72
The Structure of Part 4:
• Twelve Focal Points Super 5S Auditors Should Examine
• Rules for Participation in Super 5S Inter-Departmental Competitions (four
pages)
• A Super 5S Evaluation Form for Factory / Operation Site
• A Super 5S Evaluation Forms for Office
• A Super 5S Evaluation Summary
• 5S Guidance Stickers (here is a need for Seiri, Seiton or Seiso)
• 5S Guidance Stickers (here is an excellent example of 5S practice)
• Ten Useful Hints for Winning Super 5S Competitions
• Passport to Successful 5S - pages 1 and 4
• Passport to Successful 5S - pages 2 and 3
5S5S
How to Audit and GuideHow to Audit and GuideHow to Audit and GuideHow to Audit and Guide
SUPERSUPERSUPERSUPER5S 5S 5S 5S ActivitiesActivitiesActivitiesActivities
PARTPARTPARTPART 4 4 4 4
73
A 5S audit is conducted according to the method of Super 5S inter-departmental competitions.
Auditors evaluate and record each department’s level of 5S practiceaccording to its achievement in the six major objectives of Super 5Sprogram: Productivity, Quality, Cost, Delivery, Safety and Morale.
Auditors may use the Super 5S evaluation forms (for factory / operationsites and offices).
The method for filling out the Super 5S evaluation forms is described in therules for participating in Super 5S inter-departmental competitions.
Twelve Focal Points Super 5S Auditors Should ExamineTwelve Focal Points Super 5S Auditors Should Examine
l Do the CEO and managers support Super 5S program?
l Are people proud of their workplaces?
l Are workplaces clean and organized?
l Are workplaces safe for people to work in?
l Are machines and equipment clean and well maintained?
l Are items easy to retrieve?
l Are machines and tools conveniently located?
l Are inventories stored for FIFO retrieval?
l Are products free from dust?
l Do people clean daily without prompting?
l Are the uniforms worn by people clean and tidy?
l Is a good image of the enterprise reflected in its people?
74
materials / partswork-in-processfinished productsdefective / rejectsmachines / equipmentwiring / pipingdies / tools / jigsspare parts / lubricantscontainers / palletsracks / shelves / cabinetscarts / wagons / forkliftslifts / conveyers / cranesdesks / tables / chairsforms / files / recordsfloors / passages / stairwayswalls / windows / ceilinglighting / ventilationworking wears / shoessafety devicesfire extinguishers / fire exitscleaning tools / waste basketscanteens / toilets / lockersexternal areas / gardenssecurity guards / car parks
are they conveniently located and labeled for easy retrieval?are they conveniently located for easy handling?are they conveniently located and labeled for easy retrieval?are they clearly labeled for separation from good items?are they clean, safe, well-maintained and convenient to operate?are they laid out in a tidy, safe and convenient manner?are they conveniently labeled and placed at designated locations?are they conveniently labeled and placed at designated locations?are they clean and conveniently placed at designated locations?are they dust-free, tidy and conveniently labeled for items stored?are they well-maintained and placed at designated locations?are they clean, tidy, safe and well-maintained?are they clean and organized inside and outside?are they up-to-date, easy to retrieve and at convenient locations?are they dust-free, tidy, safe and well-maintained?are they dust-free, tidy, safe and well-maintained?are they adequate for efficient operation?are they clean and do they present a good image?are they conveniently located for use and well-maintained?are they adequate and cleaned regularly?are they clean, tidy and well-maintained?are they clean, tidy and well-maintained?are they clean, tidy, safe and do they present a good image?are they clean, tidy, safe and do they present a good image?
TOTAL SCORE (a)
ADJUSTED SCORE = (a) / (b) x 10
BONUS SCORE FOR SUPER 5S PRACTICE
FINAL SCORE
NO. OF ITEMS EVALUATED (b):
AUDITOR: DATE:
COMMENTS FOR IMPROVEMENT:
ITEM FOCUS SCORE
SUPER 5S PRACTICE IDENTIFIED:
SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE DEPARTMENT:
20 15 10 5 0
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10 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 2
Rules for Participating in Super 5S Inter-Departmental Competitions - 1Rules for Participating in Super 5S Inter-Departmental Competitions - 1
1. Objectives
Proposed competitions are aimed at improving the organization stotal productivity through everyone s participation in the Super 5Sprogram.
