1. Safety – 5S Implementation Guide

2. 5S Implementation Guide
The scope, size and timeliness of completing the 5S event must will be impacted by the availability of dedicated resources who are capable of actively participating in the event.
Note: Some sites do not have enough dedicated resources to complete a 5S event within a brief period of time (similar to a kaizen activity), under these circumstances each of the 5S can be completed separately over a planned time frame.
2. A visual display board should be established in a centralized location within the work area in order to provide a location for pictures and other standard work documentation.

3. Management Responsibility
Management must provide the following:
The area where the 5S activity will take place,
The 5S team lead and support personnel who will participate in the event,
Note: The event can be accomplished by personnel who work outside the area where the event is taking place but team selection should primarily be comprised of personnel from within the impacted area to assure direction and ownership.
Necessary resources including:
Available time and materials to perform the activities
Concise directions regarding dispositioning of tagged items

4. Identify workers, processes, and functions of the area.
Area Preparation
Identify workers, processes, and functions of the area.
Target Area Name:
2. Define the boundaries of the target area and tape it off.
3. State the primary purpose of the target area.
Criteria
Who
When
Status
Draw area map (event scope)
Identify all necessary equipment, tools and materials
Identify unnecessary equipment, tools and materials
Yellow tag unnecessary items

5. 5S Action Checklist Sort Straighten Shine Standardize Sustain
Distinguish between what is needed and not needed
BEFORE AFTER
Unneeded equipment, tools, furniture, etc. are present
Unneeded items are on walls, bulletin boards, etc.
Items are in aisles, stairways, corners, etc.
Unneeded inventory, supplies, parts, or materials are present
Safety hazards (debris, water, oil, chemical, machines) exist
Sort
Correct places for items are not obvious
Items are not in their correct places
Aisles, workstations, equipment locations are not identified
Items are not put away immediately after use
Height and quantity limits are not obvious
A place for everything and everything in its place
Straighten
Cleaning, and looking for ways to keep it clean and organized
Floors, walls, stairs, and surfaces are not free of dirt, oil, and grease
Equipment is not kept clean and free of dirt, oil, and grease
Cleaning materials are not easily accessible
Lines, labels, signs, etc. are not clean and unbroken
Other cleaning problems of any kind exist
Shine
Systematically maintain and monitor the first three S’s
Necessary information is not visible
All standards are not known and visible
Standard Work doesn’t exist for all cleaning and maintenance jobs
All quantities and limits are not easily recognizable
Items cannot be located in 5 seconds
Standardize
Area workers have not had 5-S training
5-S is not performed routinely
Personal belongings are not stowed neatly
Standard Work is not available or up-to-date
Daily 5-S audits are not performed
Stick to the rules
Sustain
Note: Check all that apply, plan countermeasures.

6. Sort Guidelines
The team lead should work with management to develop a work schedule to complete the Sort process in a expeditious manner.
If necessary management should provide 5S training to new team members.
Management will provide guidance and materials to support the following:
Focused area where the event will occur
Expected outcomes including allotted time to conduct the activity
Directions (criteria) and materials to sort, tag and disposition equipment, materials, tools etc.
Pictures should be taken in advance of and after the event to provide before and after perspective

7. Sort Red Tag Checklist Directions
Tag every item that may not be needed
Enter a X when a category is inspected
Examine all items in each category
Directions
Floors
Aisles
Operation areas
Work Stations
Corners, behind/under equipment
Stairs
Small rooms
Offices
Loading docks
Inside cabinets and drawers
Inspect storage places
Shelves
Racks
Closets
Sheds
Other storage areas
Inspect the walls, boards, etc.
Items hung on walls
Bulletin boards
Signboards
Other
Machines
Small tools
Dies
Jigs
Bits
Conveyance equipment
Plumbing, pipes, etc.
Electrical equipment
Wire, fixtures, junction boxes
Raw materials
Supplies
Parts
Work in process
Finished products
Shipping materials
Identify unnecessary material / supplies
Work clothes
Helmets
Work shoes
Trash cans
Other
Cabinets
Benches and tables
Chairs
Carts
Other

8. Tag Log
Item
Serial #
Date
Tag Status
Notes /Disposition

9. Disposition Guidelines
Directions
Determine the category each tagged item belongs
Determine required yellow tag action, record status on tag and update log
Take action
Category
Action
Obsolete
Sell
Hold for depreciation
Give away
Throw away
Defective
Return to supplier
Repair
Scrap
Remove to proper location
Trash /Waste
Dispose of
Recycle
Not needed in area
Relocate to new location
Used daily
Keep at place of use
Used weekly
Store in area
Used monthly
Store adjacent to area
Seldom used
Store in distant location
Unknown use
Determine use and storage location

