5S Sample

5S - Five
Sustain Sort
Disciplines
for High
Standardize Set In Order
Workplace
Shine Productivity
Operational Excellence Consulting. All rights reserved.

Outline
Introduction to 5S Applying 5S to:
5S Provides a Solid Safety
Foundation to Lean Quality
Implementation
Equipment Reliability
Types of Waste in the
Productivity
Workplace
What is 5S? 5S in the Office
Benefits of 5S How to Implement 5S
5S Principles - Step By Step

This document is a partial preview. Full document download can be found on Flevy: How to Sustain 5S
http://flevy.com/browse/document/5s-five-disciplines-for-high-workplace-productivity-154
How to Conduct a Red 5S Audit System

Tagging Exercise Supporting Lean Tools for 5S
Creating a Visual Workplace Critical Success Factors
Operational Excellence Consulting. All rights reserved. 4
5S Lays the Foundation for a Lean
Enterprise
Goals:
highest quality,
lowest cost, shortest lead times
Just-In-Time Jidoka
Productivity
Continuous flow Separate man &

Takt time machine work
Abnormality
Pull system Identification
Flexible workforce Poka yoke
This document is a partial preview. Full document download can be found on Flevy:
Heijunka Standardized Work Kaizen
5S

5S Integration with Corporate
Initiatives
Business Excellence
Initiatives
5S TPM
This document is a partial preview. Full document download
TQM can be found on SSSFlevy:
JIT
Safety
others

What is 5S?
Principles General Description
Remove what is not needed and keep

1S Sort
what is needed
Arrange essential items in order for easy

2S Set in Order
access
Keep things clean and tidy; no trash or

3S Shine
dirt in the workplace
Establish standards and guidelines to

4S Standardize
maintain a clean workplace
Make 5S a habit and teach others to

5S Sustain
adhere to established standards

Sort

1S : Sort Red Tagging
Red Tagging
Things to throw away
Things that are spoilt and
cannot be repaired
Red tag inspection sheet
ITEM #
DESCRIPTION:
DEPT:
USAGE:NOT REQ'D
ASSIGNED DISPOSITION TO:
NAME:
NUMBER:
DEPT:
DATE DEPOSITION
TO BE COMPLETED BY:
REMARKS:

5S Rules for Sorting
Item
Useful Unknown Useless
Keep & Monitor
Keep &
Store
Useful Sorting
http://flevy.com/browse/document/5s-five-disciplines-for-high-workplace-productivity-154 Useless
ABC Storage Dispose

2S : Set In Order
Set In Order is about locating and placing items
in an organization. It determines the rate at
which things can be located or placed.
Test: Can you find an item in less than 30 seconds?
Set In Order emphasizes on:
Functional placement of parts, tools and materials
Clearly designated names and places
Easy-to-read notice boards

Quick and easy retrieval of documents, parts and tools

2S : Set In Order - Check Sheet
Equipment Materials
Machines Raw material
Small tools Supplies
Dies Parts
Jigs Work-in-process
Bits Finished goods
Conveyance equipment Shipping materials
Cleaning equipment Cleaning supplies
Furniture Other items

Cabinets Charts, graphs, bulletin boards
Benches, tables Pens, pencils
Chairs Work clothes
Carts Helmets
Shelves Work shoes
Racks Trash cans

2S : Set In Order - Examples

Office Desk Before & After 5S
Before After
An office desk before and after conducting 5S Sort and Set In
Order. Clutter and unused items have been removed leaving
only what is needed.

3S : Shine
Principle
Cleaning as inspection
Degrees of cleanliness
Meaning
Eliminate the sources of dirt
and filth
Cleaning as a form of
inspection
Clean everything, inside out

Shine check sheet
3S : Shine Practice Tips
Paint machines, floors, walls and
ceilings
Identify the sources of dirt
Try to eliminate the need to
clean
Inspect machines and tools while
cleaning
If possible, perform some
preventive maintenance while

cleaning and inspecting

(example tightening hydraulic
hoses)
4S : Standardize
Principle
5S standardization
Visual management
Meaning
Establish guidelines
Make standards and guidelines
visual
Make standards so that any
abnormality becomes visible
Use visibility tools
4S : Standardize Practice Tips
Conduct periodic departmental 5S tours
Color-coding: gangways, pipes, directional

marks, containers, etc.
Put up warning signs, marks, labels and name

plates

Sustain

How to Sustain 5S? 1
Get management commitment
Obtain commitment from CEO and senior
management team interest in 5S must be shown
from the top
Senior management must take a strong leadership

role in 5S promotional meetings and other 5S events
Provide regular status updates to senior management,

e.g. management update by 5S committee chairman

Promote 5S in the organization
Hold 5S promotional meetings to clearly explain 5S
and to entertain all questions from all participants
Present actual examples of successful 5S

implementation
Conduct study tour to successful 5S workplaces


Conduct monthly review by 5S Committee
Tour operations and office every month
Use housekeeping criteria, e.g. audit checklist, to
evaluate each zone
Take photos of areas for improvement
Post results of before and after on notice boards
Give awards to individuals / teams / departments who

have shown improvement

5S Radar Chart
Sort
5 4.4
4
3
2
Sustain Set In Order
2.2
1 3.7
0
Standardize Shine
1.9 2.7

