August 9, 2015

Lean 5S System

Resource: 5S system steps Sifting (Seiri)  Sweeping (Seiso) Sorting (Setton) Sanitizing (Seketsu) Sustaining (Shitsuke)

5S system steps Sifting (Seiri) Sweeping (Seiso) Sorting (Setton) Sanitizing (Seketsu) Sustaining (Shitsuke)










• What is the 5S system?
A systematic approach that produces and maintains a clean, organized workplace that is highly efficient and safe.

1. Sift/ Set in order (organize)
2.  Sweep/ Shine
3. Sort
4.  Sanitize/ Standardize
5.  Sustain

5S Steps
1. Sifting (Seiri): Separation of essential items from nonessential items.
2. Sorting (Setton): Arrange and organize the work area.
3. Sweeping (Seiso): Collecting dirt and unnecessary items and removing them from the work area.
4. Sanitizing (Seketsu): Marking floor/areas, Updating work instructions, and Checking all process and equipment vital signs.
5. Sustaining (Shitsuke): Ongoing continuation of sifting, sorting, sweeping, and sanitizing as a way of life. Auditing 5S activities on a regular basis.

Sifting (Seiri):
• Cleaning the work area of items that are not being used on a regular basis (e.g. every 30 days). It is the a matter of shifting through and separating clutter from the items that are required to facilitate: the work, ease of operator movement, efficient utilization of space, and smooth material flow.

Main Points of “Sifting”
Discard un‐necessary items:
• To improve space utilization and ease for accessing items that are needed, use the following procedure to classify parts, tools and equipment. Categorize items in the work area as “needed” or “unneeded” and then discard the unneeded items:
1. Identify unneeded items
2. Freeze/ isolate unneeded items
3. Dispose unneeded items at the end of freezing period

Sweeping (Seiso)
Maintaining order by sweeping and picking up on a regular basis (e.g. daily, biweekly). A production area should be neat and clean at the end of every shift. There should be nothing missing or out of place. All tools and materials should be accounted for. For a well‐maintained area this should be able to accomplished in less then 2% (10 minutes) of the daily scheduled shift time.

Main Point of “Sweeping”
• Sweep the area so that it remains suitable for use at all times.
• The individual who makes the work area dirty should immediately sweep up.
• Take measures to avoid dirt.
• Always return the area to its normal clean condition.
• Always report any problems that are discovered and take immediate corrective action.

Sorting (Setton)
• Identifying and arranging items that belong in the area. These items should all be labeled and stored. If the item is not important enough to be labeled then it is not important enough to stay in the area. This highlights visibility for tooling, resources, materials, etc.

Main Point of “Sorting”
• To create a condition in which anyone would be able to quickly locate each item, and by clearly indicating the items’ location and quantity.
• The higher the use frequency of an item, the closer the item should be to the operator. Work areas and equipment can be categorized by their application so that they can be positioned effectively.
• All items should be placed so that each team member would not have to assume a strenuous posture to reach them (ergonomics & ease of accessibility).
• All supplies and expendable items must be ordered at the proper intervals and in the proper quantity, in order to ensure their availability when they are needed.

Sanitizing (Seketsu)
• Management discipline is required to enforce the organized workplace as a standard requirement. If the housekeeping activities do not become institutionalized, the area will not stay clean and
employees will revert back to their old ways very quickly. A regular formal audit with quantitative and qualitative expectations should be conducted and scores posted for each area of responsibility. Every area must have one individual who is responsible for the sanitizing audit.

Main Points of “Sanitizing”
• Ensure a through observation of rules, and clearly indicate safety warnings.
• Identify the area of responsibility and indicate the name of the person in‐charge.
• Implement a daily check by the person incharge.

Sustaining (Shitsuke)
• Management must reinforce the importance of housekeeping and demonstrate leadership by following through and walking the talk. People will pay more attention to what management does than what they say. As part of SUSTAINING proclaim that housekeeping is important, clarify expectations, walk the shop floor regularly, reward those who are performing, and apply constructive discipline for those who are not.