Step-by-Step Implementation

1 PublicationSORTSETINORDERSHINESTANDARDIS ESUSTAINNATIONAL PRODUCTIVITY CORPORATIONAll rights part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the National Productivity by:National Productivity Corporation(Perbadanan Produktiviti Negara) Box 64, Jalan Sultan46904 Petaling JayaMalaysiaTel: 03-79557266 / 79557050 Fax: 03-79578068 / 79551824 983-2025-12-5 Price: RM for Productivity, Go for : GuidebookStep-by-StepImplementationVISIO NTo be a world-class productivity and quality contribute significantly towards the productivity and qualityenhancement of the nation for balanced economic provide input in the area of productivity and qualityfor policy formulation and enhance organisational and human resourcesdevelopment towards culture of lead the productivity and quality PRODUCTIVITY CORPORATIONFOREWORDThe global economic challenges have changed the perspectivesof working culture towards excellent working performance withthe adoption of best practices.

2 One of the tools to achieveorganisational excellence is the 5s management management techniques have contributed significantly toimprove internal efficiencies, operational effectiveness and fosteron time delivery system to the delight of customers. To achievethis, organisations should integrate 5S activities into their businessfunctions as their organisational Productivity Corporation (NPC) has been the leadingorganisation and disseminator of 5S best practices. It hascontinuously been improving 5S activities as a more effectiveapproach in business believe this guidebook would serve as a quick reference for 5 Simplementation and will be of benefit to all industries that strive toenhance continuous improvement for Zainiah Nik Abd RahmanDirector GeneralNational Productivity CorporationiPURPOSE OF GUIDEBOOK5S.

3 Step-by-Step Implementation guidebook is intended to explainthe 5S concept in a simplified format so as to serve as a quick5S Implementation reference for is all about knowledge transfer to facilitate the on-going learningprocess that provides you with practical guidelines and actualexamples from leading organisations on how the 5s managementtechniques guidebook offers you sufficient details on how organisationsshould integrate each S into their business function as theirorganisational culture to enhance continuous , an effective way to use this guidebook is to read anddiscuss it in group-learning sessions with the guidance of the of Guidebookii5S Management TechniquesIntroduction1 Understanding 5S2 SORT3 SET IN ORDER4 SHINE5 STANDARDISE6 SUSTAIN7 Why 5S?

4 9 What is Not 5S?9 Benefits of 5S Implementation9 Keys to 5S success10 How to Initiate 5S Implementation11 PLAN - DO - CHECK - ACTR oadmap To 5S Implementation13 Phase 1: Guidelines for 5S Preparation15 step 1: Formation of 5S Council5S Steering, Training, Promotionand Audit CommitteeRoles and Responsibilities16 step 2 : Set-up of 5S Zones17 step 3 : 5S Training18 step 4 : 5S Declaration/Launch19 Examples of 5S Preparation20 Phase 2: 5S : Step-by-Step ImplementationGuidelines for Practising SORT26 DescriptionGuidelinesPotential Impact and Actual Examplescontents Guidelines for Practising SET IN ORDER31 DescriptionGuidelinesPotential Impact and Actual ExamplesGuidelines for Practising SHINE36 DescriptionGuidelinesPotential Impact and Actual ExamplesGuidelines for Practising STANDARDISE39 DescriptionGuidelinesPotential Impact and Actual ExamplesGuidelines for Practising SUSTAIN43 DescriptionGuidelinesPotential Impact and Actual ExamplesPhase 3.

5 5S Self-Assessment and 5S Certification46 ObjectivesGuidelines for 5S Self - Assessment 5S Audit Checklists47 5S Audit Summary Sheet48 3S & Excellent Stickers495S Certification51 Phase 4: KPIs for Continual Improvement52 Importance of KPIsAdapting KPIsConclusion535S Quick Self-Assessment545S Certification Enquiries561 INTRODUCTIONT oday, it is increasingly recognised that 5S management techniquesenhance productivity and competitiveness. In order to become a WorldClass Gemba, an organisation has to go through a continuous andsystematic process to:As each 5S management techniques begins with an S, this approachhas been named 5S5S is a management tool from Japan, that focuses on establishing aquality environment in the organisation, ensuring adherence tostandards and in the process, fosters the spirit of focuses on five management techniques that are the foundationfor any organisation s competitive initiative.

6 the 5s are defined withexamples as shown on page , reduce and eliminate wasteEnhance teamworkEnhance operation efffectiveness in a better working environmentForm the basic advanced model for Productivity and Management Techniques2 UNDERSTANDING 5S3 SORTTo sort and systematically discard itemsthat are not needed in the Management Techniques4 SET IN ORDERTo arrange necessary items in a neatand systematic manner so that they canbe easily retrieved for use and to returnafter Management Techniques5 SHINETo clean and inspect the workplacethoroughly so

7 That there is no dirt onthe floor, machines and Management Techniques6 STANDARDISETo maintain a high standard of workplaceorganisation by keeping everything cleanand orderly at all Management Techniques7 SUSTAINTo train people to practise the 5s systemcontinuously so that it becomes habitualand ingrained in the culture of Management Techniques8 WinneWinnerrWinneWinnerr5 Sadalah asaskepadaadalah asaskepada5 Speningkatan produktiviti dan kualitiPeningkatan Produktiviti dan IS FUNDAMENTAL TO PRODUCTIVITY IMPROVEMENT5 STo train

8 People to practise the 5s systemcontinuously so that it becomes habitual and ingrained in the culture of sort and systematically discard items that are not needed in the arrange necessary items in a neat and systematic manner so that they can be easily retrieved for use and to return after clean and inspect the workplace thoroughly so that there is no dirt on the floor, machines and maintain a high standard of workplace organisation by keeping everything clean and orderly at all IN ORDER5S POSTERS5S Management Techniques9 WHAT IS NOT 5S ?A housekeeping exerciseA way to blame people for defectsA way to force people to do their workA way to make people work harder and fasterA monthly or yearly flavour Quality MonthWHY 5S ?

9 the 5s concept is easy for everyone to understand because:It does not require the understanding of difficult is simple, driven by logic and natural to human is within the reach of all type and size of industry OF 5S IMPLEMENTATIONT oday, many organisations have implemented the 5s system withastonishing results as voiced by our customers, the CEO s and MDs ofthe Malaysian National 5S Award Winners: We have not seen any approach to improvement that isSIMPLER or more POWERFUL that can beimplemented at LOWER COST Workplace becomes cleaner and better and office operation becomes results enhance the generation of more and better benefits are :5S Management Techniques10 KEYS TO 5S SUCCESSIn order for the 5s system to be successful, the mostimportant factor is the commitment, participation and involvement ofEVERYONE and strong visible support from topmanagement.

10 Generally, 5S activities should be carried outsystematically as follows:Lead-time reducedChangeover time reduced by streamlining and minor stops eliminated on production reduced by mistake methods and standards are inventory is usage is complaints are 5S model companies for continual everyone adequately on 5S 5S systematic approach following thePlan-Do-Check-Act (P-D-C-A) Performance Measurement and Reward Management Techniques11 Sort:HOW TO INITIATE 5S IMPLEMENTATIONThe 5S approach outlined in this guidebook is a simple and systematicmethodology which can be introduced and implemented in any sizeand type of start the 5s : Step-by-Step Implementation , each phase must bethoroughly analysed and addressed using the P-D-C-A Cycle and 5W2 Happroach as follows:Provide training and education for 5S 5S 5S objectives, goals and Implementation 5S action plan and 5S in Order:Shine:Preparation.