How to Conduct a Red Tag Sort Event:
Preparation
Information on the tag should include:
Date
Item description
Location
A reason for the tag, e.g. scrap, defective, obsolete, etc.
A tag number so it can be logged
Other items you might need

A log book
A designated sorting lot (temporary parking lot for moved items)
Boxes for small items

Tag the box instead of tagging each small item individually

How to Conduct a Red Tag Sort Event:
Sorting Rules
In the sorting area there are three dispositions rules for
red tagged items:
1. The item needs to be discarded because it is no longer
needed
2. The item is out of place and needs to be put in its
designated area
3. The item is needed to do the work and should go back to
the workstation it came from
Clear the sorting area by following these three
disposition rules. Write the disposition of each item in

your log book noting the tag number, item description,
location the item came from and its disposition.
Everyday Example: Which dial turns on
the burner?
Stove A
Stove B

Why Visual Management?
Visual measures allow everyone to know the
score and they make abnormal situations
immediately obvious
Enables everyone to see how were performing
Helps highlight problems, or variances from

standard
Encourages employee involvement and open
discussions

Visual Controls

Warning Sensors
Warning sensors signal the operator that there is a
problem. These sensors use colors, alarms, lights to get
the workers attention!
These sensors may be used in conjunction with a
contact or energy sensor to get the operators attention.
Color Code Lights connected to Micro switches

& timers
Lights

Mistake-Proofing Devices for
Sustaining Quality
Mistake-Proofing devices are failsafe devices in
machines and equipment that can self-stop in
the event of a problem
Wrong Right
Orientation Orientation

4
5S for the Operations


5S and Safety 2
Do not leave tools and equipment lying around
the workplace

5S and Safety 5
Restrict the flow of oil,
coolants and other fluids
Check equipment/machines for
leakages
Clear spillage immediately

Check first aid boxes to
ensure that medications are
This document available and
is a partial preview. Fullnot reached
document download can be found on Flevy:
their expiry dates

5S and Quality 1
Train staff on 5S
Provide on-the-job training

for new staff
Educate/Train staff to
recognize and prevent
mistakes

5S and Quality 4
Understand
internal/external
customers requirements
Built quality into the

process
Install poka-yoke
This document mechanisms to prevent
is a partial preview. Full document download can be found on Flevy:
errors

5S and Equipment Maintenance 3
Train operators to perform
simple autonomous
maintenance (AM) daily
Equipment inspection
Cleaning
Lubrication
Clean equipment/machine
after use

5S and Productivity 2
Use IT systems or
technology as an enabler
Improve your skills/

competencies
Learn and share your

knowledge with others
Provide ideas to improve
productivity

Desks 1
Dispose unnecessary items in your desk
drawers
Do not place anything under your desk
Arrange items in your desk drawers neatly for

easy retrieval

Telephones 1
Place your telephone at the
most convenient location for
easy use
Set telephone wires neatly

around your desk
Adjust the flexible cord such

that it is not entangled

Office Machines 2
Reset office machines for ready use for the next
person
Remove jammed paper from the photo-copying

machine
Inspect machines regularly and take actions for

required servicing
Put up out of order signs on office machines
that need servicing

Intranet & Shared Folders
Categorize information for ease of searching
SOPs, forms, etc.
Update information as necessary
Remove outdated information

Housekeep shared drives and folders once a year
Report broken links to the webmaster

Guest Rooms
Return tables and chairs to their original
locations after use
Put all cups and saucers away after use
Clean up table tops and floor once a day

Pantries 1
Dispose refuse at least once a day
Arrange kitchen utensils neatly for easy use
Wipe away water on kitchen tables and keep

them dry

Hallways 1
Clean your shoes before entering the office
Do not smoke while walking along hallways
Do not place anything in hallways without prior

permission

Toilets 2
All users should always try to keep toilets dry,
clean and tidy
Do not smoke in the toilet
Inform the cleaners/Facility when things are not

in order
Do not wear shoe covers into and out the toilet

2. One-hour Meetings
Limit meetings to 1 hour. This will cut the
amount of time spent in meetings.
Arrange procedures and distribute the agenda before
the meeting
Minutes should be a record of decisions reached,

points for clarification and policy changes -not a
transcript of who said what
Hold meaningful meetings. Review whether or not

each meeting is really necessary. Limit participation.