10. Straighten Guidelines
“Everything should be assigned to a designated place and everything should be in its place”.
The team should identify specific locations based on work performance and frequency of use for each piece of equipment, tool and materials that are in the work area.
Note: When possible place frequently shared items on carts to establish mobility
Refer to the 5S training for examples on how create designated locations for tool shadowing in tool boxes and placement on shadow boards, etc.
3. Pictures should be taken in advance of and after the event to provide before and after perspective.
Note: Default to company policy for the application of tape protocols i.e. colors, patterns etc.

11. Straighten Inspection Sheet
Directions
Identify location for each
Move item to designated place
Enter a X when a category is inspected
Equipment
Machines
Small tools
Dies
Jigs
Bits
Conveyance equipment
Cleaning equipment
Electrical equipment
Fixtures, junction boxes, etc.
Computer equipment
Materials / supplies / inventory
Raw material
Supplies
Parts
Work in process
Finished product
Shipping materials
Cleaning supplies
Other items
Charts, graphs, etc.
Books, checklists, etc.
Bulletin boards
Signboards
Pens, pencils, rulers, etc.
Work clothes
Helmets
Work shoes
Trash cans
Personal items
Furniture
Cabinets
Benches and tables
Chairs
Carts
Shelves
Racks

12. Shine Guidelines
The team leader should assign team members specific areas to clean (see Initial Cleaning Plan).
The work area and each piece of equipment should be cleaned, assuring the removal of excess grease, oil fluids etc. to assure equipment isn’t leaking or in need of repair.
Assure the work area is cleaned (inspection ready) to establish a baseline score.
4. Pictures should be taken in advance of and after the event to provide before and after perspective.

13. Shine Inspection Sheet
Directions
Use this with the Initial Cleaning Plan
Enter a X when a category is completed
Large Surfaces
Ceilings
Aisles
Work Stations
Corners, behind/under equipment
Stairs
Loading docks
Walls
Doors
Pillars and posts
Floors
Other
Inside equipment / furniture
Machines
Conveyance equipment
Closets
Drawers
Cabinets
Sheds
Tool boxes
Storage bins
Carts
Shelves
Racks
Other items
Materials and supplies
Trash cans
Bulletin boards
Labels and signs
Small tools
Hoses, cords, tubing, etc.
Other
Surfaces of equipment and furniture
Machines
Conveyance equipment
Plumbing, pipes, sinks
Electrical equipment
Fixtures, junction boxes
Chairs

14. List tasks and complete the columns below
Initial Cleaning Plan
List tasks and complete the columns below
Target Area
Task
Area
Who
When
Materials & Tools

15. Standardize Guidelines
The basic purpose of ‘standardizing’ is to prevent set backs of the first three S’s. Management’s focus is to make them a daily habit assuring that sort, straighten and shine are maintained in there fully implemented state.
Immediately after the event has been completed management should establish a 5S job chart and assign work space personnel with daily responsibilities to maintain the 5S’d area in accordance with established standards.

16. List tasks and complete the columns below
5S Assignment Chart
List tasks and complete the columns below
Target Area
Task
Area
Who
When
Materials & Tools

17. Sustain Guidelines
The basic purpose if event lead should work with management to develop a working schedule to cover the 5S.
Management should assemble the team and provide 5S training overview.
Management should provide information and materials to support the following:
Focused area where the event will occur
Expected outcomes including allotted time to conduct the activity
Directions (criteria) and materials to sort and tag equipment, materials, tools etc.

18. Sustain Guidelines
Without organizational commitment to Sustain the benefits of the 5S activities quickly falls apart.
Positive conditions to support Sustain are:
Awareness – Use approved communication methods to help sustain 5S
Time – schedule time to perform the 5S
Support – management should provide acknowledgement, leadership and resources
Rewards & Recognition – Good efforts should be rewarded.
Conduct scheduled audits to maintain focus.

19. 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.
Alll 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).

20. 5S Rating Form

21. Event Closeout & Follow-up
The event lead should work with management to develop a working schedule to cover the 5S.
Management should assemble the team and provide 5S training overview.
Management should provide information and materials to support the following:
Focused area where the event will occur
Expected outcomes including allotted time to conduct the activity
Directions (criteria) and materials to sort and tag equipment, materials, tools etc.