1. 5-S

2. What does the 5-S mean…? Sort – Put things in order.
Set in Order – Properly arranged.
Shine – A clean workplace.
Standardize – Make procedures to maintain the workplace.
Sustain – Commitment to the process.
XONITEK Corporation

3. 5-S philosophy... A place for everything and everything in its place
The 30 second rule…
Everything that casts a shadow should have a border, ID label and home address
Create a visual workplace.
If you can’t do 5-S then you most likely can’t do the other Lean initiatives…
XONITEK Corporation

4. Initiating the Process…
Preview / Scan the workplace
Make sure that the boundaries of the area are well understood…
Use physical markers or tape the area…
Take “before” photos to demonstrate your improvements…
Flow the Process in the “as is” state…use the Flow Process Diagram Form…
Complete the Preview and Scan Worksheet / Action Log.
XONITEK Corporation

5. Workplace Preview & Scan Form…
See the sample form provided for the full details…
This form is provided for your use and can be modified to suit your organization…
XONITEK Corporation

6. Observing Industry/Company Standards
Color Codes should be reviewed and documented as per company policy or OSHA requirements.
Keep Clear Areas are defined by barriers or markings.
Example: Electrical Panel, Eyewash Station, Fire Extinguishers… etc.
XONITEK Corporation

7. Prepare for the event… Reassess the members of the team…
Make sure that you have the proper team members to contribute…
Review the Preview & Scan documents…
Establish a game plan for areas, items or processes to be targeted.
Schedule the event and notify the affected area.
XONITEK Corporation

8. 1-S… Sort
XONITEK Corporation

9. Setting Company Standards…
Red Tagging:
A method to identify items that will eventually be removed from an area.
Contains Data describing:
Red Tag No.
Name/Description of item
Reason for Tagging
Date Tagged
Current Location
Create a log maintained by the Red Tag Area Manager.
XONITEK Corporation

10. Red Tag Rules…
Dispose of anything first if possible before red tagging.
Considerations when Red Tagging items...
Obsolete – Sell, Store offsite, Donate or Discard.
Defective – Return to supplier or discard.
Scrap – Move to proper disposition area, Red Tag or discard.
Trash/Garbage – Recycle or Discard.
Frequency of use in the area:
Unneeded – Move to proper area, Red Tag or discard.
Once per day – Locate in area readily available to the employee.
Once per week – Locate in area.
Once per month – Store where accessible in the plant.
Seldom Used – Red Tag…Store where accessible, sell, donate or discard.
Use unknown – Red Tag …Find the use or disposition.
XONITEK Corporation

11. Places to look when Red Tagging…
Physical spaces
Aisles, floors, work areas, behind/under/around equipment
Behind doors, in stairways, offices, docks, cabinets, storage areas
Look for unneeded equipment
Machines, hand tools, bits, wire, fixtures
Computers, lighting, cleaning products
Identify unneeded furniture
Cabinets, benches, tables, chairs, carts
Search for papers as well
Items hung on walls, bulletin board postings, signboards
Look for unneeded materials and supplies
Raw materials, shipping supplies, loose garbage, uniforms, helmets
XONITEK Corporation

12. (Name/Description of item)
Red Tag Example…
RED TAG No._____
________________________
(Name/Description of item)
(Reason Tagged)
Date Tagged:
From Loc:
Affix to the item and log on the action list with responsibility and due dates.
Make the Red Tag area visible !!
XONITEK Corporation

13. Red Tag Example…
Pallets may be immediately removed to a designated area but ….
Chemicals must be properly located or disposed of…
XONITEK Corporation

14. Sample Red Tag Log…
Like the Red Tag location keep the Log visible to assure timely disposition.
XONITEK Corporation

15. Red Tag Holding Location…
Red Tag should not become a redistribution of the clutter…
Rules for a Red Tag Holding Location:
Local area with one week storage.
Visible and centrally located.
Clearly labeled with rules to include and remove.
Has a manager responsible for disposition of materials.
XONITEK Corporation

16. Safety Review… After all of the previously discussed
activities have been done brainstorm
the issues of safety…
Create an action plan to resolve the issues.
Use an existing program if one is currently active.
XONITEK Corporation

17. 1-S…Finalize…
Sort:
Clear the Decks…Look around the work area and remove any additional things that may require red tagging…
All remaining items should be reviewed for their appropriateness to the area…
Question each item:
What belongs to the area?
Do I need all of this equipment?
Do I have the right tools?
Do I have too many?
If the items are to be stored remotely for later use… log and store each item for quick reference.
XONITEK Corporation

18. 2-S… Set in Order
XONITEK Corporation

19. 2-S… Set in Order: Review the process flow in the area.
Flow Process Chart…
30 second storage and retrieval
Motion Study Analysis…
Position things to promote good posture and safe lifting/retrieval.
Minimize body motions and travel
Establish a layout proposal to optimize a safe work space:
Safety concerns all addressed
Material flows
Tools accessible
Safety covers in place
Anti-fatigue mats
Defined and straight aisles
Create the Visual Workplace
Tools labeled and/or outlined
Visual indicators
Material placement markers or outlines on the floor
XONITEK Corporation

20. Considerations of Optimized Flows…
How are parts to be stored. Is the area open, accessible and clearly identified so that parts can be returned?
Review all storage and placement for safety.
Too high or a blind reach?
Place most frequently used items closest to the operator.
Note the sequence of use and when possible maintain this flow for items stored.
What other considerations would you include?
XONITEK Corporation

