A fun and exciting way to present the 5S concepts to our team! The 5S Numbers Game A fun and exciting way to present the 5S concepts to our team!

Introduction This is a simple training game we will use to show how to perform 5S and to drive home important key points Hopefully you find it challenging (like the real-world) and have some fun along the way Credits This exercise is based on an exercise from www.superteams.com which was adapted from one created by Kirt Tassmer of Stanley Fastening Systems. The original game was developed by RWD Technologies, Ltd. Disclaimer This is for entertainment purposes only. 5S Supply is not liable for any unintended outcomes.

“Behind all workplace successes and failures are the 5S’s.” From “5 Pillars of the Visual Workplace: The Sourcebook for 5S Implementation” by Hiroyuki Hirano Agenda Before State – Round 1 Sort – Round 2 Simplify – Round 3 Systematic Cleaning Standardize Sustain – Round 4 Benefits – Round 5

Instructions – Round 1 Please wait until you hear the entire instructions before starting – DO NOT turn over the page until asked to do so Individually, with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…) You will have 30 seconds to complete this task

2 8 23 84 3 88 92 7 13 36 97 19 14 17 52 65 12 34 11 62 32 15 21 24 28 95 22 25 82 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 GO! 67 47 50 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 6 10 78 71 86 76 39 77 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

Report Out – Round 1 Record your highest number found and a comment on your Overall Scorecard sheet The instructor will ask for your score – the lowest score is what’s recorded for the entire group What was it like trying to do this? How did it feel? How can we apply this to everyday life?

Were there any quality issues? 2 8 23 Is this an 8, 88, 4, 84??? 84 3 88 92 7 13 36 97 14 17 52 19 65 12 34 11 62 32 15 28 95 21 24 Why is 39 listed twice? 82 22 25 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 67 47 50 Which one is the 6 and which one is the 9? 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 6 10 78 71 86 76 39 Is this 66 or 99? 89 or 68? 77 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

Sort To sort through, to sort out Guideline: If it is not needed in the next 30 days, Orange Tag it “When in doubt, move it out!” 5S Orange Tag Technique Place a Orange Tag on the item and move it to the 5S Orange Tag Holding Area Items will be dispositioned: keep, throw out, donate, scrap, shred, recycle, etc.

2 8 23 84 3 88 92 7 13 36 Let’s orange tag the numbers we don’t need (51-100) and the duplicate 39. 97 19 14 17 52 65 12 34 11 62 32 15 28 95 21 24 22 25 82 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 67 47 50 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 6 10 78 71 86 76 39 77 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

2 8 23 84 3 88 92 7 13 36 97 19 14 17 52 65 12 34 11 62 32 15 21 24 28 95 25 82 22 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 67 47 50 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 10 78 71 6 86 76 39 77 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

2 8 23 84 3 88 92 7 13 36 Now let’s move them to the 5S Orange Tag Holding Area. 97 19 14 17 52 65 12 34 11 62 32 15 28 95 21 24 22 25 82 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 67 47 50 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 6 10 78 71 86 76 39 77 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

2 8 23 84 3 88 92 7 13 36 97 14 17 52 19 65 12 34 11 62 32 15 28 95 21 24 22 25 82 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 67 47 50 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 10 78 71 6 86 76 77 39 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

2 8 23 3 7 13 36 17 19 14 12 34 11 32 15 21 24 28 22 25 43 41 31 35 26 38 47 50 29 45 49 5 9 30 18 37 33 44 40 6 10 39 48 46 16 1 20 4 27 42

Instructions – Round 2 Let’s do the same exercise with the unneeded items removed from the work area - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…) You will have 30 seconds to complete this task

2 8 23 3 7 13 36 17 19 14 12 34 11 32 15 21 24 28 22 25 43 41 31 35 26 38 GO! 47 50 29 45 49 5 9 30 18 37 33 44 40 6 10 39 48 46 16 1 20 4 27 42

Report Out – Round 2 Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is what’s recorded for the entire group What was the exercise like this time? What can we learn from this?

