2. Why 5S? Workplace organization required when:
Safety risks due to physical obstacles and hidden hazards
Product defects and equipment breakdowns resulting from a dirty environment
Lost productive time searching for information, material & tools
Poor customer responsiveness and incorrect work
Difficulty in distinguishing between
what is needed/ unneeded

3. What is 5S ?
5S is a method of creating a clean and orderly workplace that exposes safety risk.
It’s important to realize that 5S is far more than a just a housekeeping initiative….

4. History of 5S Clean up Arranging Neatness Discipline
Ongoing Improvement
Henry Ford’s CANDO program was an obvious precursor to what we call 5S today. The Japanese studied Ford’s methods to develop the Toyota Production System.

5. 5S are action verbs ! Sort Sustain Shine Straighten Standardize Safety
When 5S is implemented and sustained significant improvements can be obtained within any environment.

6. One Piece Flow Reduced Lead time Cell Team Working
Need for 5S
One Piece Flow Reduced Lead time Cell Team Working

7. How do we Apply 5S ?
SAFETY FIRST! Identify and remove unnecessary items from the work area that can contribute to slips trips and falls.
Sort - Eliminate what is not needed.
Straighten - Establish a place for everything based on
usage and keep everything in its place.
Shine - Clean, inspect, and look for ways to keep
everything clean.
Standardize - Maintain (organize) and monitor the first 3 S’s.
Sustain- Make 5S a way of life.

8. Safety First Get rid of the clutter!
To help prevent slips, trips and falls…..identify and remove unnecessary items from the workplace that are not needed.

9. Step 1 - SORT

10. Why Sort ?
By clearing out equipment and materials that are no longer required to perform work:
available space can be freed up
clutter that contributes to slip, trip, and fall hazards and/or items falling off of shelves can be greatly reduced.
Additionally sorting can also improve workflow since there is less clutter in the way.
If implemented correctly, sorting can also increase productivity.

11. Steps in Sorting 1. Identify an area to sort
2. Identify equipment needed
3. Identify what is not needed
4. Yellow tag event
5. Dispose of unwanted items
The steps are used to identify, tag and disposition what is not needed in a work area and to clear out unnecessary items.

12. 1. Identify the area to sort
The first step of sorting will identify the targeted area where the tag activity will be performed.
It’s extremely important to define the area in which the team plans to perform the event and only stay within that area.
When the area is completely sorted the team can move into another location.
This step basically challenges the team to focus on unnecessary items and clutter within a specified location.

13. 2. Identify equipment needs
The second step of sorting is to define the red/ yellow tag criteria, which should be based on frequency of use and equipment location etc.
Establishing advanced criteria will help the team objectively determine if an item should be tagged or not.
A common criterion is to base decisions on what’ll be needed for a specified production timeframe.
1 Week Rule
If an item is not going to be used in the immediate work area within 1 week, move to a different location.

14. 2. Identify equipment needs cont…
When reviewing the work area, the team should consider equipment, tools, excess materials, supplies and paperwork etc.
It is also a good time to determine if something that should be in the work area is missing and to evaluate the proper quantities of items kept in the work area.
Equipment
Tools
Materials
Supplies
Paperwork
What is Missing?
Correct Quantities?

15. 3. Define what is not needed
Apply the 1 Week Rule
Supplies and materials that are not used weekly
Tools and equipment that is not used frequently
Old paperwork such as old files and obsolete postings
After the team has identified what should be in the area, the team should now focus on what doesn't need to be in the area.
If an item is not needed to immediately repair the component, or support the operation of the equipment, then for safety reasons do not leave it in the direct work area.

16. 4. Tag Event
The fourth step of sorting is to conduct the tag event.
The 5S team should visually sweep the sorting area and apply tags per the previously determined criteria.
Note: Tagging must be performed by a team comprised of people who work in the immediate area. The team’s goals are to accomplish the following:
Identify equipment to be removed and assign proper locations for the remaining items.
Find storage locations for all supplies that are needed but not used every day.
Place tagged items in a designated temporary hold area.
Establish a time frame (five days), to move the tagged item(s) to a centralized storage area for further review and disposition.

17. Red/ Yellow Tag
Tags should be numbered with a specific serial numbers to aid in tracking each item’s status.
Tagged items should be staged in a designated ‘tag’ hold area (for short and long term disposition).
Items should be dispositioned when guidelines /expiration dates have been met.

18. Kept At Another Location √
Log Sheet
Tag Log Sheet
Date In
Tag #
Item Description
Supervisor Tagged-In
Target Date
Supervisor Removed
From What Area
Remove/Dispose
Kept At Another Location √
Sold √
Scrap √
A log sheet must be completed and maintained during and after disposition to track equipment.

19. 5. Dispose of unwanted items
The fifth step of sorting is used to evaluate the tagged item(s) against previously established criteria.
The remaining tagged items should be moved into a centralized tagged holding area (30 days or longer) that can provide visibility to other stakeholders in the organization.

