By George Murigi

Objectives

To understand the importance of 5s to our Lean
initiatives.

To know what the 5Ss are and know the key
benefits of each.

Identify and overcome the barriers to
productivity

To be able to participate in group and individual
5s activities.

Improve quality of work

Practice efficiency at all times.

Contents

5S Introduction
5S Steps
Hints on 5S implementation
5S and TPM implementation
Syndicate exercise

Introduction

TPM Pillars
TPM

Safety, Health,
Environmental
Administration

Quality

Early Equipment
Management

Training & Education

Planned Maintenance

Focussed Improvement

Autonomous Maintenance

Introduction

5S
Clearing (Sort)
Organising (Set)
Cleaning (Shine)
Standardising (Standardise)
Discipline (Sustain)

Introduction
5S is a system to reduce waste and optimize productivity through maintaining an orderly
workplace and using visual cues to achieve more consistent operational results.
Implementation of this method "cleans up" and organizes the workplace basically in its
existing configuration, and it is typically the first lean method which organizations implement.
The 5S pillars, Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardize (Seiketsu), and
Sustain (Shitsuke), provide a methodology for organizing, cleaning, developing, and sustaining
a productive work environment. In the daily work of a company, routines that maintain
organization and orderliness are essential to a smooth and efficient flow of activities. This lean
method encourages workers to improve their working conditions and helps them to learn to
reduce waste, unplanned downtime, and in-process inventory.
A typical 5S implementation would result in significant reductions in the square footage of
space needed for existing operations. It also would result in the organization of tools and
materials into labeled and color coded storage locations, as well as "kits" that contain just what
is needed to perform a task. 5S provides the foundation on which other lean methods, such as
TPM, cellular manufacturing, just-in-time production, and six sigma can be introduced.

The 5S Pillars
Sort. Sort, the first S, focuses on eliminating unnecessary items from the workplace
that are not needed for current production operations.
An effective visual method to identify these unneeded items is called "red tagging",
which involves evaluating the necessity of each item in a work area and dealing
with it appropriately. A red tag is placed on all items that are not important for
operations or that are not in the proper location or quantity. Once the red tag items
are identified, these items are then moved to a central holding area for subsequent
disposal, recycling, or reassignment. Organizations often find that sorting enables
them to reclaim valuable floor space and eliminate such things as broken tools,
scrap, and excess raw material.

Introduction

Our Environmental (Generally)

Introduction

Just across the Road...

Introduction

Our Environmental (Generally)

5S Steps

5S Steps

Clearing
To do this you may need to develop a policy or fix
some rules, i.e.
 Low priority items may be stored in a distant
place.
 High priority items may be kept in a designated
area.
The team should agree the rules and must stick to
them.
A red tag is affixed to each item that is put into the
Red Tag area.

5S Steps
Stratify Strategy for Clearing (Seiri)
Separate necessary items
from unnecessary items and
discard unnecessary items.
Categorise items according
to their frequency of use,
importance, storage space
required or the place
requiring the item, for
Example, control the
categorised items
according to their type.

Red Tagging
Red Tag is one of the implementation plans for Sort
(seiri), part of the kaizen strategy of workplace
improvement.
A method of identifying potentially unneeded items
in the work area.
Ensures that no needed items are accidentally
disposed of.
Allows us to evaluate the usefulness of an item by
segregating it when we are unsure of its use.

Red Tagging
The three questions to ask
- Is this item needed?
- If it is needed, is it needed in this quantity?
- If it is needed, is this the best location for it?
Holding areas
- A safety net between questioning whether
something is needed and getting rid of it.
- Items are held for a set time (30 days?).
- Notices are put out for unknown items so that they
may be claimed by anybody who has a genuine need
for them.
After the allocated time, unwanted items are disposed of.

Red Tagging Aims

Define the necessity of the item in order to perform
the work required on a day to day basis.
- If it isnt needed it should be disposed of.
Determine the frequency with which the item is
needed.
- If its needed infrequently it can be stored away
from the work area.
Decide the quantity of the item required to perform
the regular work.
- Excess items can be disposed or stored away.

Sample

Sample

Example of a red
tag station

Example

Example

5S Steps
Clearing - (Remember to take photos for the Before
and After to gauge the work done)

Different part in red tag zone after the clearing step

Clearing up the red tag zone

5S Steps
After Clearing

Before

After

Benefits of Seiri (
,
sort)
a) Remove unnecessary items and dispose of them properly
b) Make work easier by eliminating obstacles
c) Reduce chance of being disturbed with unnecessary items
d) Prevent accumulation of unnecessary items
e) Evaluate necessary items with regard to dept/cost/other
factors.

5S Steps

5S Steps

Organising
Workplace organisation
 to fix the layout of tools and equipment
 everything should be readily available when
needed.
Everything needed should be Easy to see, Easy
to retrieve, Easy to use, Easy to return.

4E Philosophy

5S Steps
Organising
Useful check points for a organised workplace:
1. Are tools divided into specialised use and regular
use items?
2. Is the number of tools required kept to a minimum?
3. Are pallets, waste bins, hoses always placed in the
correct location?
4. Is anything stored around safety or fire fighting
equipment?
5. Are positions of main corridors and aisles clearly
marked?
6. Can you immediately and safely find the items you
need?