Qualification for Participation
Any department which is implementing 5S on a certain level is eligiblefor participation.
3. Competition Period
Each competition will be organized for a period of 6 months, two timesa year on a continuing basis.
4. Auditing Team
An auditing team appointed by the Super 5S Steering Committee willvisit each competing department and evaluate its Super 5S activities atthe end of each competition period.
5. Super 5S Evaluation Forms
One of the following Super 5S Evaluation Forms will be used by theauditors according to the function of the participating departments:
75
Rules for Participating in Super 5S Inter-Departmental Competitions - 2Rules for Participating in Super 5S Inter-Departmental Competitions - 2
(a) Super 5S Evaluation Form - Factory / Operation Site
(b) Super 5S Evaluation Form - Office
6. Evaluation
1) Two Aspects of the Evaluation
Evaluation scores will be recorded by each auditor in two aspects ofSuper 5S activities for each participating department:
(a) Scores on the 5S Level Achieved
(b) Scores on the Super 5S Practice Identified
2) Evaluation on the 5S Level Achieved
Each auditor is expected to mark his score on each itemized questionlisted on the form and enter the added total score in the space TOTALSCORE (a). ADJUSTED SCORE (maximum 100) will be obtained by thethe following formula:
ADJUSTED SCORE = TOTAL SCORE (a) / NO. OF ITEMS EVALUATED(b) x 10
materials / partswork-in-processfinished productsdefective / rejectsmachines / equipmentwiring / pipingdies / tools / jigsspare parts / lubricantscontainers / palletsracks / shelves / cabinetscarts / wagons / forkliftslifts / conveyers / cranesdesks / tables / chairsforms / files / recordsfloors / passages / stairwayswalls / windows / ceilinglighting / ventilationworking wears / shoessafety devicesfire extinguishers / fire exitscleaning tools / waste basketscanteens / toilets / lockersexternal areas / gardenssecurity guards / car parks
are they conveniently located and labeled for easy retrieval?are they conveniently located for easy handling?are they conveniently located and labeled for easy retrieval?are they clearly labeled for separation from good items?are they clean, safe, well-maintained and convenient to operate?are they laid out in a tidy, safe and convenient manner?are they conveniently labeled and placed at designated locations?are they conveniently labeled and placed at designated locations?are they clean and conveniently placed at designated locations?are they dust-free, tidy and conveniently labeled for items stored?are they well-maintained and placed at designated locations?are they clean, tidy, safe and well-maintained?are they clean and organized inside and outside?are they up-to-date, easy to retrieve and at convenient locations?are they dust-free, tidy, safe and well-maintained?are they dust-free, tidy, safe and well-maintained?are they adequate for efficient operation?are they clean and do they present a good image?are they conveniently located for use and well-maintained?are they adequate and cleaned regularly?are they clean, tidy and well-maintained?are they clean, tidy and well-maintained?are they clean, tidy, safe and do they present a good image?are they clean, tidy, safe and do they present a good image?
