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In this session, I would like to talk about organization(sorting & arranging), and some essential safety rules

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Accident prevention is closely related to organization and tidying as we may say safety begins and ends with those two


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Generally, when we talk about organization(sorting&arranging), we simply think it as tidying up scattered items and cleaning them in one place, however, from a safety perspective, it holds a deeper meaning


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Shall we explore the methods of organization and essential safety rules that should be known before starting work?

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So, what is "organization"?

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Sorting refers to the act of distinguishing necessary and unnecessary items, and only keeping the right ones

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Arranging means setting items in a way that makes them easy find and use by marking their proper location and quantity

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To understand the concept of organization, it is necessary to first understand 3R5S

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3R5S was developed as one of the methods when building the JIT production system by the Deputy Manager of Toyota Motor in the 1970s

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JIT, or Just In Time production, is a concept that eliminates waste in daily life and manufacturing plants

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by managing inventory at "0" to minimize unnecessary costs

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The term 5S refers to the 5 Japanese words that start with S and was derived from the mindset of reconsidering the basics

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The purpose of 3R5S is to distinguish between normal and abnormal conditions in both the on-site and management, making it easy to identify problems and take corrective actions

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Firstly, 3R refers to visual management, making it easy for anyone to see how, how much, and where items are located by managing items

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in terms of Right Product, Right Quantity and Right Location

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Right Product is determining which products should be stored and its storage methods, then labeling those names

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Right Quantity means understanding the usage status of stored items to indicate appropriate storage quantities

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and Right Location means determining storage locations to enable visual management

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and involved in organization such as first in first outs

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Next, we will have a look at the 5S

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First is Seiri(Sorting)

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Sorting means distinguishing between necessary and unnecessary items, keeping the necessary ones, and discarding the unnecessary ones

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It involves establishing principles for distinguishing between usable, unusable, and surplus items, identifying and categorizing between unusable and surplus items, registering their status, and disposing of them

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Surplus items are those that can be reused but have a low frequency of use or should not be in the current storage location

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while unusable items are those that are useless and should be disposed of, sold, or returned to the supplier

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Second is Seiton(setting in order), which means marking proper locations and quantities to facilitate easy access to necessary items

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Arranging items neatly in rows is called "arrangement," not "setting in order"

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Designating storage areas and quantities, determining storage methods, and attaching inventory boards are part of setting in order

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Third is Seisoh(cleanling), which involves removing dust and foreign matter from areas or items after sorting, arranging, and 3Rs

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Designating cleaning areas and inspection facilities, standardizing cleaning methods, creating cleaning method and equipment inspection guidelines, and conducting small group activities based on 5S themes are part of cleaning


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Fourth is Seiketsu(hygeine)

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which involves maintaining a clean environment without dust or dirt, keeping an area clean means maintaining organization and cleanliness


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If these are not maintained, it's easy to determine whether a condition is normal or abnormal

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Lastly, fifth is Shitsuke(habituation), which means establishing habits to correctly execute designated tasks

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Conducting 5S-related education through consciousness-raising and guidance checks, establishing and operating guidance check teams, and holding regular check meetings are essential for habituation

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Among the 5S we've discussed, sorting, setting in order, cleaning, and hygiene are the means, while the end(purpose) is Shitsuke(habituation)


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5S activities without habituation result in the continuous generation of unnecessary items, failure to maintain organization, and only showing effectiveness during activities

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not contributing to productivity improvement, and resulting a passive consiousness

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Therefore, these activities should be aimed to be done habituated


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When implementing 3R5S, it's crucial to follow the sequence of sorting, setting in order, cleaning, hygiene, and habituation


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The effect of organization improves efficiency by reducing waste and cutting costs

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Long-term waste of inventory and wasted storage space are eliminated

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Moreover, unnecessary actions such as excess transportation equipment and unnecessary actions such as searching or dodging items are removed

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and other worthless actions wasting time and effort are eliminated

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Secondly, it enhances safety, leading to accident prevention

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Effective cleaning helps identify hazardous areas easily, and proper material arrangement allows for space allocation for rest and clearance of passages

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By securing only the minimum amount of materials for stacking, risks of collapse, protrusion, and handling large quantities can be minimized

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Also, in case of unforeseen accidents such as fires, well-organized fire extinguishing system allows


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for swift action and easy evacuation, consequently minimizing damage

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Thirdly, machine and equipment maintenance becomes easier


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Cleaning removes factors such as dust and sand that cause defects in machinery and equipment, extending their lifespan and maintaining performance


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Good cleaning facilitates essential managements and makes it easier to identify abnormalities

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Fourth effect is on the improvement on product quality

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By maintaining equipment and machinery, defective products are not produced, preventing deformation due to temperature differences during waiting between processes


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and ensuring the use of unspoiled materials enhances the quality

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Fifth effect is on minimizing losses during product changes

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Well-organized tools reduce search losses, enabling rapid adjustment to changed production plans within a short period