5s and Kaizen

5S METHODOLOGY
5S is the name of a workplace organization method that uses a list of five

Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke.
The list describes how to organize a work space for eciency and
eectiveness by identifying and storing the items used, maintaining
the area and items, and sustaining the new order.
The decision-making process usually comes from a dialogue about

standardization, which builds understanding among employees of
how they should do the work.
SORT
Remove unnecessary items and dispose of them properly.
Make work easier by eliminating obstacles.
Reduce chance of being disturbed with unnecessary items.
Prevent accumulation of unnecessary items.
Evaluate necessary items with regard to cost or other factors.
Remove all parts not in use.
Segregate unwanted material from the workplace.
Need fully skilled supervisor for checking on regular basis.
Don't put unnecessary items at the workplace & define a red-

tagged area to keep those unnecessary items.
Waste removal.
SET IN ORDER
Arrange all necessary items so they can be easily
selected for use
Prevent loss and waste of time by arranging work station

in such a way that all tooling / equipment is in close
proximity
Make it easy to find and pick up necessary items
Ensure first-come-first-served basis
Make workflow smooth and easy
All above work should be done on regular basis

SHINE
Clean your workplace completely
Use cleaning as inspection
Prevent machinery and equipment deterioration
Keep workplace safe and easy to work
Keep work place clean and pleasing to work in
When in place anyone not familiar to the environment must be

able to detect problems in 5 seconds within 50 feet.
STANDARDIZE
Standardize the best practices in the work area.
Maintain high standards and workplace organization at all

times.
Maintain orderliness. Maintain everything in order and

according to its standard.
Everything in its right place.
Every process has a standard.

SUSTAIN
To keep in working order
Also translates as "do without being told
Perform regular audits
Training and Discipline
Training is goal oriented process. Its resulting feedback is

necessary monthly
5S APPLICATIONS
5S methodology has expanded from manufacturing and is now being
applied to a wide variety of industries including health care, education,
and government.
Although the origins of the 5S methodology are in manufacturing, it can

also be applied to knowledge-economy work, with information, software,
or media in the place of physical product.
Examples of companies using 5S methodology are Infineon

Technologies and Nonin Medical
THE ORIGIN OF 5S
5S was developed in Japan and was identified as one of

the techniques that enabled Just in Time manufacturing.
Two major frameworks for understanding and applying

5S to business environments have arisen, one proposed
by Osada, the other by Hirano.
Hirano provided a structure for improvement programs

with a series of identifiable steps, each building on its
predecessor.
As noted by John Bicheno,Toyota's adoption of the

Hirano approach was '4S', with Set in order and Shine
combined.
KAIZEN MODEL
Kaizen in Japanese means "improvement." Kaizen refers to
activities that continuously improve all functions and involve all
employees from the CEO to the assembly line workers.
It also applies to processes, such as purchasing and logistics,

that cross organizational boundaries into the supply chain.
It has been applied in healthcare, psychotherapy, life-coaching,

government, banking, and other industries.
By improving standardized activities and processes, kaizen

aims to eliminate waste.
Kaizen is most commonly associated with manufacturing operations, as at
Toyota, but has also been used in non-manufacturing environments.
At Toyota, it is usually a local improvement within a workstation or local area

and involves a small group in improving their own work environment and
productivity.
This group is often guided through the kaizen process by a line supervisor;
sometimes this is the line supervisor's key role.
Kaizen on a broad, cross-departmental scale in companies,
generates total quality management, and frees human efforts
through improving productivity using machines and computing
power.
Kaizen methodology includes making changes and monitoring

results, then adjusting.
Large-scale pre-planning and extensive project scheduling are

replaced by smaller experiments, which can be rapidly adapted as
new improvements are suggested.
Cycle of Kaizen activity
Plan ahead for change.
Analyze and predict the results
Establish the objectives and processes necessary to deliver results

in accordance with the expected output.
By establishing output expectations, the completeness and

accuracy of the spec is also a part of the targeted improvement.
When possible start on a small scale to test possible eects.