TOTAL SCORE (a)
ADJUSTED SCORE = (a) / (b) x 10
BONUS SCORE FOR SUPER 5S PRACTICE
FINAL SCORE
NO. OF ITEMS EVALUATED (b):
AUDITOR: DATE:
COMMENTS FOR IMPROVEMENT:
ITEM FOCUS SCORE
SUPER 5S PRACTICE IDENTIFIED:
SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE DEPARTMENT:
20 15 10 5 0
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101112131415161718192021222324
10 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 2
76
materials / partswork-in-processfinished productsdefective / rejectsmachines / equipmentwiring / pipingdies / tools / jigsspare parts / lubricantscontainers / palletsracks / shelves / cabinetscarts / wagons / forkliftslifts / conveyers / cranesdesks / tables / chairsforms / files / recordsfloors / passages / stairwayswalls / windows / ceilinglighting / ventilationworking wears / shoessafety devicesfire extinguishers / fire exitscleaning tools / waste basketscanteens / toilets / lockersexternal areas / gardenssecurity guards / car parks
are they conveniently located and labeled for easy retrieval?are they conveniently located for easy handling?are they conveniently located and labeled for easy retrieval?are they clearly labeled for separation from good items?are they clean, safe, well-maintained and convenient to operate?are they laid out in a tidy, safe and convenient manner?are they conveniently labeled and placed at designated locations?are they conveniently labeled and placed at designated locations?are they clean and conveniently placed at designated locations?are they dust-free, tidy and conveniently labeled for items stored?are they well-maintained and placed at designated locations?are they clean, tidy, safe and well-maintained?are they clean and organized inside and outside?are they up-to-date, easy to retrieve and at convenient locations?are they dust-free, tidy, safe and well-maintained?are they dust-free, tidy, safe and well-maintained?are they adequate for efficient operation?are they clean and do they present a good image?are they conveniently located for use and well-maintained?are they adequate and cleaned regularly?are they clean, tidy and well-maintained?are they clean, tidy and well-maintained?are they clean, tidy, safe and do they present a good image?are they clean, tidy, safe and do they present a good image?
TOTAL SCORE (a)
ADJUSTED SCORE = (a) / (b) x 10
BONUS SCORE FOR SUPER 5S PRACTICE
FINAL SCORE
NO. OF ITEMS EVALUATED (b):
AUDITOR: DATE:
COMMENTS FOR IMPROVEMENT:
ITEM FOCUS SCORE
SUPER 5S PRACTICE IDENTIFIED:
SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE DEPARTMENT:
20 15 10 5 0
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101112131415161718192021222324
10 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 2
Rules for Participating in Super 5S Inter-Departmental Competitions - 3Rules for Participating in Super 5S Inter-Departmental Competitions - 3
3) Evaluation of the Super 5S Practice Identified
Each auditor is also expected to look for Super 5S practice(s)implemented in each department, and give an additional score tosuch good practice(s) according to it(s) value(s) in the space BONUSSCORE FOR SUPER 5S PRACTICE(S) provided on the form(maximum 20).
4) Final Score
The ADJUSTED SCORE (for 5S level achieved) and the BONUSSCORE FOR SUPER 5S PRACTICE(S) are totaled and become theFINAL SCORE (maximum 120).
5) Auditor s Explanation on Super 5S Practice(s) Identified
Each auditor should explain his reason(s) for awarding a BONUSSCORE in the space SUPER 5S PRACTICE(S) IDENTIFIED.
6) Auditor s Comments for Future Improvement
Each auditor is advised to state his comments for future improvementsuggested in the space COMMENTS FOR IMPROVEMENT.
77
Rules for Participating in Super 5S Inter-Departmental Competitions - 4Rules for Participating in Super 5S Inter-Departmental Competitions - 4
7. Awarding
With better results and psychological effects in mind, theimplementing organization should work out an awarding method thatcan encourage, but not discourage, the participating colleagues anddepartments toward intended objectives.
IMPROVE YOUR PRODUCTIVITYIMPROVE YOUR PRODUCTIVITY
THROUGH 5S ACTIVITIESTHROUGH 5S ACTIVITIES
IN 5S INTER-DEPARTMENTAL
COMPETITION
PRODUCTIVITY AWARDPRODUCTIVITY AWARD
FORFOR
BEST WINNER 1997BEST WINNER 1997
Congratulations!
78
Enlarge this form to A4 size.
