Bulletin EQM 89 - 5S
Bulletin EQM 89 - 5S
Bulletin EQM 89 - 5S
GOOD HOUSEKEEPING
TECHNIQUES FOR ENHANCING
PRODUCTIVITY, QUALITY AND
SAFETY AT THE WORKPLACE
5S:
GOOD HOUSEKEEPING TECHNIQUES FOR
ENHANCING PRODUCTIVITY, QUALITY AND SAFETY
THE WORKPLACE
This bulletin provides information on 5 S good housekeeping techniques which can be used as a tool for systematic approach for productiv
The designations employed and the presentation of material in this document do not imply the expression of any opinion
whatsoever on the part of the International Trade Centre concerning the legal status of any country, territory, city or area or of its
authorities, or concerning the delimitation of its frontiers or boundaries.
This document has not formally been edited by the International Trade Centre.
Contents
1. What is 5S all about? 12. What is the meani
Annexes
I. Diagnostic Checklist for 5S 11
II. Applying 5S in a Quality Improvement Project in the Light Engineering Sector (LES)
in Bangladesh 14
Table 1. The five steps of Japanese 5 S 1Table 2. Sort - Seiri
EXPORT QUALITY
BULLETIN
NO 89/2012
QUES FOR
UALITY AND SAFETY AT
as a tool for systematic approach for productivity, quality and safety improvement in all types of business.This bulletin has been prepared, without forma
11
or (LES)
14
1Table 2. Sort - Seiri 4Table 3: Set-in-order - Se
1. What is 5S all about?
5S is amongst the first and fundamental steps implemented by an enterprise towards the path of implementin
Quality Management and continuous improvement at the operation level. 5S is a process designed to organi
workplace, keep it clean, maintain effective and standard conditions. It instils the discipline required to
individual to achieve and maintain a world-class environment.
The use of this tool was started in 1972 by Henry Ford in the United States as the CANDO program
Cleaning up, Arranging, Neatness, Discipline and Ongoing improvement. The technique was populariz
‘Japanese 5S’ in 1980 by Hiroyuki Hirano.
Many enterprises have practiced the 5S and derived significant benefits from it. In particular, this tech
been widely practiced in Japan. Most Japanese 5S practitioners consider 5S useful not just for improving t
environment, but also for improving their thinking processes too. In Japan it is also called ‘workplace m
5S will be needed if the workplace is messy and unorganized. It will also be needed if employees spend extra t
searching tools, papers, information, etc.
Seiton (Set in order) Enforce the dictum ‘a place for everything and everything in its place’.
Seiso (Shine) Clean up the workplace and look for ways to keep it clean.
Seiketsu (Standardize) Maintain and monitor adherence to the first three Ss.
Shitsuke (Sustain) Follow the rule to keep the workplace 5S-right. Hold the gain.
ces or set up so that they are readily available for use, eliminating
y placed for quality and safety, it can then be deemed that the
at items are needed, Seiton helps you to decide the way things are to
Table 3: Set-in-order - Seiton
Meaning Methods
Arranging items in such a manner that they are easy If necessary, reassign spaces, racks, cabinets, etc.
to use. Decide the right places for everything.
Labelling them so that they are easy to find and put Put all materials and equipment at a place
back. allocated to them with proper label or signalization.
This means a place for everything (necessary) Use alerts or indications for out-of- stock situations.
and everything in its place. No more Use floor paint marking to define working area,
homeless items.
path, entrance/exit, safety equipment, cart/ trolley
locations, etc.
Use standard colour coding for pipelines for
steam, water, gas, drainage, etc.
Use display cautions, messages, instructions at
proper place at proper height and written clearly
nna.com )
Table 3. Shine - Seiso
Meaning Methods
This means removing dirt, strain, filth, soot Divide the total area in zones and allocate
and dust from the work area. responsibility for cleaning for each zone.
This includes cleaning and care for
equipment and facilities and also
inspecting them for abnormalities. In Decide on cleaning points, order of cleaning, type
a way it also includes primary maintenance of cleaning, cleaning aid required, etc.
of equipment.
Note: Cleaning is not polishing, etc.,
Display cleaning schedule.
to make the piece of equipment
more beautiful – it looks after its During cleaning look for defective conditions
condition and fitness for use. (loose bolts, vibrations, excessive sound, high
temperature, fallen tools, etc.) and solve the problem.
