1. LT6
5S + 1
CONTINUOUS IMPROVEMENT
OFFICE

2. Session Agenda Introduction Background and History
Components and Implementation

3. Introduction
5S + 1 is a method to improve and sustain workplace organization
Represents 6 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.
Reduces clutter
Reduces the time it takes to look for tools and equipment
“A place for everything and everything in its place”
Improves how the operation appears to customers – always be “tour ready”
Creates pride in the workplace
Many companies have a standard that any tool must be able to be found within 60 seconds.

4. Background and History
Taiichi Ohno created the original “4S” concept of workplace organization and visual control at Toyota during the early 1950’s.
The concept was further refined into “5S” during the 1960’s and 1970’s.
U.S. manufacturers added a sixth “S” for “safety” during the 1990’s.
The 5S+1 tools were recently modified by Gwendolyn Galsworth to include “Visual Workplace” disciplines.

5. Elements of 5S + 1 and Visual Workplace
Sort
Scrub/Shine
Secure Safety
Select Locations
Set Locations
Sustain

6. Elements of 5S +1 & Visual Workplace
Sort
Remove all unnecessary materials and equipment
Scrub/Shine
Clean everything, inside and out
Secure Safety (often called “6S” or “5S + 1”)
A safety commitment in all activities
Select locations
Decide where everything remaining should be
Set locations
Put remaining items in place, provide “anchors”
Sustain
Establish policies and procedures to ensure 5S
Training, daily activities, audits

7. Types of Waste Defects Over-Production Waiting Non-Utilized Talent
Transportation
Inventory
Motion
Extra Processing
Other Wastes:
Inappropriate Systems
Wasted Utility Resources
Wasted Materials

8. The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S

9. The Good – After 5S + 1

10. After 5S + 1 Clear, shiny aisles Color-coded areas
Posted processes, metrics and other current information
Always “customer tour ready”

11. 5S + 1 Examples
After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
Before 5S

12. Sort Identify clutter and disposition When in doubt, move it out
Red tag exercise (more later)

13. Scrub/Shine Clean everything, inside and out
Prevent dirt and contamination from reoccurring
Remove outdated material (like old posted charts, news, and metrics!)
Results in
Fewer breakdowns
Greater safety
Product quality
More satisfying work environment

14. Shine Check Sheet Ceilings Aisles Workstations
Corners, under equipment
Loading docks
Walls
Doors
Pillars, posts
Floors
Machines
Conveyance equipment
Plumbing, sinks
Cabinets, shelves, racks
Carts, Racks
Drawers, storage bins
Fixtures, power boxes

15. 5S Examples - Shine
The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.

16. Safety Does not replace the existing site safety plan
During 5S audits also review all areas for safety

17. Select Locations Make it obvious where things belong Lines Labels
Divider lines
Outlines
Limit lines (height, minimum/maximum)
Arrows show direction
Labels
Color coding
Item location
Signs
Equipment related information
Show location, type, quantity, etc.
Consider your “Value Field”

18. Select Locations Check Sheet
Equipment
Machines
Small tools
Dies
Jigs
Bits
Conveyance equipment
Cleaning equipment
Furniture
Cabinets
Benches, tables
Chairs
Carts
Shelves
Racks
Materials
Raw material
Supplies
Parts
Work-in-process
Finished goods
Shipping materials
Cleaning supplies
Other items
Charts, graphs, bulletin boards
Pens, pencils
Work clothes
Helmets
Work shoes
Trash cans

19. 5S Examples See the difference?
Sort - All unneeded tools, parts and supplies are removed from the area
Scrub/Shine – Cleaned/Painted
Select & Set Locations - A place for everything and everything is in its place

20. Set Locations & Standards
Establish guidelines for the team 5-S conditions
Make the standards and 5-S guidelines visual
Maintain and monitor those conditions

21. Typical Team Standards
Sort
Amount of inventory
Tools that belong in the area
How often to remove scrap
Straighten
Location of aisleways
Location of tools, equipment
Shine
Cleaning schedule
Maintenance tasks
Checklist of what to look for as cleaning is performed

22. Sustain
Determine the methods your team will use to maintain adherence to the standards
5-S concept training
Before and after photos
Checklists, standards and procedures
Daily 5-minute 5-S activities
Monthly 5S Audit

23. © 2007 Superfactory™. All Rights Reserved.
5S Implementation
Begin reviewing your areas for 5S
Discuss 5S with each of your groups (brief group meeting)
Red tag sorting process (one time)
Brief, simple daily 5S individual activity (“just look around”)
Brief 5S checklist or procedure for each area
Monthly 5S audit beginning __________
Area Lead plus at least one person from outside that area
Post results (I will look for them!)
Review results with your group
Take corrective action
© 2007 Superfactory™. All Rights Reserved.

24. Red Tag Process One-time activity to remove or disposition clutter
To be started within two weeks of this training
Identify clutter, unused equipment, etc
Fill out and attach red tag
Note in red tag log
Must disposition Red Tags within (XX) days

25. Red Tag Example Item Tagged by: ________________________
Name of Item: __________________________
Date: _________________________________
Location of Item: ________________________
Reason for Red tagging (Check One)
For Office Use Only:
Item No. ___________________________
Disposition:_________________________
__________________________________
Obsolete
Defective
Scrap
Trash
Unneeded
Used once/day
Used once/week
Used < once/month
Seldom Used
Use Unknown

26. Red Tag Hints Search Floors Aisles Operation areas Workstations
Corners, under equipment
Small rooms
Offices
Loading docks
Inside cabinets

27. Look for unneeded equipment
Red Tag Hints
Look for unneeded equipment
Machines, small tools
Dies, jigs, bits,
Conveyance equipment
Plumbing, electrical parts

28. Red Tag Hints Look for unneeded furniture Cabinets Benches, tables
Chairs
Carts

29. Red Tag Hints Search these storage places Shelves Racks Closets Sheds
Search the walls
Items hung up
Old bulletin boards
Signs

30. Red Tag Hints Look for other unneeded items Work clothes Helmets
Work shoes
Trash cans
Other

31. Red Tag Hints Look for unneeded materials Raw material Supplies Parts
Work in process
Finished goods
Shipping materials

32. Visual Factory Mark-off the inventory locations
Mark-off equipment/machine locations
Mark-off storage locations (cabinets, shelves, tables)
Visually indicate amount of allowed inventory
Keep metrics, wall charts, and other information current
Label all cabinets, shelves, etc with their contents
Posted production status, upcoming jobs

33. WASTE WALK then Return and discuss