6
Implementing 5S

5S : Getting Started 2
Company-wide
housekeeping
5S competitions
CEO (and 5S steering
committee) walk-about
Gemba walk
Launch a 5S Day
(see details on next slide)

Example: 5S Improvement
Project type: 5S Area: Sales & Marketing Office Team Leader: John Smith
Before After
Reasons project chosen: Results:

Difficult to move around a cluttered Unwanted materials were discarded
officeis a partial preview. Full document download can be found
This document onLess
Flevy:waste e.g. transportation,
Difficult to find information and motion, waiting, etc.
supplies Improved staff morale
Tools used on project: Next steps:
Cleaning equipment and tools Conduct monthly 5S audits
5S principles 5S for other common areas

Supporting Lean Tools for 5S
Sort
5 4.4
Drilling (20) Welding (28) Assembly (34)
4
D
3
18
A A A 19 A A
D
20 30
16
24
17
21
31
2
23
22
29
Sustain Set In Order
D 27
32
2.2 1 3.7
F
33
34
0
25
15
26 E
28 37 35
38 36
3
1
OFFICE
39
F
C 14
42
A
Packaging (44)
13
B
41
43
12
G
44
11
A 40
45
4
A 46
7
A A
B
8 5
10
9 47
2
6
A 48
Standardize Shine
G
49
X Transport using truck or man

50 1.9 2.7
Machining (10) X Inventory or buffer stocks
5. Radar Chart
51
X Value adding process
4. Spaghetti Diagram
Complaints
10
On-time Ship %
5 100%
0 50%
0%
6. Performance Chart
Summary
Clean-up and organize your
work area every day so that
each new day is easier and
safer than the day before
Share your feedback with

your leaders so that they can
better support you in
increasing
This document your
is a partial preview. efficiency
Full document download can be found on Flevy:
Make 5S a way of life @

work, home and play

5S Five Disciplines for High
Workplace Productivity

Flevy (www.flevy.com) is the marketplace
for premium documents. These
documents can range from Business
Frameworks to Financial Models to
PowerPoint Templates.
Flevy was founded under the principle that

companies waste a lot of time and money
recreating the same foundational business
documents. Our vision is for Flevy to
Contact Us
become a comprehensive knowledge base
Please contact us with any questions you may have
of business documents. All organizations, about our company.
from startups to large enterprises, can use General Inquiries
support@flevy.com
Flevy whether it's to jumpstart projects, to
Media/PR
find reference or comparison materials, or press@flevy.com
just to learn. Billing

billing@flevy.com

5S Sample

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

5S Sample

Hochgeladen von

Copyright:

Verfügbare Formate

5S - Five

Operational Excellence Consulting. All rights reserved.

Benefits of 5S How to Implement 5S

5S Principles - Step By Step

How to Conduct a Red 5S Audit System

Continuous flow Separate man &

Operational Excellence Consulting. All rights reserved. 7

Operational Excellence Consulting. All rights reserved. 10

Remove what is not needed and keep

Arrange essential items in order for easy

Keep things clean and tidy; no trash or

Establish standards and guidelines to

Make 5S a habit and teach others to

Operational Excellence Consulting. All rights reserved. 13

Operational Excellence Consulting. All rights reserved.

Operational Excellence Consulting. All rights reserved. 19

Useful Unknown Useless

Keep & Monitor

ABC Storage Dispose

Operational Excellence Consulting. All rights reserved. 22

Easy-to-read notice boards

Operational Excellence Consulting. All rights reserved. 25

Furniture Other items

Operational Excellence Consulting. All rights reserved. 28

Operational Excellence Consulting. All rights reserved. 31

Operational Excellence Consulting. All rights reserved. 34

Clean everything, inside out

preventive maintenance while

cleaning and inspecting

Color-coding: gangways, pipes, directional

Put up warning signs, marks, labels and name

Operational Excellence Consulting. All rights reserved. 46

Operational Excellence Consulting. All rights reserved.

Senior management must take a strong leadership

Provide regular status updates to senior management,

Operational Excellence Consulting. All rights reserved. 52

Present actual examples of successful 5S

Conduct study tour to successful 5S workplaces

Operational Excellence Consulting. All rights reserved. 55

Give awards to individuals / teams / departments who

Operational Excellence Consulting. All rights reserved. 58

Operational Excellence Consulting. All rights reserved. 61

Other items you might need

Boxes for small items

Operational Excellence Consulting. All rights reserved. 64

disposition rules. Write the disposition of each item in

Operational Excellence Consulting. All rights reserved. 70

Enables everyone to see how were performing

Helps highlight problems, or variances from

Operational Excellence Consulting. All rights reserved. 73

Operational Excellence Consulting. All rights reserved. 76

Color Code Lights connected to Micro switches

Operational Excellence Consulting. All rights reserved. 79

Operational Excellence Consulting. All rights reserved. 82

5S for the Operations

Operational Excellence Consulting. All rights reserved.

Operational Excellence Consulting. All rights reserved. 88

Clear spillage immediately

Operational Excellence Consulting. All rights reserved. 91

Provide on-the-job training

Operational Excellence Consulting. All rights reserved. 94

Built quality into the

Operational Excellence Consulting. All rights reserved. 97