1. BE-TL1-001-DRAFT-5S 5S
Business Excellence
DRAFT
October 5, 2007

2. Table of Contents Overview & Scope 3 Objective 4 Introduction to 5S 5
Contents Slide(s)
Overview & Scope 3
Objective
Introduction to 5S 5
5S : Steps
5S : Steps
5S : Steps
5S : Steps
5S : Steps
Keys to 5S Success
5S is a foundation of FLE 18
Create Standards … Detect Abnormalities
Leadership Responsibility 25
Exercise
Gemba walk

3. Overview & Scope Overview Scope
This system is called "5S" because it involves a Five Step process. Each step in the process is named using a word that starts with the letter "S". The five steps are:
Sort
Set In Order
Shine
Standardize
Sustain.
5S advocates believe that the benefits of this methodology come from deciding what should be kept, where it should be kept, and how it should be stored
Scope
5S is a lean manufacturing technique that uses effective workplace organization and standardized procedures to improve profits, safety, quality, productivity, customer satisfaction and employee retention.

4. Objective Establish standards to detect an abnormality
Create and maintain an organized, clean and safe work area
Conditioning discipline for Action Workout
Increase productivity
Increase employee satisfaction
Save money and cut costs

5. Introduction to 5S
First S: Sort (Seri) Distinguish between what is needed and not needed.
Second S: Set In Order (Seiton) A place for everything and everything in its place.
Third S: Shine (Seiso) Cleaning and Inspecting the workplace.
Fourth S: Standardize (Seiketsu) Share established standards and make standards obvious.
Fifth S: Sustain (Shitsuke) Practicing and repeating this discipline until it becomes a way of life.

6. When In Doubt . . . Throw It Out
Step 1 : Sort (Seri)
Eliminate all unnecessary items …
Items not needed now for production
PURPOSE
ASK YOURSELF
What do we need ?
What can we remove ?
When In Doubt Throw It Out

7. When in doubt……… Move it out!
Sort (Seri)
Tips For Sorting
Start in a small area and expand area by area
Include all the affected people when sorting
Include outside observers
Use Red Tag system
When in doubt……… Move it out!

8. Everything you REALLY Need at your Fingertips
Step 2 : Set in Order (Seiton)
PURPOSE
Organize and arrange what you need
What do we need to use 1st, 2nd
Where should it be?
ASK YOURSELF
Everything you REALLY Need at your Fingertips

9. Set In Order (Seiton)
A place for everything and everything in its place.
Assign permanent place for all needed items
Choose proper storage methods
Visually indicate locations
Missing items easily noticed
Utilize sign boards

10. Be able to quickly detect an abnormality
Step 3 : Shine (Seiso)
PURPOSE
Identify abnormalities by visually sweeping the area
Does this belong here?
Is it needed right now?
ASK YOURSELF
Be able to quickly detect an abnormality

11. Cleaning and looking for ways to keep it clean.
Shine (Seiso)
Cleaning and looking for ways to keep it clean.
Eliminate dirt, dust, oil, scrap, etc. Allows
inspection and early detection of problems.
Keep workplace swept & wiped down
Clean in, under, and around equipment
and furniture.
Integrate cleaning into everyday tasks
2006

12. Step 4 : Standardize (Seiketsu)
PURPOSE
Arrange items so that they can be found quickly by anybody
Does everything has a place?
Is everything in its place?
ASK YOURSELF
Anyone should be able to easily understand proper arrangement and abnormalities

13. Standardize (Seiketsu)
Process for Maintaining the first 3 S’s
Define procedures and activities to
ensure that Sort, Set in Order and Shine practices are maintained and executed consistently.