Simplify Now that the area has been cleared out of unnecessary items, it is time to find a “home” for items that will remain Guideline: Any item that you want to keep after the 5S Orange Tagging Event needs to have a specific home “A place for everything and everything in its place.” Organize items to make them convenient to get and put away Use visual controls to help this process (signs, lines, labels, color-coding)

2 8 23 3 7 13 36 Let’s rearrange the numbers in order that we will use them. 17 19 14 12 34 11 32 15 24 28 21 22 25 43 41 31 35 26 38 47 50 29 45 49 5 9 30 18 37 33 44 40 6 10 39 48 46 16 1 20 4 27 42

2 8 23 3 7 13 36 17 19 14 12 34 11 32 15 21 24 28 22 25 43 41 31 35 26 38 47 50 29 45 49 5 9 30 18 37 33 44 40 6 10 39 48 46 16 1 20 4 27 42

2 5 4 8 9 10 3 6 1 7 19 11 13 16 18 15 20 12 14 17 26 23 27 28 21 22 29 31 24 25 30 32 33 35 37 36 34 44 38 40 43 41 45 39 42 48 46 47 49 50

2 5 4 8 9 10 3 6 1 7 Did you notice that we had to work around a few things like the numbers that were already there? 19 11 13 16 18 15 20 12 14 17 26 23 27 28 21 22 29 31 24 25 30 32 33 35 37 36 34 44 38 40 43 41 45 39 42 48 46 47 49 50

Instructions – Round 3 Let’s do the same exercise with the numbers better organized - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…) You will have 30 seconds to complete this task

2 5 4 8 9 10 3 6 1 7 19 11 13 16 18 15 20 12 14 17 26 GO! 23 27 28 21 22 29 31 24 25 30 32 33 35 37 36 34 44 38 40 43 41 45 39 42 48 46 47 49 50

Report Out – Round 3 Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is what’s recorded for the entire group What was the exercise like this time? What benefits can you see from “Sort” and “Simplify”? Record on Scorecard sheet

Systematic Cleaning Now that the area has been cleared out of unnecessary items, it is time to “shine” the items that remain Guideline: Get items to a “like-new” condition “Clean and inspect or inspect through cleaning” Everyone participates, make it simple and easy to get cleaning supplies and schedule it! If you find something out that may become an issue, fix it or have it fixed

2 5 4 8 9 10 3 6 1 7 For Shine we will make sure the numbers are in good working order. So let’s clean this mess up! 19 11 13 16 18 15 20 12 14 17 26 23 27 28 21 22 29 31 24 25 30 32 33 35 37 36 34 44 38 40 43 41 45 39 42 48 46 47 49 50

4 5 8 2 3 10 1 6 7 9 11 13 18 16 12 15 17 19 20 14 26 23 27 30 21 22 24 28 29 25 31 33 34 32 35 36 37 39 40 38 41 43 44 47 48 50 42 45 46 49

Standardize We need to have standards for the first three S’s: Sort, Simplify and Systematic Cleaning Guideline: Make up the rules for the first three S’s and then follow and enforce them. “Make up the rules and then follow them” Don’t forget to consider companywide policies like color-coding, signage, replenishment, etc Make the rules easy to follow

4 5 8 2 3 10 1 6 7 9 After looking at all the styles of font and sizes the team determined that some of these items can be standardized. 11 13 18 16 12 15 17 19 20 14 26 23 22 27 30 21 24 28 29 25 31 33 34 32 35 36 37 39 40 38 41 44 47 48 50 43 42 45 46 49

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 Let’s add some more visuals like color-coding and lines. 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Sustain Now that you have a well organized, clean and safe work environment, we must keep it that way Guideline: It’s not something extra, it’s part of everyday work “Make 5S part of everyday life.” Sustain helps build the discipline we need to have a great Lean organization

Instructions – Round 4 In order to Sustain our gains we must be able to recognize abnormal conditions Let’s do a quick 5S Audit of the area Circle any “defects” that you find You will have 30 seconds to complete this task

1 3 4 5 6 7 8 9 10 16 12 11 13 14 15 17 18 19 20 21 22 23 34 25 26 27 28 29 30 GO! 31 32 33 24 35 36 37 38 40 46 41 42 43 44 45 47 48 49 50

Report Out – Round 4 How many did you find? The “2” is missing “9” is upside down 11 and 12 are mixed up “16” is not completely in it’s home 24 and 34 are in the wrong location “39” is missing 46 is askew How did you know?