21. 2-S… Motion Study Analysis…. The 5 ranges of Operator Motion: Fingers
Wrist
Elbow
Shoulder
Hips
XONITEK Corporation

22. 2-S…
Bill of Resource…. List the major items that are expected to be in the workplace.
Identifies WHAT should be in the area…
Post this list at the work station as a sustain and audit aid.
What should we expect:
Simplicity
Values of the organization and employees are emphasized.
Discipline in daily work activity is reinforced.
XONITEK Corporation

23. 2-S… Creating the Visual…
Visual Control & Tool Categories…
Story Boards – to share information about projects or improvements…
Meant to educate and motivate…
Sign Boards – to give information at the point of use…
Maps – these show the processes, physical locations or procedures…
Checklists – methods for maintaining a standard process…
Indicators – show activity, status, direction, etc…
Alarms – used specifically to identify a significant out of control situation…
Mistake Proofing – visual aides, overlays or gages to validate outcomes…
XONITEK Corporation

24. Markings and ID’s…
XONITEK Corporation

25. Visual…
XONITEK Corporation

26. Tool Organization…
XONITEK Corporation

27. Visual – Color Coding…
XONITEK Corporation

28. Labels for Information…
XONITEK Corporation

29. Borders for Placement…
XONITEK Corporation

30. Tool Placement Guides…
XONITEK Corporation

31. Set in Order…
Make sure that you have a designated “posting” area that includes locations for the area instructions and procedures...
This may also include other relevant and approved postings such as:
Performance Metrics
Next Jobs
Audit Sheets
Cleaning Procedures
Etc…
XONITEK Corporation

32. Work aides and instructions…
XONITEK Corporation

33. Test the Set in Order…
Using the Red Tag review process to verify success
Anything found out of place should be immediately processed.
Perform the Preview and Scan process…
Sort and Set in Order should not have any issues at this point…
XONITEK Corporation

34. 3-S… Shine
XONITEK Corporation

35. 3-S… Shine… Clean everything inside and out!!
Thoroughly clean the workplace and equipment.
Inspect while you are cleaning and note issues on the 5-S Action Log that cannot be immediately resolved.
Identify troublesome areas… those that seem to be the points of dirt collection and note them as a “target area” on the cleaning log.
Replace or clean all dirty hoses or wires on equipment.
Determine how to make Shine standards obvious…
Clean everything inside and out!!
XONITEK Corporation

36. Shine Checklist…
A finalized checklist should be posted at the area in the specified location.
The list should include the “target areas” that were identified as trouble spots.
An inventory of materials necessary for the cleaning should be listed.
XONITEK Corporation

37. Checklist… Here is an example of a list…
Identify by Color those areas that are “targeted” as troublesome…
XONITEK Corporation

38. Definitions of Checklist…
5-S Area Under Review – List the area on the layout that this represents. This should be correlated to a layout highlight.
Task – What position, equipment or item specifically is targeted for cleaning.
When – The frequency and/or day to perform the task.
Materials Required – List the materials necessary and approved. This is the authorization to have these materials in the workplace.
Done? – Enter the date when this task was completed.
Post the Check List for inspection in the approved location.
XONITEK Corporation

39. 4-S… Standardize
XONITEK Corporation

40. 4-S Guidelines… Make standards obvious from a distance.
Necessary information is located on or near the process it relates to…
Everyone can understand the standards.
Visuals created:
Checklists
Labels
Material placements
Safety Equipment labeled and accessible
Gage limits are labeled
XONITEK Corporation

41. 4-S Guidelines… Establish and implement areas of standardization
Documents, instructions, labels, signage
Material handling, color codes
Review cycles
Also, standardize the work itself
How is the work process done properly in this area?
Create / revise Standard Work
Post it prominently in the work area
XONITEK Corporation

42. Color Coding Standards…
Color Code to provide meaning
OSHA and ANSI Standards
Red: Fire, Danger, Stop
Yellow: Caution
Green: Safety
Black/ : Boundaries
Blue: Warning
White
XONITEK Corporation

43. Visual Cues for Material Replenishment…
Color cues as a methodology to replenish various items or stop producing…
XONITEK Corporation

44. Test of Standardize…
Use the Red Tag review process for the physical environment
Observe a crew trying out the process area Standard Work
Anything found out of compliance should be immediately processed.
Proceed with the Preview & Scan process…
Take Final Pictures to Post as the “Approved State”.
XONITEK Corporation

45. Quick Check: Five Minute 5-S
Goals: Validation of the approved state…
Identify the process flaws
Establish a good sequence
Determine if the work can be done in the allotted time
Confirm the document to be posted
Conduct your first 5 Minute 5-S.
XONITEK Corporation

46. 5-S… Sustain
XONITEK Corporation

47. 5-S…
Sustain…
Establish clear signs that Management supports the 5-S program.
Rewards and recognition
Management on site reviews
Establish and follow auditing procedures.
Publish schedules for audits…
Post locally
Include 5-S in the company news letter
Validate safety precautions are in place and acknowledged
Constantly test that everyone is 5-S trained.
XONITEK Corporation

48. 5-S… How to Start the Process…
Brainstorm potential control ideas with the team…
Test and Validate, if necessary modify these concepts.
Document and Incorporate into the process area.
Monitor the effectiveness with the local employees.
Don’t be afraid to change… remember we’re in a process of continuous improvement…
XONITEK Corporation

49. Audit Check List …
Workplace audit form…
XONITEK Corporation

50. *** Questions and Discussion ***