Lean Training 5S

Agenda What is it? What’s it for? How does it work? When do you use it? What’s an example?

What is it? 5S is a workplace organization technique It is a way to involve associates in the ownership of their workspace It helps create and maintain the efficiency and effectiveness of a work area 5S is a common starting point for Lean activities in a company

What’s it for? It is a way to create: Cleaner work areas More organization Safer working conditions Less wasted time Efficient work processes and practices More available space

How does it work? 5S is most effective when applied in a systematic way The following video illustrates the 5S methodology 5S Video

The Five S’s Sorting – separating the needed from the not-needed Simplifying – a place for everything and everything in its place, clean and ready to use Systematic Cleaning or Sweeping – cleaning for inspection Standardizing – developing common methods for consistency Sustaining – holding the gains and improving

The First S - Sorting Separating the Needed from the Not- Needed Eliminate not-needed items and perform an initial cleaning Establish criteria/handling of items Identify not-needed items Move not-needed items to holding area Conduct a white-elephant sale Conduct an initial cleaning

The Second S - Simplifying A place for everything and everything in its place, clean and ready to use Arrange workplace for safety and efficiency Identify key equipment and supplies Determine location for each item Outline locations and zones Develop shadow boards, label items Document layout, equipment, supplies

The Third S – Systematic Cleaning Cleaning for Inspection Perform daily cleaning and inspection to understand work conditions Identify points to check for performance Determine acceptable performance Determine visual indicators/controls Mark equipment/controls Conduct daily cleaning/inspections

The Fourth S - Standardizing Developing Common Methods for Consistency Make abnormal conditions noticeable and document agreements Document agreements and checks Establish/document standard methods across similar work areas Document new standard methods

The Fifth S - Sustaining Holding the Gains and Improving Maintain the gains from other 5S activities and improve Determine 5S Level of Achievement Perform routine checks Analyze results of routine checks Measure progress and plan for continuous improvement

Getting Started Planning – launches your 5S activity Evaluating – tells you what you need to do Preparing – gets you ready for implementation

Planning Assemble a 5S Lead team Define the work area 5S boundaries Assign work group members to their 5S areas Install a 5S communication board Determine 5S targets, activities, and schedule Review/finalize plans with work group and site leadership

5S Boundaries Area 1 Area 2 Area 3 Area 4 Monica & Chandler Rachel & Ross Joey & Phoebe Jerry & Kramer

Five S Communication Board Levels of Achievement Five S Team Members Five S Boundaries Five S Routine Checklist Five S Routine Checklist Five S Implementation Plan Five S Implementation Plan Photos Current Situation After Five S

Evaluating Your Initial Situation Prepare to take work area photos Take work area photos Evaluate current 5S Level of Achievement

Preparing for Implementation Obtain existing standards for color-coding and signage Decide on 5S color-coding and signage standards Prepare for Sorting Prepare for Simplifying Prepare for Systematic Cleaning Prepare for Standardizing Prepare for Sustaining

Summary: Implementing Five S’s Share 5S Overview Choose work area implementation group Determine implementation targets, activities, and schedules Document current situation Apply 5S’s Document improvements Determine new improvement goals and action steps

Issues and Concerns Communicating across shifts Disposing of, or moving, personal items Making time available Following agreements consistently Maintaining the gains Giving rewards and recognition Integrating 5S with other improvement activities

What’s an example?

Before After

What’s an example?

Questions?