20. A: Used about once a week B: Used once a month
Examples - of Disposition Guidelines
A: Used about once a week
Store it close to the work area
B: Used once a month
Store it somewhere accessible in the facility
C: Used once a year or less frequently
Consider storing outside (determine what type of protection is needed)
D: No longer needed
Consider moving it off-site
These are frequency of use guidelines to help
teams disposition equipment.

21. Disposition Area
Identify a temporary local holding area.
After the specified time has lapsed, the item should be dispositioned in accordance with established criteria.
The holding area should be accessible to other stakeholders for review and consideration of the item.

22. Sort - Summary When sorting, consider everything in the work area…
Sorting will effectively accomplish the identify and remove process of waste, gains needed space, ensure a safer work environment and remove clutter that contributes to slips, trips and falls.
Sorting process:
Start in one area and sort through everything.
Divide items into two categories:
Necessary
Unnecessary
Categorize necessary items:
Rarely used
Occasionally used or shared
Frequently used
Discard unnecessary items:
Discuss removal of items with all persons involved
Items that cannot be removed immediately should be tagged

23. Step 2 - STRAIGHTEN

24. Why Straighten ?
The purpose of straightening is to arrange necessary items in such a way as to safely maximize movement (avoid slips, trips and falls, etc.).
In other words we should place the items we use most, close to where the work is performed and in a clearly identifiable designated location.

25. Step 2 - Straighten Draw a layout for each work area:
Designate a specific place for everything needed to complete the assigned task at that station.
Establish Point of Use rules supporting work being performed. 1 2
Bounds of the work area
Tire & Repair
Process equipment
Storage “on” the equipment
Assembly
Storage in the work area
Storage close to the work area
Everything in the work area should have a place and everything should be in it’s place – eliminate the need to have to search for tools, supplies, parts, devices, and equipment.

26. Step 2 - Straighten
Three ‘F’ Standards
In order to properly store things it is recommended that the following points be considered:
Fixed location: Items have a dedicated location
Fixed item: A place for everything, and everything in its place
Fixed quantity: Only a pre-determined amount of items can be stored

27. Step 2 - Straighten
Designate use and storage locations based on factors such as frequency of use, sequence of use, and the bulk or cubic feet occupied by the item being stored.
Select the best types of storage systems for the items being set in order (examples: cabinets, shelves, carts, benches, etc).
Use signs and labels to identify what is to be stored where.
When it is determined what should be left in the work area, identify a specific location for everything.

28. Put supplies, tools and parts in “build / use” sequence
Visual Controls
Put supplies, tools and parts in “build / use” sequence
Having a designated location for everything enables workers to utilize visual control in their operations.
At a glance they are able to notice if things are in-place or out-of-place and if they need to order more materials, supplies, tools etc.

29. Visual Controls
5S and visual workplace are complementary
A visual workplace is when anyone can walk in and visually understand the current situation
Workplace organization
The work process
When there is an abnormality
We create the visual workplace with visual controls (signs, labels, etc.)

30. Designated Space TIPS:
Outline the space with cut-outs, colored tape or paint.
Colors of paint or tape should stand out.
Use different colors for different types of storage.

31. Waste Containers - Tips
Trash cans
Waste carts
Recycle bins (paper)
Cardboard scrap
Large material to be recycled (boxes)
Space in the work area should be dedicated for trash cans, waste carts, recycle bins, etc. The designated locations for these items must be convenient to the work area but must not be in the way.

32. Straighten – Summary
When you straighten, you are arranging all your necessary items.
“A place for everything and everything in it’s place.”
Straightening Process:
Determine location of needed items
Keep items that you use together, located together
Use labels, tape, floor markings, signs and shadow outlines
Shared items should be kept at central locations to eliminate excess
Straightening Benefits:
Visually shows what is required or out of place
More efficient to find items or documents
Saves time not having to search for items
Shorter travel distances

33. Step 3 - SHINE

34. Why Shine ?
The primary benefit of shine is that it improves safety by reducing slips, trips and falls.
Shine or sweep means to clean in such as way as to identify and remove sources of contamination. Thereby making defects and potential failures more visible.

35. Implement a plan to systematically clean the designated work area.
Step 3 - Shine
Implement a plan to systematically clean the designated work area.
Eliminate all forms of contamination, including dirt, dust, fluids, etc.
Inspect equipment and look for abnormal wear or conditions that might lead to equipment failure.
Establish a plan /standard to maintain workspace cleanliness.
Develop preventative measures to keep the workspace clean.

36. Step 3 - Shine
The first step is to assign areas of responsibility. Everyone should be assigned a zone within the area and be responsible for keeping it in order.
The second step is to establish ‘sweep’ standards, by doing this we can find equipment breakdowns and establish ways to improve.
3. The third step is to ‘keep to the clock’, be sure to establish an allotted time to perform daily activities regarding 5S.
4. The fourth step is to start at the same time. This makes it easy to see if proper work assignments are being accomplished and completed related to daily maintenance.