S’s, Seiri, Seiton, and Seiso a constant routine. The emphasis here is on
ndardized conditions to enable the individuals always act quickly (Osada,
g.com)
Table 4. Sustain - Shitsuke
Meaning Methods
Sustain also means Create awareness and publicize the system. For example develop
‘Discipline’. It denotes your 5S News, 5S Posters, 5S Slogans, 5S Day, etc.
commitment to maintain
orderliness and to practice first 3S
as a way of life. This also requires Create a structure of how and when 5S activities will be
that your employees show implemented.
positive interest and overcome Formulate guidelines for audit/evaluation of 5S implementation.
resistance to change.
REFERENCES
Harper-Franks, Kathy; The 5S for the Office User’s Guide. Published by MCS Media Inc., 2008 Hirano, Hiroyuki. 5S for Operators:
Benefits
Promotes habit for
complying with workplace rules
and procedures.
Creates healthy atmosphere and a
good work place.
Helps you to develop team work.
Provides you with data for
improving 5S.
Media Inc., 2008 Hirano, Hiroyuki. 5S for Operators: 5 Pillars of the Visual Workplace. Productivity Press, 1996. Ho, Samuel K. TQM: An Integrated app
ANNEX I: DIAGNOSTIC CHECKLIST FOR 5S
Use the scoring table below to rate your progress with 5S. Total your score and check against the Assessment Report table at the end.
SCORING TABLE
0 Not at all.
5S - CHECKLIST
REQUIREMENT SCORE*
2.1 Are direction indications available to all facilities from the entrance
onwards?
2.2 Do all items of equipment have identification labels?
2.3 Are all rooms, cubicles and similar areas clearly numbered or named?
REMARKS
SCORING TABLE
Score* Stage of readiness
0 Not at all.
5S – CHECKLIST (CONTINUED)
REQUIREMENT SCORE*
3.0 SHINE-SEISO
5.1 Is there a system for how and when the 5S activities will be implemented?
TOTAL SCORE
REMARKS
Assessment report
(Add the score obtained and check the assessment)
Score Percentage Maturity
level
Less than 30 Less than 25% Lack of awareness
More than 30 and More than 25% and less No formal approach
less than 60 than 50%
More than 60 and More than 50% and less Formal approach
less than 90 than 75%
Annex II: Applying 5S in a Quality Improvement Project in the Light Engineering Sector (LE
Bangladesh
Context: Bringing the LES to the level of quality management (QM) by firstly making the industry aware of syste
of good housekeeping and quality control (QC) practices.
The Bangladesh Quality Support Programme (BQSP) had two components, one implemented by UNIDO for strengthening the qualit
infrastructure and the other by ITC for export diversification. The ITC component in particular assisted Bangladesh in harmonising th
all relevant stakeholders through the development of export strategies at sector level using value chain approach and focusing on su
management, quality and food safety management and packaging to achieve export diversification objectives by enhancing the comp
and quality of products.
Objective
The objective of ITC interventions was to contribute to implement some of the recommendations for quality improvement included in
document “A strategy for developing the light engineering sector in Bangladesh”:
Lack of standards and quality of product.
Develop quality gradually into world-class quality.
Build capacities for manufacturers to meet export requirements in terms of quality and production volume through trai
involving quality control and quality assurance.
In the implementation plan of the above strategy document, inter alia, the following two activities have been suggested:
- Regularly organize group training courses on quality control and safety awareness.
- Develop quality management guidelines.
Testimonials on results of 5S
“ITC project has been well received by the industry in the LES which is in a very nascent stage in Bangladesh. All the assisted
enterprises have found Japanese 5S as a very simple and good tool to practice and they demonstrated this by initiatin
implementation of 5S in a short period of time of six months. QCS practices were also understood well by them and the
QCS Manual, now developed by four enterprises with project assistance, will guide them to continue practicing QCS. The
TCCs have also taken keen interest in practicing these two concepts (5S & QCS) and they could get hands on experien
in implementing them in small companies. These TCCs can continue assisting other companies in future. This is a
unique example of capacity building.”