Execute the plan, taking small steps
in controlled circumstances.
Implement the plan, execute the process, make the product.
Collect data for charting and analysis in the following

"CHECK" and "ACT" steps.
Check, study the results.
Study the actual results and compare against the expected results
(targets or goals from the "PLAN") to ascertain any differences.
Look for deviation in implementation from the plan and also look for the
appropriateness and completeness of the plan to enable the execution,
i.e., "Do".
Charting data can make this much easier to see trends over several
PDCA cycles and in order to convert the collected data into information.
Information is what you need for the next step "ACT".

Take action to standardize or improve the
process
If the CHECK shows that the PLAN that was implemented in DO is an

improvement to the prior standard, then that becomes the new standard for
how the organization should ACT going forward.
If the CHECK shows that the PLAN that was implemented in DO is not an
improvement, then the existing standard will remain in place.
In either case, if the CHECK showed something dierent than expected, then
there is some more learning to be done... and that will suggest potential future
PDCA cycles.
Benefits of PDCA Cycle
Daily routine management-for the individual and/or the team

Problem-solving process
Project management
Continuous development
Vendor development
Human resources development
New product development
Process trials
When to Use PlanDoCheckAct
As a model for continuous improvement.
When starting a new improvement project.
When developing a new or improved design of a

process, product or service.
When defining a repetitive work process.
When planning data collection and analysis in order to

verify and prioritize problems or root causes.
When implementing any change.

PlanDoCheckAct Procedure
1. Plan. Recognize an opportunity and

plan a change.
2. Do. Test the change. Carry out a small-

scale study.
3. Check. Review the test, analyze the

results and identify what youve
learned.
4. Act. Take action based on what you

learned in the study step: If the change
did not work, go through the cycle
again with a different plan.
Vaishnavi Laxmi Mubashshir
T.H.A.N.K.Y.O.U
Paritosh Sreyashi Noorain Jenny

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5S METHODOLOGY

5S is the name of a workplace organization method that uses a list of five

The decision-making process usually comes from a dialogue about

Make work easier by eliminating obstacles.

Reduce chance of being disturbed with unnecessary items.

Prevent accumulation of unnecessary items.

Evaluate necessary items with regard to cost or other factors.

Remove all parts not in use.

Segregate unwanted material from the workplace.

Need fully skilled supervisor for checking on regular basis.

Don't put unnecessary items at the workplace & define a red-

Prevent loss and waste of time by arranging work station

Make it easy to find and pick up necessary items

Ensure first-come-first-served basis

Make workflow smooth and easy

All above work should be done on regular basis

Use cleaning as inspection

Prevent machinery and equipment deterioration

Keep workplace safe and easy to work

Keep work place clean and pleasing to work in

When in place anyone not familiar to the environment must be

Maintain high standards and workplace organization at all

Maintain orderliness. Maintain everything in order and

Everything in its right place.

Every process has a standard.

Also translates as "do without being told

Perform regular audits

Training and Discipline

Training is goal oriented process. Its resulting feedback is

Although the origins of the 5S methodology are in manufacturing, it can

Examples of companies using 5S methodology are Infineon

5S was developed in Japan and was identified as one of

Two major frameworks for understanding and applying

Hirano provided a structure for improvement programs

As noted by John Bicheno,Toyota's adoption of the

It also applies to processes, such as purchasing and logistics,

It has been applied in healthcare, psychotherapy, life-coaching,

By improving standardized activities and processes, kaizen

At Toyota, it is usually a local improvement within a workstation or local area

Kaizen methodology includes making changes and monitoring

Large-scale pre-planning and extensive project scheduling are

Establish the objectives and processes necessary to deliver results

By establishing output expectations, the completeness and

When possible start on a small scale to test possible eects.

Implement the plan, execute the process, make the product.

Collect data for charting and analysis in the following

Information is what you need for the next step "ACT".

If the CHECK shows that the PLAN that was implemented in DO is an

Daily routine management-for the individual and/or the team

As a model for continuous improvement.

When starting a new improvement project.

When developing a new or improved design of a

When defining a repetitive work process.

When planning data collection and analysis in order to

When implementing any change.

1. Plan. Recognize an opportunity and

2. Do. Test the change. Carry out a small-

3. Check. Review the test, analyze the

4. Act. Take action based on what you