materials / partswork-in-processfinished productsdefective / rejectsmachines / equipmentwiring / pipingdies / tools / jigsspare parts / lubricantscontainers / palletsracks / shelves / cabinetscarts / wagons / forkliftslifts / conveyers / cranesdesks / tables / chairsforms / files / recordsfloors / passages / stairwayswalls / windows / ceilinglighting / ventilationworking wears / shoessafety devicesfire extinguishers / fire exitscleaning tools / waste basketscanteens / toilets / lockersexternal areas / gardenssecurity guards / car parks
are they conveniently located and labeled for easy retrieval?are they conveniently located for easy handling?are they conveniently located and labeled for easy retrieval?are they clearly labeled for separation from good items?are they clean, safe, well-maintained and convenient to operate?are they laid out in a tidy, safe and convenient manner?are they conveniently labeled and placed at designated locations?are they conveniently labeled and placed at designated locations?are they clean and conveniently placed at designated locations?are they dust-free, tidy and conveniently labeled for items stored?are they well-maintained and placed at designated locations?are they clean, tidy, safe and well-maintained?are they clean and organized inside and outside?are they up-to-date, easy to retrieve and at convenient locations?are they dust-free, tidy, safe and well-maintained?are they dust-free, tidy, safe and well-maintained?are they adequate for efficient operation?are they clean and do they present a good image?are they conveniently located for use and well-maintained?are they adequate and cleaned regularly?are they clean, tidy and well-maintained?are they clean, tidy and well-maintained?are they clean, tidy, safe and do they present a good image?are they clean, tidy, safe and do they present a good image?
TOTAL SCORE (a)
ADJUSTED SCORE = (a) / (b) x 10
BONUS SCORE FOR SUPER 5S PRACTICE
FINAL SCORE
NO. OF ITEMS EVALUATED (b):
AUDITOR: DATE:
COMMENTS FOR IMPROVEMENT:
ITEM FOCUS SCORE
SUPER 5S PRACTICE IDENTIFIED:
SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE DEPARTMENT:
20 15 10 5 0
123456789
101112131415161718192021222324
10 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 2
79
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20 15 10 5 0
TOTAL SCORE (a)
ADJUSTED SCORE = (a) / (b) x 10
BONUS SCORE FOR SUPER 5S PRACTICE
FINAL SCORE
NO. OF ITEMS EVALUATED (b):
AUDITOR: DATE:
COMMENTS FOR IMPROVEMENT:SUPER 5S PRACTICE IDENTIFIED:
desks / tables / chairscabinets / shelvesdocuments / filesforms / office suppliestelephonesfacsimilestypewriters / word-processorscomputers / monitorsprinterscopying machineselectric wiringlighting / ventilationfloors / walls / windows / ceilingfire extinguishersemergency exitssafety devicesworking clothes / shoeswaste baskets
are they tidy and conveniently organized?are they clean and labeled for the easy retrieval of things needed?are they clean and systematically organized?are they tidy and conveniently stored for retrieval?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?Is it tidy, safe and conveniently laid out for operation?are they adequate for efficient operation?are they dust-free and well-maintained?are they adequate and well-maintained?are they adequate and clear of obstacles in case of emergencies?are they adequate and well-maintained?are they clean and do they present a good image?are clean and well-maintained?
ITEM FOCUS SCORE
SUPER 5S EVALUATION FORM - OFFICE DEPARTMENT:
10 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 2
123456789
101112131415161718192021222324
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DEPARTMENT DATE OF AUDIT ADJUSTED PT. SUPER 5S PT. TOTAL PT. AUDITORRANKING
SUPER 5S EVALUATION SUMMARY ORGANIZATION: DATE:
81
Three kinds of stickers in different colors for SEIRI (red), SEITON (blue)and SEISO (green) are used respectively by the 5S auditor for correctiveactions as illustrated below:
Here is a need forHere is a need for
SEIRISEIRI
Here is a need forHere is a need for
SEIRISEIRI
Here is a need forHere is a need for
SEIRISEIRI
Here is a need forHere is a need for
SEIRISEIRI
Here is a need forHere is a need for
SEIRISEIRI
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEISOSEISO
Here is a need forHere is a need for
SEISOSEISO
Here is a need forHere is a need for
SEISOSEISO
Here is a need forHere is a need for
SEISOSEISO
Here is a need forHere is a need for
SEISOSEISO
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
Here is a need forHere is a need for
SEITONSEITON
When the auditor identifies a
place in need of 5S Kaizen,
paste an applicable sticker to
the specific location for action
by the individual or group in
charge. In these examples,
stickers for SEITON are
applied.
Here is a need forHere is a need for
SEITONSEITONK.T.