5S Steps

5S Steps

Organising (Examples)

Visual indications to easily show

visibility of tools and equipment

5S Steps
Organising (One more Example)

Shadow boards for

tools

5S Steps
Organising (5S Cabinet - Example)

5S Steps
After Organising

Benefits of Seiton (? )
1) Arrange all necessary items in order so they can be
easily picked for use
2) Prevent loss and waste of time
3) Make it easy to find and pick up necessary items
4) Ensure first-come-first-serve basis
5) Make work flow smooth and easy
6) Can also be translated as "set in order"

5S Steps

38

5S Steps

Cleaning
Cleaning sounds simple enough, but it
involves a host of activities:
removing from the workplace everything
that should not be there
maintaining everything (that should be
there) in the best possible condition by
constant checking and constant care
Ultimately then "cleaning is careful
checking"

5S Steps

Cleaning
Before

After

5S Steps

Cleaning

Before...

Leaks all over the floor and no name

indications of the equipment

5S Steps

Pilot equipment

After...

5S Steps

Cleaning How to do it ?
Dividing zones/dividing roles
Indicate the role each person is to play (area of
responsibility)
Responsibility maps and check lists are
effective
Implement cleaning by area/equipment
Careful and systematic cleaning of particular
areas and equipment will help spot potential
problems
Not simply wipe off dust - Cleaning is
Inspection.
43

5S Steps

Cleaning How to do it ?
Implementing improvements
Speed up the cleaning process
Make difficult/dirty places easier to reach and
access. (DTAs)
Eliminate sources of contamination (SOCs).
Defining rules for the team (Code of Conduct)

5S Steps
Cleaning How to do it ?
Introduce a plant slogan

Take 5 minutes for 5S

Take the time to make it shine!!

5S Steps

After Demarcating

Area of operation

Benefits of Shine
Machine reliability
- Easier to identify issues on clean machines,
meaning they can be addressed sooner.
- Cleaning is a form of inspection.
Equipment / Tools
- Clean equipment functions more effectively.
- Easier to spot damage or wear on clean
equipment and tools than on dirty ones.

5S Steps

5S Steps

Standardising
The state that exists when the first 3 S's are
properly maintained.
 make sure that clearing, organising and
cleaning are being maintained and incorporated
into everyday activities.
 identify, eliminate or take preventive action to
help prevent 3S conditions to deteriorate.
A never-ending activity!

5S Steps

Standardising
People should have clear job assignments based
on their own workplaces.
A useful tool is the 5S Map:
 it shows how the workplace is divided into
sections and lists names of the people
responsible for maintaining 5S conditions in
those areas
 it makes 5S job assignments visible at a
glance.

5S Steps

After Standardising
Note the exact number
of items piling up the
standard

Benefits of Standardising
Safety
- Walkways and floors are kept clear and hazard
free.
Efficiency
- Storage areas remain organised.
- Materials, tools and equipment remain
organised and cared for.
We maintain all the benefits gained from Sort, Set
and Shine.
We have a template for expanding the 5s area
across the whole plant.

5S Steps

5S Steps

Discipline
Defined as "making a habit of properly maintaining
correct procedures".

So what happens to 5S Programmes that do not

keep discipline?

5S Steps

Discipline 5S Audit
5 S

Audit

(Produktie Afdeling)

Datum Audit: 19-02-2001

Datum volgende audit: WEEK 12 2001

Afdeling: VERWERKING
Machine: MID 2 (PILOT LIJN)
Audit uitgevoerd door: SHIFT A
Onderwerp:
0

score:
2
3

Opmerkingen:
4

Wordt 5 S als prioriteit binnen de afdelings doelstellingen

gezien
P
R
O
M
O
T
I
E

Is er tijd voor de 5 S implementatie gereserveerd

Heeft iedereen informatie ontvangen betreft wat 5 S kan
inhouden en wat de werkzaamheden inhouden (bewustzijns
training)
Zijn er duidelijke doelstellingen voor 5 S afgesproken
(tijdspad)

Nog niet voor Alle stappen

Is iedereen aan board , en wordt het nut van 5 S in gezien

Is het 5 S gebied duidelijk afgebakend en zijn de
verantwoordelijkheden duidelijk afgestemd

Gebieden zijn afgestemd, verantwoordelijkheden nog niet

Is er een open cultuur waarin een ieder zich op zijn gemak

voelt en waarin alles gezegd kan worden

Heel af en toe zijn er wat irritaties over de shiften heen welke uit eindelijk wel uitgesproken worden

Is er een 5 S activiteiten bord, (waar duidelijk, het team, de

doelstellingen,activiteiten, verantw, overleg structuur, ed) up to
date gehouden wordt
Is er budget gereserveerd om kleine verbeteringen door te
voeren

Ja, per maand is er 1000,- verbeter budget uitgetrokken, voor zaken zoals: verf, plakband,stofzuiger, etc

Is de Omgeving rond de Installatie, vrij van niet relevante

materialen
O
P
R
U
I
M
E
N

O
R
G
A
N
I
S
E
R
E
N

Liggen er machine onderdelen die niet gebruikt worden

Er sta nog een krik achter de multipal wat daar niet hoort

VISUALISATIE, niet relevante materialen zijn in een

oogopslag te herkennen.

