Look for heavy noise, vibrations and heat in machines, analyze for root cause and take action
•Create visual control systems
•Devise ways to expose hidden problems
•Create standards

Shitsuke

•Create awareness of first 4 S’s
•Develop action details for maintaining standards
•Make them easily understandable
•Give specific directions
•Display correct work procedure on the floor
•Correct deviations on the spot
•Maintain punctuality
•Conduct audits
•Demonstrate sincerity in following rules
•Share success to enthuse others

Consequences of Not Practicing 5S

Seiri

•The unwanted clutters up the place and the wanted is hard to find
•More time spent for searching things
•More space required
•We can’t bring in new things in the same place
•Causes mis-identification and rejected parts are moved to work station

Seiton

•Things are seldom available when needed. More time spent for locating misplaced things
•Defective and good items/similar looking items get mixed up
•Items are lost
•Prone to accidents
•Loss of production
•Excess inventory
•Pressure for more space

Seiso

•Dust and dirt will affect the machine performance
•Cleaning reveals hidden problems which may get overlooked otherwise
•Dust and dirt affect performance and aesthetic quality
•Unpleasant work place

Five Levels of 5 S Housekeeping

•Housekeeping of one’s inner self
•Following the 5 S principles and reducing waste
•Extending the 5 S concept to include ergonomics
•Extending the 5 S concept to include aesthetics
•Maintaining records and educating others

Stages of 5S Housekeeping

Stage 1: Floor is full of unwanted material
Stage 2: Clutter found by the walls
Stage 3: Factory/office is clean but tools, papers, files and materials dis-organized
Stage 4: Storage area/offices are clean and furniture, documents, material organized
Stage 5: Factory/office is immaculate

Critical Factors/Steps in Implementing 5S

Top /Senior Management commitment
Leadership by location heads
Awareness training programs for all employees
Launching of 5S program
Allocation of funds
Identification on 5S areas
Team formation involving employees
Developing standards
Developing checklists
Guidance, training, sorting out problems
Developing audit check lists
Publishing audit results
Reviewing audit findings, follow up corrective actions
Holding competitions- awards

Implementation Methodology

All employees to undergo 5 S Housekeeping training
A vision statement to be evolved and started with all employees
Divide the organization into convenient zones
Divide each zone in to convenient sub-zones
Decide on date(s) for launching 5 S in each zone, sub-zone
Take pledge (refer the section titled "5S Pledge" for couple of formats of the pledge as examples. they can be customized to your requirements)
Apply 5 S principles step by step
Form audit teams
Carry out audits

5S Pledge

Examples of Pledge Formats:

Example 1: It shall be my (our) constant effort to maintain my workplace in an excellent order by sorting out unwanted material periodically and discarding them, assigning a place for everything and keeping everything in its place and keeping my workplace neat and clean all the time everyday.

Example 2: It shall be my (our) endeavour to delight our customers (or internal and external customers) by adhering to the standards of putting things in order and maintaining cleanliness at our workplace.

Criteria for Good Housekeeping Award

Space occupied
Ease of retrieval
Ingenious storing methods
Waste elimination
Aesthetics

5 S Audit

Form an audit team for each zone consisting of 4-5 members. The members should belong to that zone. One member may belong to another zone so as to maintain impartiality.
Auditing should be carried out once a month or once in two months based on a carefully prepared check list.

An Example of Auditor’s Check List

•Documents maintained as per retention plan : 10 points
•Other items at assigned places : 10 points
•Innovative methods of storage/visual display system: 5 points
•Cleanliness/hygiene : 5 points
•Space released : 5 points
•Reporting of waste reduction : 5 points
•Aesthetic aspect : 10 points
•Safety aspect : 15 points
•Auditee’s personal appearance : 5 points
•Layout : 5 points
•Lighting level : 5 points
•Noise level : 5 points
•Temperature/humidity : 5 points
•General ergonomics : 10 points

What Various Practitioners Say about 5S Housekeeping

5S Housekeeping is literally the work place management.
It is pre-requisite for world class manufacturing practices.
It is an ideal housekeeping system and beyond.
5S is doing away with unwanted things and waste reduction.
5S Housekeeping is keeping things in their respective places without any one's supervision.
It paves way for almost zero retrieval time situation.
It is keeping the work place spic and span.
It is keen inspection.
5S is about adopting standards for sustenance.
It provides for good service practices.
It is a habit and not just a one time or intermittent action.
It is an attitude and not an audit or policing.
In a way 5S should become the work culture.
It promotes safety of high order.
It adds confidence.
It subtracts pain.
It multiplies productivity.
It divides pleasure among all.