6/16/97
6/16/97
6/16/97
82
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
Here is anHere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
The sticker for congratulation is used by the 5S auditor when he identifies a
Super5S practice as shown below:
here is anhere is an
Excellent ExampleExcellent Example
of of 5S5S PracticePractice
K.T.K.T.
6/16/976/16/97
83
Seven Categories of Waste:
1) Waste arising from overproduction
2) Waste arising from defects
3) Waste arising from waiting time / delays
4) Waste arising from the accumulation of work-in-process
5) Waste arising from transport
6) Waste arising from process
7) Waste arising from unnecessary motions or actions
If you make a thorough analysis into the origin of these categories of wasteand practice Super 5S so as to eliminate this waste, you will reduce costsand improve productivity.
Ten Useful Hints for Winning Super 5S CompetitionsTen Useful Hints for Winning Super 5S Competitions
l Two heads are better than one - try brainstorming.
l Look for inconvenient areas to improve.
l Look for disorganized areas to improve.
l Look for unsafe areas to improve.
l Look for dirty or untidy areas to improve.
l Look for seven categories of waste to eliminate.
l Clean the surface of machines extensively.
l Pay more attention to common areas including
canteens, toilets, gardens, external passages and car
parks.
l Show evidence that more colleagues are involved in
Super 5S activities.
l Make your Super 5S practices more visible.
84
Copy this on one side of the paper and copy the next page on the reverseside, to make a handy 5S manual.
What is 5S?
Sort and discard unnecessary items in the
workplace.
Arrange necessary items so that they caneasily be selected for use.
Clean your workplace completely so that
there is no dust on the floors, machines or
equipment.
Keep one s workplace productive and
comfortable by repeating Seiri-Seiton-
Seiso.
Train people to follow good work habits.
Seiri:
Seiton:
Seiso:
5S Contributes to PQCDSM
Productivity - increased competitiveness
Quality - no defects
Cost - no waste
Delivery - no delays
Safety - no accidents
Morale - good teamwork
STEP 1
Seiri 1
Seiton 1
Seiso 1
Seiketsu 1
Shitsuke 1
Keep onlynecessaryitems
Assign itemsa place.
In eachsection cleanone machinewell
Create acleanworkplace
STEP 2
Seiri 2
Seiton 2
Seiso 2
Seiketsu 2
Shitsuke 2
Do not putanything onthe floor
Make neededitemsaccessible
Increase thenumber ofcleanmachines
Create acomfortableworkplace
STEP 3
Seiri 3
Seiton 3
Seiso 3
Seiketsu 3
Shitsuke 3
Separate workareas frompassageways
Reducesearchingtime
Increase thenumber ofcleanmachines
Create ahealthy andsafeworkplace
STEP 4
Seiri 4
Seiton 4
Seiso 4
Seiketsu 4
Shitsuke 4
Create morespace foreffective use
Reducewalkingdistances
Keep all themachinesclean andshiny
Create ahighlyproductiveworkplace
Discardunnecessaryitems moreoften
Arrangeitems by typeand size-
Select amachine andclean itcompletely
Clean one s
workplacedaily
Use wagonsto transportitems-
Removeobstaclesaroundneeded items
Use moreconvenientcleaningtools
Set up acleaningschedule
Draw lines toseparatepassagewaysfor people
Use labels tosimplifyretrieval-
Preventmachinesfrom gettingdirty
Eliminatehazards
Reduceexcessinventory-
Placefrequentlyused itemsclose by
Combinecleaningwithinspection
Introducecreativethinking
T
A
R
G
E
T
S
A
C
TI
O
N
S
4 1
Seiketsu:
Shitsuke:
How to do 5S Step by Step PASSPORT TO SUCCESSFUL 5S
5S is fundamental to productivity improvement
85
Copy this on the reverse side of a copy of the previous page, to make ahandy manual.
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
2
checkpointsscore score
The 5S Activity Bulletin Board is well-
organized and data are updated
The locations for materials, components and
work-in-process are labeled for easy retrieval
Dies, jigs, fixtures and tools are conveniently
located so that there is no need to search
Bolts, nuts, components and other materials
are not kept on the floor
Passages and operation areas are clearlyindicated and separated by distinct lines
Failures found are immediately fixed (uneven
floor, projections, machine failures, etc.)