Ja, voorlopig liggen deze in de rode zone

is er een STANDAARD VOOR AFVAL VERWERKING,

Ja, er zijn duidelijke regels, alleen liggen deze niet vastgelegd

Bureaus en werktafels zijn opgeruimd

Ja, nog wel aandacht geven aan de maximale voorraden in de bureau laden

er zijn geen overbodige materialen meer te vinden rond de

installatie, of deze moeten voorzien zijn van een tagging
OPSLAG LABELS, labels op kasten, laden,
tafels,gemarkeerde plaatsen, etc. vertellen in een oogopslag
de inhoud
DOKUMENT EN ONDERDELEN LABELS, alle materialen zijn
voorzien van een label en een index
GEBRUIKSGEMAK, de benodigde materialen en middelen
zijn makkelijk in gebruik en toegankelijk
VASTE PLAATSEN, alle materialen hebben een vaste plaats
en zijn duidelijk gemarkeerd
PADEN EN BORDEN, alle paden zijn duidelijk gemarkeerd,
en borden hebben een duidelijke indelingen

S
C
H
O
O
N
M
A
K
E
N

VLOEREN, de vloeren zijn schoon

STOF EN VUIL, ramen, afschermingen, bureaus, werktafels
zijn opgeruimd en schoon
VERANTWOORDELIJKHEDEN, er zijn duidelijke
verantwoordelijkheden op roulatie basis afgestemd
AFVALBAKKEN, er is een duidelijk gescheiden afval systeem,
welke goed wordt onderhouden
GEWOONTE, stoffen, vegen, en schoonmaken is een
dagelijkse gewoonte

S
T
A
N
D
A

VENTILATIE, de lucht is schoon,reukloos,

LICHT, de licht verdeling en sterkte is goed

5S Steps

Discipline Lack of Discipline

1. The workplace would become dirty and chaotic
again.
2. Unneeded items would soon begin piling up.
3. People would neglect to wear their PPE and
eventually sustain an injury.
4. Equipment malfunction and defective products
5. Customers would become disgusted by our dirty
and disorganised factory.

5S Steps
Discipline Important Hints
1. Total team involvement and focus on the challenge is vital
2. Develop complete visual control to make maintaining the standards as
easy as possible
Remember it's about working smarter not
harder!
3. Use Fixed position photographs of before, during and after to display
your efforts.
4. Use specific audits to evaluate your 5S effectiveness

5S Steps

Building the Discipline

Provide activity boards

for performance follow up

5S Steps

Discipline Activity Board (Example)

Activity Board - 5S
5S Progress
TEAM

AUDIT PLAN

ACTION
PLAN

ACTION
PLAN

ACTION
PLAN

ACTION
PLAN

ACTION
PLAN

5S
VISION

AUDIT SHEET

TAGS
CONTROL

TAGS
CONTROL

TAGS
CONTROL

TAGS
CONTROL

TAGS
CONTROL

BENEFITS

BENEFITS

BENEFITS

BENEFITS

BENEFITS

OPL

OPL

OPL

OPL

OPL

OPL

OPL

OPL

STANDARD

OPL

5S
MISSION

LAY OUT

OBJECTIVES

IMPLEMENTATION
PLAN

TOTAL TAGS
PROGRESS

5s Radar Chart

5S Steps
Discipline Activity Board (Example)
Line Layout

Team Infor.

Line Infor.

OEE
Autonomous
Maintenance

Tag-list
OPL

5-S
Red Tag
list

Work
request

Results
Autonomous
Maintenance

Results
5S

Hints on 5S implementation

5S Hints to start up

Select a Pilot area for 5s

Document the current situation. Photograph
Conduct a Risk Assessment
Define what can be achieved. Set the Vision.
Establish resources required
Plan the approach and communicate
Share equally the responsibilities
Monitor via auditing
Measure the benefits

Hints on 5S implementation

5S Hints to start up

And of courseII...Continuously
Improve!!

5S and TPM implementation

Waste & loss
Programme
12

Training

Autonomous
Maintenance

10
Continuous
8 improvements

Factory
6
Goals

Safety &
Environment
Effective
Maintenance

4
2
0

5S
Time

TPM in
Administration

5S and TPM implementation

Safety and Environ.

Continuous Improve.
Effective Maintenance

Autonomous Maint.
TPM in Administration

Training

5S implementation

5S by Teams

Using the sophisticated equipment supplied and the

materials (e.g.: radar, audit sheet, typical activity board,etc)
available be inventive, imaginative, resourceful in
demonstrating:

Clearing, Organising, Cleaning,

Standardising & Discipline
(Seiri, Seiso, Seiton Seiketsu and Shitsuke)
Where: YOUR Syndicate Room
Important Note
Remember that 5s needs to be applied during the 2 weeks