Red Tag Date 13/12/11 5S

Sort Set in order Shine Standardise Sustain Safety SORT BEFORE "Sorting" means to sort through everything in each work area. Keep only what is necessary. Materials, tools, equipment and supplies that are not frequently used should be moved to a separate, common storage area. Items that are not used should be discarded. Red Tag Date 13/12/11 Clearing the area means organising the workplace so that it is a more effective, more efficient place to work. It involves sorting out what is not needed to perform the required work in the work area. If it's not needed, remove it. Use the 48-Hour Rule Instead of keeping things around that might get used someday, apply the 48-hour rule to everything in the work area. The 48-hour rule says: If it is not going to be used in the work area within 48 hours, it does not belong there. The steps used to identify what is and is not needed in a work area and then to clear the work area of the unnecessary items are: Define what is needed. Define what is NOT needed. Dispose of the items. Take action: Sort out (move out) what is not needed and move in what is needed (and is not there now). Define what is needed When considering what is needed in a work area, don't just look at the core equipment and tools used. Consider the materials, supplies, and even the paperwork. This is also a good time to evaluate the proper quantities of items to keep in the work area. Defining what is needed in a work area is not something that can be done effectively by one person working alone; use a team representing all that work in the area. Define what is NOT needed After the team has identified what needs to be in the area, focus on all the other items currently in the work area. If an item is not needed to make the product, support the operation of the equipment, or for safety reasons, then it probably should not be kept in the direct work area. Dispose of the items Once items that are not needed in the work area are identified, it's time to disposition them and determine where they should be stored. Tag items to be removed; use a standardized set of usage-based guidelines to disposition items to be removed. Whenever possible, use data to determine the frequency of use, do not guess. The less frequently an item is used, the farther from the work area it should be stored. Take action Once items are dispositioned, it's time to take action to clear the work area and move tagged items to a temporary holding area. The holding area should be an accessible place where others not on the team can examine the items, confirm that they do not need to be kept in the work area, or discuss why they think an item is needed in the work area. Recap The goal of the first of the 5S's, Sort, is to have only what is needed for the job in the work area. The Sort phase applies to all work areas, manufacturing departments, service processes, and offices. RED TAGGING 5S

L 50 A 44 19 10 23 J 17 30 26 9 39 5 43 2 Numbers game 1 E 13 18 3 SORT – 6S K 27 21 36 B 34 I Numbers game Using a pencil or pen strike out the numbers 1 – 50 in order within the next 30 seconds… Good luck! C 22 N 31 15 4 29 8 42 46 P F 16 28 40 6 G 37 49 14 33 48 12 M The team score is the lowest score… How do you feel about the score? What got in the way? 25 41 32 7 D 38 O 20 24 11 45 35 47 H Exercise

44 50 19 10 23 17 30 26 9 39 5 43 2 Numbers game 1 13 18 3 SORT – 6S 27 21 36 34 22 Numbers game Same rules as before… Good luck! 31 15 4 29 8 42 46 16 28 40 6 37 49 14 33 12 48 The team score is the lowest score… Is the score any better? What else could we improve? 25 41 32 7 38 20 24 11 45 35 47 Exercise

Sort Set in order Shine Standardise Sustain Safety SET IN ORDER Organise, arrange and identify everything in the work area for the most efficient and effective retrieval and return to its proper place. Commonly used tools should be readily available. Storage areas, cabinets and shelves should be properly labelled. Clean and paint floors to make it easier to spot dirt, waste materials and dropped parts and tools. Outline areas on the floor to identify work areas, movement lanes, storage areas, finished product areas, etc. Put shadows on tool boards, making it easy to quickly see where each tool belongs. So in the previous game, we quickly realised that the letters A – P got in the way, so we could remove them. This is sorting. Labelling / Set order 5S

6 24 21 39 36 33 9 12 42 18 3 15 30 27 Numbers game 48 45 SET IN ORDER – 6S 50 47 26 14 20 Numbers game Same rules as before… Good luck! 23 8 2 41 17 32 44 38 11 5 35 29 19 31 34 46 25 Okay, so this time we have installed some racking on the job site. This means that number 1 is in the bottom left rack, number 2 is in the middle left rack and number three in the top left rack. Number 4 is then in the bottom middle rack and so on. The team score is the lowest score… Is the score any better? What else could we improve? 22 1 10 49 7 13 4 16 37 40 43 28 Exercise

Sort Set in order Shine Standardise Sustain Safety SHINE Cleaning and tidying Once you have everything, from each individual work area up to your entire facility, sorted (cleaned up) and organised, you need to keep it that way. This requires regular cleaning, or to go along with our third S, "shining" things up. Regular, usually daily, cleaning is needed or everything will return to the way it was. This could also be thought of as inspecting. While cleaning it's easy to also inspect the machines, tools, equipment and supplies you work with. 5S

Sort Set in order Shine Standardise Sustain Safety STANDARDISE The good practices developed in steps 1 - 3 should be standardised and made easy to accomplish. Develop a work structure that will support the new practices and make them habitual. Update and modify the standards to make the process simpler and easier. One of the hardest steps is avoiding old work habits. It's easy to slip back into what you've been doing for years. Use standards to help people work into new habits that are a part of your Five S program. Procedures 5S

1 5 6 2 3 7 8 9 4 10 Numbers game 17 20 11 12 14 15 13 16 18 19 STANDARDISE – 6S Numbers game Same rules as before… Good luck! 21 23 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 39 After some in depth work flow analysis, we have installed the more detailed racking shown above. This allows us to reorganise the numbers in a standardised fashion to help you complete your task The team score is the lowest score… Is the score any better? What else could we improve? 41 42 50 43 44 45 46 47 48 49 Exercise

Sort Set in order Shine Standardise Sustain Safety SUSTAIN Monitoring systems Have a formal system for monitoring the results of your Five S program. Don't expect that you can clean up, get things organised and labelled, and ask people to clean and inspect their areas every day — and then have everything continue to happen without any follow-up. Continue to educate people about maintaining standards. 5S

If you are going to do a job, do it SAFELY Sort Set in order Shine Standardise Sustain Safety If you are going to do a job, do it SAFELY For example: In addition to red tagging unwanted items in the sort stage, you could also yellow tag items which are hazardous / unsafe / potential pollutants and ensure that they are properly housed and managed! Can you think of any other ways we can incorporate HSE into 5S? Do we need to say any more? The last S should be incorporated into ALL of the previous 5! Yellow Tag Date 13/12/11 Safety the extra S

L A 44 50 19 10 23 J 17 30 26 9 39 5 43 2 Numbers game 1 E 13 18 3 Missing inventory – 5S benefits K 21 36 B 27 34 I Numbers game In the final game, 2 numbers are missing… Which 2? Call out the missing numbers as soon as you see them… Good luck! C 31 N 15 4 29 8 42 P F 16 28 6 40 G 37 49 14 33 48 12 M 22 46 25 41 32 7 D 38 O 20 24 11 45 35 47 H Benefits of 5S

1 5 6 2 3 7 8 9 4 10 Numbers game 17 20 11 12 15 13 14 16 18 19 Missing inventory – 6S benefits Numbers game How much easier is it now? Good luck! 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 39 After some in depth work flow analysis, we have installed the more detailed racking shown above. This allows us to reorganise the numbers in a standardised fashion to help you complete your task The team score is the lowest score… Is the score any better? What else could we improve? 41 42 50 43 44 45 47 48 49 Benefits of 5S