Areas difficult to clean are cleaned
periodically
Without searching tools or documents can be
retrieved in less than 30 seconds
Rules for 5S practice are implemented and are
observed without prompting
A 5S patrol is regularly conducted by
supervisors for continued improvement
5S inspections are practiced and recorded at
starting and closing times
Jigs and tools are easy to return to theirdesignated locations
Dirt and stains on machines are removedimmediately
Things that cause dirt or stains are eliminated
-
Tools and measurement devices are
periodically checked and failures are fixed
People are active in implementing Kaizen for
the improvement of safety, quality and cost
Violators of rules are warned by colleagues
-
Components, tools and documents are labeled
and easy to retrieve
Rules are strictly observed (punctuality,
cleaning at the end of the day, etc.)
5S is well maintained and upgraded throughcreative activities
checkpoints
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1 Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1
Checklist for Step 3 Checklist for Step 4 3
86
SUPERSUPER5S5S Practices Practices
A Collection ofA Collection of
PhotographsPhotographs
IllustratingIllustrating
PARTPARTPARTPART 5 5 5 5
The Structure of Part 5:
• Photographs Taken at 4 Model Organizations in Singapore
• Photographs Taken at 9 Model Organizations in Thailand
1 2 3 4 5 6 7 8 9 101112
HE�E �� ��HE�E �� ��HE�E �� ��HE�E �� ��
E�������� E������E�������� E������E�������� E������E�������� E������
�� �� �� �� 5S5S5S5S ��������������������������������
132
Postscript
Have you decided to implement the program of Super 5S? It is a matter of
course that before participating in this program you must prepare elaborate
plans (preparations and plans) according to the cycle of management (plan,
do and see). At this stage, since seeing is believing, a very effective
approach to success would be to visit or organize study tours to model
Super 5S companies and exchange information with those involved in
implementing Super 5S activities.
As I said before, since 1986 I have had the experience of guiding 5S
activities in many countries for about ten years. During this time I have tried
to improve this book to make it easier for non-Japanese to understand. The
title of this book has changed according to these revisions as follows:
1986: How to Implement 5S Activities in Your Organization
1990: Introduction to Advanced 5S Activities
1995: Introduction to Super 5S Engineering
1997: Super 5S is for Everyone
The reason I have lately added super is that I intend to make the program
surpass the generally understood level of 5S. I want to indicate to those
involved in 5S practices the objectives and substance of being more and
more creative, being more human and contributing more to productivity.
The EndThe EndThe EndThe End of the of the of the of the
PresentationPresentationPresentationPresentation
Thank You Very MuchThank You Very MuchThank You Very MuchThank You Very Much
for Your Participationfor Your Participationfor Your Participationfor Your Participation
Kazuo TsuchiyaKazuo TsuchiyaKazuo TsuchiyaKazuo Tsuchiya
133
What is 5S?
Sort and discard unnecessary items in the
workplace.
Arrange necessary items so that they can
easily be selected for use.
Clean your workplace completely so that
there is no dust on the floors, machines or
equipment.
Keep one’s workplace productive and
comfortable by repeating Seiri-Seiton-
Seiso.
Train people to follow good work habits.
Seiri:
Seiton:
Seiso:
5S Contributes to PQCDSM
Productivity - increased competitiveness
Quality - no defects
Cost - no waste
Delivery - no delays
Safety - no accidents
Morale - good teamwork
STEP 1
Seiri 1
Seiton 1
Seiso 1
Seiketsu 1
Shitsuke 1
Keep onlynecessaryitems
Assign itemsa place.
