Definition
5S provides a structured approach to workplace organization and visual discipline: Sort, Set in Order, Shine, Standardize and Sustain. TPM applies preventive and operator-involved maintenance principles to handling equipment, racks, material-handling systems and other Store assets.
Stores improvement principleRemove → Arrange → Clean → Standardize → Sustain → Maintain Equipment → Measure
5S in Stores
| S | Stores Application |
|---|---|
| Sort | Remove obsolete, broken, duplicate and unnecessary items from working areas |
| Set in Order | Assign locations, labels, racks, bins and visual identification |
| Shine | Clean floors, racks, handling equipment and storage areas |
| Standardize | Define layouts, labels, cleaning standards and inspection routines |
| Sustain | Audit, train, review and continuously improve the standard |
TPM in Stores
- Maintain forklifts, pallet trucks, cranes, hoists and other handling equipment.
- Use preventive maintenance schedules.
- Conduct operator checks before use.
- Record breakdowns and downtime.
- Control safety devices and load-rated equipment.
- Analyze recurring failures.
- Maintain critical spare parts for Store equipment.
Implementation Workflow
- Define Store zones and standards.
- Remove unnecessary materials and equipment.
- Create location and visual-management standards.
- Clean and inspect the workplace.
- Define standard work and checklists.
- Train Store personnel.
- Conduct regular 5S/TPM audits.
- Record abnormalities and corrective actions.
- Review KPI trends.
- Standardize successful improvements.
Visual Management
- Bin/location labels.
- Floor and aisle markings.
- Maximum/minimum level indicators.
- Quarantine and rejected-stock identification.
- Fire and emergency markings.
- Equipment status boards.
- Cleaning and inspection schedules.
- RGP/job-work outstanding boards.
Common Errors
- Treating 5S as one-time cleaning.
- Keeping obsolete materials in active storage.
- Unlabelled temporary locations.
- Blocked aisles and emergency access.
- Skipping equipment inspections.
- Closing abnormalities without corrective action.
KPIs
5S Audit Score
Compliance with defined Store organization standards.
Housekeeping Compliance
Completion of cleaning and inspection activities.
Equipment Availability
Availability of Store handling equipment.
Breakdown Frequency
Repeated failures of material-handling assets.
Excel / MIS Application
Track Area, Standard, Audit Date, Finding, Risk, Action, Owner, Due Date, Closure, Equipment ID, Preventive Maintenance Due, Breakdown Hours and Corrective Action.
Related Areas
Stores Management · Inventory Management · Purchase Management · Material Planning · ERP & MIS