How to create a 5-S Workplace

How does your workplace look like? 

What and how does your workplace look like, be it a work-table, an office, the entire plant site or your work-bag while moving around in market-field:

Do you have to search for things, tools, parts, papers needed for the process you wish to perform? 
Do people throw things around at workplace carelessly? 
Is the workplace polluted by dusty, dirty, and unsafe (or dangerous) situations.
Are there frequent breakdowns of equipment?
Is morale of employees and/or other stakeholders down due to recurring irritations such as above?
Does your customer-delivery process-flow get affected due to delays, quality issues?

If yes, then it is most likely that Cost-of-Poor-Quality (CoPQ) built into your company's Profit & Loss account is more than 1
5% of the Total Costs of Operations

Apart from this your own as well that of other's Safety, Hygiene, and even Environment is at stake.

And in order to overcome this danger, you badly need Five-S!

For Various Posters such as aboveClick here to see Table of Contents
Pictures here-above are PURPOSELY KEPT  in LOW RESOLUTIONClick here to see Actual Resolution YOU will GET
Why Five-S?

The objective of 5-SYou need 5-S in order to - create Visual-Factory-Workplace & - save tangible costs such as above along with corresponding intangibles such as to improve morale and improve engagement of your stakeholders/employees.


What is Five-S?

5-S is a management innovation evolved by Japanese industry from commonsense living practices. 

Easy to remember 5-English-words having nearly the same meaning are: 

1/ Sorting Out for Seiri
2/ Systematic Arrangement for Seiton
3/ Shine or Spic-n-Span cleanliness inspection for Seiso
4/ Standardizing for Seiketsu and 
5/ Self-Discipline and Training for Shitsuke.

Seiri-based improvements for instance help in making a workplace transparent, free-of-clutter and hold-ups. 

Thereby it facilitates interruption-free, smooth-flow of processes and hence reduced Cost-of-Poor-Quality (CoPQ) as a result of eliminated causes of costs


How does Five-S help in making workplace competitive

There was this rack full of clutter above kitchen platform in an apartment. A piece of nylon cloth from it fell over the gas stove below and became the cause enough to set the house on fireIn another case, there was this snack-shop (a part of a quick-service-restaurant: QSR retail-chain outlet) that had cartons on floor spilled with frying-oil on it that caught fire. 

Can you now imagine the importance of 'costly' lesson that they learned post-the-fire on doing Seiri-principle based improvements that of preventing clutter on the floor?

Seiton-based improvements neatly arrange the workplace so that the needed things are available within reach and within a few seconds. 

Seiso based improvements, make the workplace cleaner, 

breakdown-free and defect-free by eliminating it's root causes

Seiketsu helps to create highly standardized workplace so that repeat-ability of achieved standards is sustained. 

Shitsuke helps in creating a learning organization so that higher standards are aimed at and achieved. 


5-S thereby helps in improved productivity, quality of work and reduced costs-of-quality (CoQ) if implemented with a strategic objective in mind rather than misunderstanding it as and merely reducing it as 'rule-book-for-housekeeping'. This module shows the participants (top management in particular) of 'Why-What-How' of doing so.

What will the participants learn? – (Generic Contents for the 1+1 day duration as in the table below)

1. Preliminary-assessment by work-sampling (including Business-specific Need-assessment)

2. Base-Audit Scores, alignment on the findings and its impact on business!

3. Awareness about 5-S: What is 5-S? It's principles-&-practices.

4. How it helps improve performance and measurable goals on Productivity, Quality, Costs, Safety, Health, Morale, etc.

5. How to enable 5-S implementation (so as to create continual improvement culture) 

6. How to participate in enabling the 5-S culture?

7. Align to the 5-S Implementation Approach as follows:


How To Evolve and Undertake The IMPLEMENTATION Road-Map: A typical 4-stage journey?

Stage-1Preliminary or Preparation stage: Laying Foundation & Piloting              I- - - -I 6-months       
Stage-2Initial implementation, Pilot improvement & 'Kick-Off'                                   I- - -I 1-year
Stage-3Full implementation or full development of each 5-S-Pillar                            I- - - - - - - -I 1-to-2-years
Stage-4Maturity: Steady application & Institutionalization (Audits & Certification)               I- - - - - - - Graduate To TPM, Lean - -I

            Role of Gemba-Kaizen ActionSmall-Group-ActivityOne-Point-Lessons (OPL) & Daily Management (Nichijo-Kanriin each of 5-S-Pillars.

8. Alignment with the target audience to create a Demo-Pilot. 

9. Organise for the required improvement culture: PREPARATION of RESOURCES for the next step.

10. Interactive session in order to satisfy your business specific queries


For Activity Milestones (Tentative Themes & Contents) considered in Implementation Roadmap

Refer book 'Visual Management Through 5-S, 5-S in 5-Days: Fundamental Kaizen Tool To Create Kaizen Culture' by Shyam Talawadekar

Duration: (Session-1: (9.30 Register), Session-2: (11.30 -13), Session-3: (13.45 Report), Session-4: (15.30 -17 approx)

Learning Intensity & Objectives

Typical Program Spread and Coverage over weeks

1

2

3

4

 

 

 

Knowledge level 

Preliminary-assessment 

Comprehensive-assessment

1-day/s

1-day/s

Need-based

Awareness. Cases. Tentative Plan of Action.

Business-specific Need-assessment & alignment!

Audit Score: 'Where do you stand' vs 'Where to go'

Application level 

(As Coordinator/

Practitioner/Trainer/Auditor/Mentor)

6-days 

(spread over  

2-to-5-weeks)

Application (part of stage-1): ‘Train-The-Trainers to create a Fast-track Demo-Pilot by Gemba-Kaizen practice. Reinforce Principles and the infrastructure needed for Company-wide implementation. Evolve tentative road-map.

Advanced level 

Tools Application 

Scale-up & Certification

Need-based

Need-based

Need-based

5-S-Pillars (Each pillar to its core/depth) 

5-S tools 5-W-1-H, 5-whyOPL, etc.

Company-wide implementation 

 * Key milestones may get reorganized & reworked for depth & for greater effectiveness depending upon audience/duration/objective of the course as in the table above. 

For effective results, please ask for diagnostic questions on the above points & reply before the course.

Methodology (depending upon availability of time and teaching aids): Presentations, Case studies, Exercises, Action-oriented Gemba Kaizen depending upon the proximity of workplace, Group Discussions, Video clippings, etc. (The participant company may arrange Industrial Visits.)

Course Material: The book 'Visual Management Through 5-S, 5-S in 5-Days: Fundamental Kaizen Tool To Create Kaizen Culture'  by Shyam Talawadekar


Please do e-mail/ask for customized-contents of the module 
to create a 5-S Workplace and Road-map for the same.

For Various Posters such as aboveClick here to see Table of Contents. 
Pictures here-above are PURPOSELY KEPT  in LOW RESOLUTION
Click here to see Actual Resolution YOU will GET.