In eachsection cleanone machinewell
Create acleanworkplace
STEP 2
Seiri 2
Seiton 2
Seiso 2
Seiketsu 2
Shitsuke 2
Do not putanything onthe floor
Make neededitemsaccessible
Increase thenumber ofcleanmachines
Create acomfortableworkplace
STEP 3
Seiri 3
Seiton 3
Seiso 3
Seiketsu 3
Shitsuke 3
Separate workareas frompassageways
Reducesearchingtime
Increase thenumber ofcleanmachines
Create ahealthy andsafeworkplace
STEP 4
Seiri 4
Seiton 4
Seiso 4
Seiketsu 4
Shitsuke 4
Create morespace foreffective use
Reducewalkingdistances
Keep all themachinesclean andshiny
Create ahighlyproductiveworkplace
Discardunnecessaryitems moreoften
Arrangeitems by typeand size-
Select amachine andclean itcompletely
Clean one’sworkplacedaily
Use wagonsto transportitems-
Removeobstaclesaroundneeded items
Use moreconvenientcleaningtools
Set up acleaningschedule
Draw lines toseparatepassagewaysfor people
Use labels tosimplifyretrieval-
Preventmachinesfrom gettingdirty
Eliminatehazards
Reduceexcessinventory-
Placefrequentlyused itemsclose by
Combinecleaningwithinspection
Introducecreativethinking
T
A
R
G
E
T
S
A
C
TI
O
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Seiketsu:
Shitsuke:
How to do 5S Step by Step PASSPORT TO SUCCESSFUL 5S
5S is fundamental to productivity improvement
What is 5S?
Sort and discard unnecessary items in the
workplace.
Arrange necessary items so that they can
easily be selected for use.
Clean your workplace completely so that
there is no dust on the floors, machines or
equipment.
Keep one’s workplace productive and
comfortable by repeating Seiri-Seiton-
Seiso.
Train people to follow good work habits.
Seiri:
Seiton:
Seiso:
5S Contributes to PQCDSM
Productivity - increased competitiveness
Quality - no defects
Cost - no waste
Delivery - no delays
Safety - no accidents
Morale - good teamwork
STEP 1
Seiri 1
Seiton 1
Seiso 1
Seiketsu 1
Shitsuke 1
Keep onlynecessaryitems
Assign itemsa place.
In eachsection cleanone machinewell
Create acleanworkplace
STEP 2
Seiri 2
Seiton 2
Seiso 2
Seiketsu 2
Shitsuke 2
Do not putanything onthe floor
Make neededitemsaccessible
Increase thenumber ofcleanmachines
Create acomfortableworkplace
STEP 3
Seiri 3
Seiton 3
Seiso 3
Seiketsu 3
Shitsuke 3
Separate workareas frompassageways
Reducesearchingtime
Increase thenumber ofcleanmachines
Create ahealthy andsafeworkplace
STEP 4
Seiri 4
Seiton 4
Seiso 4
Seiketsu 4
Shitsuke 4
Create morespace foreffective use
Reducewalkingdistances
Keep all themachinesclean andshiny
Create ahighlyproductiveworkplace
Discardunnecessaryitems moreoften
Arrangeitems by typeand size-
Select amachine andclean itcompletely
Clean one’sworkplacedaily
Use wagonsto transportitems-
Removeobstaclesaroundneeded items
Use moreconvenientcleaningtools
Set up acleaningschedule
Draw lines toseparatepassagewaysfor people
Use labels tosimplifyretrieval-
Preventmachinesfrom gettingdirty
Eliminatehazards
Reduceexcessinventory-
Placefrequentlyused itemsclose by
Combinecleaningwithinspection
Introducecreativethinking
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4 1
Seiketsu:
Shitsuke:
How to do 5S Step by Step PASSPORT TO SUCCESSFUL 5S
5S is fundamental to productivity improvement
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checkpointsscore score
The 5S Activity Bulletin Board is well-
organized and data are updated
The locations for materials, components and
work-in-process are labeled for easy retrieval
Dies, jigs, fixtures and tools are conveniently
located so that there is no need to search
Bolts, nuts, components and other materials
are not kept on the floor
Passages and operation areas are clearly
indicated and separated by distinct lines
Failures found are immediately fixed (uneven
floor, projections, machine failures, etc.)
