5S METHODOLOGY HAND NOTES by ELECTRICAL ZINDAGI
Table of Contents
Introduction
5S is a simple but powerful workplace organization method that originated in Japan and forms the foundation of lean management. For electrical labs, workshops and maintenance teams, applying 5S dramatically improves safety, reduces time wasted looking for tools, and helps prevent equipment damage. These notes give a practical, hands-on guide you can apply in classrooms, small shops or large maintenance departments.
What is 5S?
5S stands for five Japanese words: Seiri (Sort), Seiton (Set in order), Seisō (Shine), Seiketsu (Standardize), and Shitsuke (Sustain). Together, these form a step-by-step routine to create an efficient, orderly and safe workplace. Think of 5S as system housekeeping with purpose — it's not cleaning for cleaning's sake but designing a workspace that prevents mistakes.
The 5 Steps (Practical)
1. Sort (Seiri): Remove unnecessary items. Tip: use red-tagging — tag unknown or unused items and move to a temporary hold area.
2. Set in order (Seiton): Arrange tools and parts so that the most-used items are nearest. Label shelves and use shadow boards for hand tools.
3. Shine (Seisō): Regular cleaning to detect leaks, wear or faults early. Include simple checklists for daily walk-arounds.
4. Standardize (Seiketsu): Create visual standards — photos of correct setups, color codes, floor markings. This makes deviations visible instantly.
5. Sustain (Shitsuke): Make 5S a habit. Use short weekly audits, and give small rewards for teams that maintain standards.
Quick Tricks & Familiar Examples
- Electrical box labeling: Use clear, printed labels and add a small photo of the breaker layout.
- Tool shadow board: Cut foam and mark outlines — you can see instantly if a tool is missing.
- One-touch bins: Arrange part bins so common resistors/fasteners are accessible with one hand.
- Daily 5-minute sweep: At shift change, do a 5-minute walk and pick up any out-of-place items — prevents pileups.
These small steps multiply: 5 minutes saved per task across a team becomes hours saved each week.
Download Hand Notes
Click the button below to download printable 5S hand notes (PDF). These are formatted for quick reference in workshops and training sessions.
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