37. Shine - Summary
When you shine, you are keeping your area clean on a continuing
basis.
Shining Process:
Sweep and vacuum
Dust and mop
Polish and paint
Cleaning becomes a form of inspection
Shining Benefits:
A clean workplace is indicative of a quality product and process
Dust and dirt cause potential health hazards

38. Step 4 - STANDARDIZE

39. Why Standardize ?
In the context of 5S, standardize is simply the result of doing the first three steps properly: sort, straighten and sweep.
A chief proponent of the 5S program said, “Where there is no standard there can be no improvement.” In other words, if there is no consistency in the way work is done how can we ever improve on it?

40. Examples of Standardize

41. Examples of Standardize

42. Examples of Standardize

43. Examples of Standardize

44. Standardize - Summary
When you standardize, you are maintaining your guidelines for
sorting, straightening and shining.
Standardizing Process:
Develop checklists
Develop schedules to perform the tasks
Evaluate the area using the 5S evaluation sheet
Continually improve the area’s appearance and efficiency
Standardizing Benefits:
Prevents regression to an unclean or disorganized environment
Eliminates the need for special clean-up efforts
Integrates 5S duties into regular work duties

45. Step 5 - SUSTAIN

46. What is Sustain?
In the context of 5S, sustain means to have the commitment and self discipline to maintain the previous steps.
Use approved communication methods to help sustain 5S efforts.
Conduct audits to maintain focus on 5S initiatives.

47. Step 5 - Sustain
Incorporating 5S involves an organizational culture change. To achieve this kind of a change it must be supported by everyone at all levels. (Note the labels …)

48. Step 5 - Sustain
Implementing and supporting 5S must become ingrained in the culture of the organization.
Incorporating 5S involves an organizational culture change. To achieve this kind of a change it must be supported by everyone at all levels.

49. Organization Understanding
5S Audit Form 5S
Audit Form
Sort
Straighten
Shine
Standardize
Sustain
Level 5
Habit
Needed items can be retrieved in 30 seconds or less. Obsolete materials are routinely removed from the area. Preventative measures are in place to keep unnecessary items, reports etc. from entering the area.
Anyone can walk into the work area and easily locate work by priority. Corrective measures are in place to address abnormal conditions.
Work area housekeeping is a routine way of life. Corrective action measures are in place to address cleanliness issues.
Team is adhering to standards work methods, visuals and work area controls. A system of improving work methods and work area controls is clearly being utilized
Information on the area information board is meaningful and influences the daily decisions of the work area. Root causes of problems are eliminated and actions focus on preventative methods.
Level 4
Commitment
All work material has been sorted according to what will be worked today, this week. Materials, tooling, files and reports are routinely reviewed for necessity.
Team members can easily determine what items are currently in-use and their priority. Visual controls are in place to indicate normal / abnormal work conditions.
Work area housekeeping responsibilities are established and being followed on a daily basis. Cleaning materials are stored and readily available.
Team is utilizing standard work methods and work area controls on a daily basis. Possible for visitors to tell what work is performed and where in most cases.
Team routinely checks area to maintain the 5S's. Information on the area information board is meaningful to the work area. Source and frequency of problems are documented and corrective actions taken. Planning occurs to reach next 5S levels.
Level 3
Organization Understanding
Only documents and tools necessary to the work area are stored at the workstations and are stored in an orderly manner.
A priority system has been established to highlight the order in which jobs will be performed. All tooling, gages, hand tools have designated locations.
Cleanliness problems have been identified and preventative measures are documented and in place.
Team has documented needed items, work methods, and work area controls and has made them available in the work area. Possible for visitors to tell what work is performed and where in some cases.
5S presentation has been made to all Team members and a general understanding for the need and direction exists. Area information board is present, visible, and maintained.
Level 2
Awareness of Need
Needed and unneeded items have been identified and unneeded items have been removed from the area. Nothing is placed on top of machines, cabinets, etc.
Needed items have been organized according to use, including production tooling, hard tools and work procedures.
Initial cleaning has been performed. All machines and equipment are neatly painted. Workbenches and desks are free of unnecessary objects.
Team has agreed on needed items, work methods, and work area controls. Hard for visitors to tell what type of work is performed and where, but employees generally know.
Team members have knowledge of and are employing some aspects of 5S.
Level 1
Initial Effort
Team has identified needed items for the work area.
All needed items are present in the work area. It is not difficult to determine
Area cleaning is performed on a random basis.
Work methods are documented in some cases.
Some 5S awareness exists among Team members in the area.
Overall Score
(Sum of Totals divided by 5)
_____ 5 =
Total =
The factory 5S evaluation form (explain how it is used to the audience).

50. 5S Rating Form

51. Sustain - Summary
When you sustain, you are maintaining a discipline. We need to
practice and repeat the process until it becomes a way of life.
Sustaining Process:
Training everyone is vital
Involvement from all is necessary
Commitment and discipline toward housekeeping is essential in taking the first step in being world class
Sustaining Benefits:
Builds housekeeping into the every day process
Correct procedures become a habit

52. What is 5S all About? #1 Sort 2. Shine Make it inspection ready
Keep what is needed
2. Shine
Make it inspection ready
3. Straighten
Assign a location #1
4. Standardize
Repeat the process
5. Sustain
Establish discipline

53. 5S in Your Office