Areas difficult to clean are cleanedperiodically
Without searching tools or documents can be
retrieved in less than 30 seconds
Rules for 5S practice are implemented and are
observed without prompting
A 5S patrol is regularly conducted by
supervisors for continued improvement
5S inspections are practiced and recorded at
starting and closing times
Jigs and tools are easy to return to their
designated locations
Dirt and stains on machines are removed
immediately
Things that cause dirt or stains are eliminated
-
Tools and measurement devices are
periodically checked and failures are fixed
People are active in implementing Kaizen for
the improvement of safety, quality and cost
Violators of rules are warned by colleagues
-
Components, tools and documents are labeled
and easy to retrieve
Rules are strictly observed (punctuality,
cleaning at the end of the day, etc.)
5S is well maintained and upgraded through
creative activities
checkpoints
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1 Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1
Checklist for Step 3 Checklist for Step 4 3
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checkpointsscore score
The 5S Activity Bulletin Board is well-
organized and data are updated
The locations for materials, components and
work-in-process are labeled for easy retrieval
Dies, jigs, fixtures and tools are conveniently
located so that there is no need to search
Bolts, nuts, components and other materials
are not kept on the floor
Passages and operation areas are clearly
indicated and separated by distinct lines
Failures found are immediately fixed (uneven
floor, projections, machine failures, etc.)
Areas difficult to clean are cleanedperiodically
Without searching tools or documents can be
retrieved in less than 30 seconds
Rules for 5S practice are implemented and are
observed without prompting
A 5S patrol is regularly conducted by
supervisors for continued improvement
5S inspections are practiced and recorded at
starting and closing times
Jigs and tools are easy to return to their
designated locations
Dirt and stains on machines are removed
immediately
Things that cause dirt or stains are eliminated
-
Tools and measurement devices are
periodically checked and failures are fixed
People are active in implementing Kaizen for
the improvement of safety, quality and cost
Violators of rules are warned by colleagues
-
Components, tools and documents are labeled
and easy to retrieve
Rules are strictly observed (punctuality,
cleaning at the end of the day, etc.)
5S is well maintained and upgraded through
creative activities
checkpoints
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1 Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1
Checklist for Step 3 Checklist for Step 4 3
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PHASE PREPARATION PENETRATION AND ADVANCEMENTSTEP
SUPER 5S PROGRESS CHART FOR TWO-YEAR MASTER IMPLEMENTATION PLAN
MONTH
MAINTENANCE AND UPGRADING
Preparations* Understanding philosophy and benefits of Super 5S by CEO* CEO s visit to Super 5S model companies* CEO s commitment to Super 5S implementation
* Organize Super 5S Working Committee* Appoint Super 5S facilitators* Train Super 5S facilitators and practitioners
CEO s Official Announcement
* CEO officially announces implementation of Super 5S for 2 years
* CEO explains objectives of Super 5S program to all colleagues* Publicize Super 5S organization and assignments by area* Promote Super 5S with banners, posters and newsletters* Organize basic Super 5S training programs for all colleagues
Big Cleaning by All Colleagues* Organize a full-day of Big Cleaning Day twice a year
* Organize small groups who are responsible for assignments in dividedareas of the company s premises.
* Provide enough cleaning tools and materials* Implement a company-wide big cleaning for one day* Big cleaning includes the elimination of unnecessary items and wastes
Initial Seiri* Establish a Disposal Standard for unnecessary items* Organize a full-day of Seiri activity twice a year
* Everyone concentrates to identify and stratify unnecessary items forelimination* Unnecessary items that cost a lot should be evaluated so as to preventthe occurrence of such waste
Daily Seiri, Seiton and Seiso* Seiri: Throw away things that are not needed and not being used* Seiton: Improve locations and methods for storing things so that
searching time is minimized* Seiso: Set up a daily cleaning schedule for the creation of a healthy andcomfortable workplace
* Motivate colleagues to come up with creative improvements
Periodic Audits on Super 5S* Establish a Super 5S evaluation and incentive plan
* Conduct a Super 5S audit regularly by auditors* Organize a Super 5S inter-departmental competition for upgrading* Award groups and individuals for their contributions
* Organize study tours to other companies doing Super 5S* Organize Super 5S inter-company competition to sustain the program
SUPER S PROGRAMS
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