14. Steps of Implementation Easy To Measure … Stay Focused
Step 5: Sustain (Shitsuke)
PURPOSE
Leadership responsibility to sustain the first 4S’s
Are the actions clearly defined?
Clear ownership ?
ASK YOURSELF
Area team leaders
identified and
responsibilities
documented.
Level
Anything not required for immediate production is removed from the line.
Immediate actions taken against abnormalities; Shop kept orderly on a continuous basis.
Non-utilized cabinets,
benches, tables, etc.
removed from area.
Unneeded materials
removed from plant; not stored away.
Needed and unneeded
materials have been
separated.
Needed and unneeded materials are mixed throughout the work area.
Daily cleanliness
inspection of
equipment, tools
and supplies.
Visual controls established and well marked for work area.
Work areas unkept; No
visual controls in place.
Information is “hidden”
in the computer system. 4 3 2 1
Immediate actions taken
against assembly
abnormalities.
Area’s individuals take
ownership; standards are
followed.
Daily checks performed
by area leaders;
standards are regularly
reviewed and updated.
Periodic checks are performed by area leaders.
No area checks are
performed; standards are
not established.
Self Discipline
Sort
Sweep
5S’s
Establish & follow
standard procedures.They
are clear, up-to-date, and
displayed in work areas.
Material layout, assembly,
& communications are
documented, standardized
& followed rigorously.
Labeling of items with
required quantities are
standardized.
Procedures are
documented, but not
consistently followed.
No procedures in place.
Standardize
All items can be easily
retrieved by anyone;
they are clearly marked.
Standardized item
quantities are established;
Shadow boards are utilized.
Needed items have dedicated locations which are clearly labeled.
Needed items have
been safely stored
and organized.
Items are placed
randomly throughout
the work place.
Simplify 5
Level Of Improvement
Steps of Implementation
Easy To Measure … Stay Focused

15. Sustain (Shitsuke)
Practicing and repeating this discipline until it becomes a way of life
Make 5S a habit.
5S should be a personal goal.
Set a good example!
Should be voluntarily observed
Maintain a favorable 5S atmosphere
Both management and operations have the
responsibility for sustaining 5S.

16. Sustain (Shitsuke) Tips for Sustaining Develop a commitment to
housekeeping
Institute 5S Audits
Have different areas “inspect”
each other.
Management must lead by
example
5S is not just for the shop
floor

17. Keys To 5S Success Get everyone involved.
Integrate 5S Principles into daily work requirements.
Communicate need for 5S, roles of all participants, how it is implemented.
Be consistent in following 5S Principles in all areas
Business Team Leader involvement is a must !
Follow through -finish what is started - 5S takes effort and persistence.
Link 5S activity with all other Action Workout initiatives.

18. In order to visually detect any abnormal condition,
The 5S is a foundation for FLE
In order to visually detect
any abnormal condition,
we need to establish
Visual Management & Standards.

19. Create Standards … Detect Abnormalities
Look Here …
5 cowboys to drive 1000 cattle
Should take one look and understand the situation
Clearly differentiate between what is “Normal” and “Abnormal”
Detect what is “Abnormal”
Not Here …
Don’t “Manage” a Standard … Detect the Abnormality

20. Very Easy to Detect Abnormalities !
Create Standards … Detect Abnormalities
Very Easy to Detect Abnormalities !

21. Create Standards … Detect Abnormalities

22. Which Situation is Easier to Manage ?
Create Standards … Detect Abnormalities
Which Situation is Easier to Manage ?

23. Create Standards … Detect Abnormalities

24. Create Standards … Detect Abnormalities
All small Parts
have defined
place
Horizontal Limit

25. Leadership Responsibility
Management at all levels must be committed to establishing and maintaining the 5S process.
Before people leave work for the day, everyone must ensure that the cell meets 5S principles.
The use of checklist for monitoring adherence, quantifying results of cell inspections and prominent display of each area’s results are tools which management can use to help sustain the process.
Management must lead by example Walk the Talk !

26. 5S - Exercise
To illustrate the impact that 5S can have on productivity and
quality, we will use the following numbers exercise.
(Instructors: use 5S_Game.ppt file and handouts.)

27. Gemba Walk
Let’s Go to Gemba ; Practice Genchi Gembutsu (Go & See); Write down your observations!
Sort
Set in Order
Shine
Standardization
Sustain