- Mr. Arora, ITC International Consultant
“Our factory is now more organized and tidy, stores and warehouses are well arranged and productivity has also increased
considerably. We are confident that the Quality Policy and Quality Manual now introduced will enable us in achieving better
quality control which will contribute in boosting our exports which we have recently ventured into. We assure top
continuous endeavour in conforming and improving our 5S and QCS practices for our greater benefit. Thanking once again
to the International Trade Centre, Geneva, for its invaluable contribution.”
- Mr. Fazle RM Hasan FCA, Managing Director, North Bengal Cycle Industries Ltd. Mirzapur
“We are happy to say that we have very much benefited from the ITC assistance, for example, we had the opportunity to atten
training workshops which helped us review our understanding of quality and good housekeeping. We have modified our
layout to make it safer. We have eliminated many unnecessary items from the factory which gave us more space to do value
adding activities. Store activity is more organized now. We do problem solving in a more organized way following the workforce
become more efficient. We have also prepared a Quality Manual compiling our 5S and quality control activities. We will continu
our journey towards improving our 5S and QCS practices and adopt this knowledge in other units of our group of
companies.”
- Mr. Shiblee Noman, Chief Engineer, Sigma Technologies Ltd, Dhaka
ment)
Assessment
You are on the right track. If your score is close to 90 then you have fully implemented
first 4S. At this stage your work place should have a general appearance of orderliness
and cleanliness
Your management is committed to maintain 5S and employees are showing positive
interest in 5S activities
l of quality management (QM) by firstly making the industry aware of systematic use
ntrol (QC) practices.
e (BQSP) had two components, one implemented by UNIDO for strengthening the quality
rt diversification. The ITC component in particular assisted Bangladesh in harmonising the efforts of
pment of export strategies at sector level using value chain approach and focusing on supply chain
ement and packaging to achieve export diversification objectives by enhancing the competitiveness
ontribute to implement some of the recommendations for quality improvement included in the
ht engineering sector in Bangladesh”:
uct.
-class quality.
to meet export requirements in terms of quality and production volume through training
nce.
ve strategy document, inter alia, the following two activities have been suggested:
urses on quality control and safety awareness.
nes.
m BQSP assistance. By
better working
our productivity by 30%. By
sting and machining we
returns from market from
ncreased by 20%. We are
recently selected by a big
hand pump components. We
ations for the valuable
port provided by the local
us in implementing 5S and
Razul Karim, Proprietor,
m BQSP assistance. By
better working
our productivity by 30%. By
sting and machining we
returns from market from
ncreased by 20%. We are
recently selected by a big
hand pump components. We
ations for the valuable
port provided by the local
us in implementing 5S and
Razul Karim, Proprietor,
was imparted to 40 delegates from small enterprises and other stakeholders and 15 potential Trainers-
erprises along with 6 TCCs, selected for assisting the enterprises, received two-day training on quality
y support to implement 5S and QCS by International Consultant and TCC attached to each enterprise
conducting training on 5S and QCS to other key players in the sector
were disseminated in an experience sharing workshop attended by 51 delegates from LES both from
and sales volume and reduction in waste and product returns)
Testimonials on results of 5S
ustry in the LES which is in a very nascent stage in Bangladesh. All the assisted
very simple and good tool to practice and they demonstrated this by initiating
of six months. QCS practices were also understood well by them and the
prises with project assistance, will guide them to continue practicing QCS. The
ng these two concepts (5S & QCS) and they could get hands on experience
These TCCs can continue assisting other companies in future. This is a
ores and warehouses are well arranged and productivity has also increased
y Policy and Quality Manual now introduced will enable us in achieving better
ting our exports which we have recently ventured into. We assure top
oving our 5S and QCS practices for our greater benefit. Thanking once again
for its invaluable contribution.”
tor, North Bengal Cycle Industries Ltd. Mirzapur
benefited from the ITC assistance, for example, we had the opportunity to attend
our understanding of quality and good housekeeping. We have modified our
any unnecessary items from the factory which gave us more space to do value
ed now. We do problem solving in a more organized way following the workforce to
d a Quality Manual compiling our 5S and quality control activities. We will continue
QCS practices and adopt this knowledge in other units of our group of
Source: ITC
AFTER