1 3 4 5 6 7 8 9 10 16 12 11 13 14 15 17 18 19 20 21 22 23 34 25 26 27 28 29 30 31 32 33 24 35 36 37 38 40 46 41 42 43 44 45 47 48 49 50

Instructions – Round 5 Let’s do the same exercise after applying our 5S principles - with a pen or pencil strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…) You will have 30 seconds to complete this task

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GO! 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Report Out – Round 5 Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is what’s recorded for the entire group What was the exercise like this time? What benefits can you see from “Sort” and “Simplify”? How can we apply this to everyday life?

Before & After State Before Excess materials Excessive search time Large area Cluttered Difficult After The correct materials Minimal search time Smaller area Clean, neat & organized Easy

2 8 23 84 3 88 92 7 13 36 Before 97 19 14 17 52 65 12 34 11 62 32 15 28 95 21 24 22 25 82 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 67 47 50 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 6 10 78 71 86 76 39 77 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

1 2 3 4 5 6 7 8 9 10 After 13 14 15 16 17 18 19 20 11 12 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Benefits of 5S What benefits did we realize by applying 5S to our simulated workplace? Quality Cost Delivery/Service Quantitative Qualitative _________________

Wrap-up Can we apply this to the real world? Share an “Ah-ha” – something you learned, something that’s new, something that’s different or something that made an impression on you ________________________________________________________________

Thank You for participating Follow us @ www.blog.5Ssupply.com Twitter.com/5Ssupply LinkedIn Group 5S Supply YouTube.com/5Ssupply www.5Ssupply.com 888 4 LEAN 5S 5S Simplified. Everything you need… all in one place!

Forms and Facilitator Notes Participant Forms & Tips and Tricks

Instructor Notes This section has the forms and instructor notes to use during this training exercise Items needed: PowerPoint presentation (if desired) Pens or pencils, enough for each participant Stopwatch, timer or watch with seconds hand to time each round (30 seconds) One copy each of the forms for each participant (see next slide)

Forms Print the Overall Scorecard form single sided Print the Rounds 1, 2, 3, 4 and 5 forms double sided with the words “Please do not turn over until told to do so.” on the front and the exercise on the back

Overall Scorecard Handout the Overall Scorecard at the beginning when you are explaining the exercise Ask the participants to record their individual scores on this sheet and any comments or “take-aways” from the round

Overall Scorecard Comments _________________ Exercise Number Round 1

Please do not turn over until told to do so. Round 1 Please do not turn over until told to do so.

TOP 2 8 23 84 3 88 92 7 13 36 97 19 14 17 52 65 12 34 11 62 32 15 28 95 21 24 22 25 82 64 93 39 43 58 41 98 54 99 31 35 100 96 26 38 90 67 47 50 29 53 45 49 5 73 9 59 30 51 56 91 66 57 18 83 75 37 61 33 55 68 63 70 44 40 6 10 78 71 86 76 39 77 79 48 81 46 16 1 20 72 89 4 85 27 74 60 80 42 87 94

Please do not turn over until told to do so. Round 2 Please do not turn over until told to do so.

TOP 2 8 23 3 7 13 36 17 19 14 12 34 11 32 15 24 28 21 22 25 43 41 31 35 26 38 47 50 29 45 49 5 9 30 18 37 33 44 40 6 10 39 48 46 16 1 20 4 27 42

Please do not turn over until told to do so. Round 3 Please do not turn over until told to do so.

TOP 2 5 4 8 9 10 3 6 1 7 19 11 13 16 18 15 20 12 14 17 26 23 27 28 21 22 29 31 24 25 30 32 33 35 37 36 34 44 38 40 43 41 45 39 42 48 46 47 49 50

Please do not turn over until told to do so. Round 4 Please do not turn over until told to do so.

TOP 1 3 4 5 6 7 8 9 10 16 12 11 13 14 15 17 18 19 20 21 22 23 34 25 26 27 28 29 30 31 32 33 24 35 36 37 38 40 46 41 42 43 44 45 47 48 49 50 Circle the “defects”. How many did you find?

Please do not turn over until told to do so. Round 5 Please do not turn over until told to do so.

TOP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 62