1 © 2005 Superfactory™. All Rights Reserved. Lean Office - 5S and Visual Controls Superfactory Excellence Program™

2 © 2004 Superfactory™. All Rights Reserved. 5S and Visual Control Our Lean program Our Lean program What is 5S? What is 5S? 5S and Lean Enterprise 5S and Lean Enterprise Elements of 5S Elements of 5S Sort Sort Straighten Straighten Shine Shine Standardize Standardize Sustain Sustain Safety Safety Visual Workplace Visual Workplace Implementation plan Implementation plan Summary Summary

3 © 2004 Superfactory™. All Rights Reserved. What is 5S? 5S is a method to improve and sustain workplace organization 5S is a method to improve and sustain workplace organization 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). These are foundational to continual improvement and a manufacturing strategy based on "Lean Manufacturing" (waste removing) concepts. These are foundational to continual improvement and a manufacturing strategy based on "Lean Manufacturing" (waste removing) concepts. Reduces clutter Reduces clutter Reduces the time it takes to look for tools and equipment Reduces the time it takes to look for tools and equipment “A place for everything and everything in its place” “A place for everything and everything in its place” Improves how the operation appears to customers – always be “tour ready” Improves how the operation appears to customers – always be “tour ready” Creates pride in the workplace Creates pride in the workplace Many companies have a standard that any tool must be able to be found within 60 seconds. Many companies have a standard that any tool must be able to be found within 60 seconds.

4 © 2004 Superfactory™. All Rights Reserved. 5 Elements of 5S Workplace Organization Workplace Organization Sort Sort Remove all unnecessary materials and equipment Remove all unnecessary materials and equipment Straighten Straighten Make it obvious where things belong Make it obvious where things belong Shine Shine Clean everything, inside and out Clean everything, inside and out Standardize Standardize Establish policies and procedures to ensure 5S Establish policies and procedures to ensure 5S Sustain Sustain Training, daily activities, Training, daily activities, Safety (often called “6S” or “5S + 1”) Safety (often called “6S” or “5S + 1”) A safety commitment in all activities A safety commitment in all activities

5 © 2005 Superfactory™. All Rights Reserved. Eight Service Industry Wastes 1. Errors in documents 2. Transport of documents 3. Doing unnecessary work not requested 4. Waiting for the next process step 5. Process of getting approvals 6. Unnecessary motions 7. Backlog in work queues 8. Underutilized employees

6 © 2004 Superfactory™. All Rights Reserved. The Good – After 5S

7 © 2004 Superfactory™. All Rights Reserved. Straighten Make it obvious where things belong Make it obvious where things belong Lines Lines Divider lines Divider lines Outlines Outlines Limit lines (height, minimum/maximum) Limit lines (height, minimum/maximum) Arrows show direction Arrows show direction Labels Labels Color coding Color coding Item location Item location Signs Signs Equipment related information Equipment related information Show location, type, quantity, etc. Show location, type, quantity, etc.

8 © 2004 Superfactory™. All Rights Reserved. 5S Examples - Sort, Straighten See the difference? 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Straighten - A place for everything and everything is in its place