1. Lean Manufacturing Series
5S and Visual Factory
Lean Manufacturing Series

2. Disclaimer and Approved Use
This presentation is intended for use in training individuals within an organization. The handouts, tools, and presentations may be customized for each application.
THE FILES AND PRESENTATIONS ARE DISTRIBUTED ON AN "AS IS" BASIS WITHOUT WARRANTIES OF ANY KIND, EITHER EXPRESSED OR IMPLIED.
Copyright
This presentation is created and copyrighted by Factory Strategies Group LLC.
Approved Use
Each copy of this presentation can be used throughout a single Customer location, such as a manufacturing plant. Multiple copies may reside on computers within that location, or on the intranet for that location. Contact us for authorization to use this presentation at multiple locations.
The presentation may be customized to satisfy the customer’s application.
The presentation, or portions or modifications thereof, may not be re-sold or re- distributed without express written permission.
Current contact information can be found at:

3. Contents Introduction Background and History
Components and Implementation
Knowledge Check

4. Introduction
5S is a method to improve and sustain workplace organization
5S represents 5 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.

5. 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.

6. Components and Implementation
5S and Lean Manufacturing
Elements of 5S
Sort
Straighten
Shine
Standardize
Sustain
Safety
Visual Factory
Implementation plan

7. Elements of 5S Sort Straighten Shine Standardize Sustain
Remove all unnecessary materials and equipment
Straighten
Make it obvious where things belong
Shine
Clean everything, inside and out
Standardize
Establish policies and procedures to ensure 5S
Sustain
Training, daily activities
Safety (often called “6S” or “5S + 1”)
A safety commitment in all activities

8. Types of Waste Overproduction Excess inventory Defects
Non-value added processing
Waiting
Excess motion
Transportation
Other Wastes:
Untapped Human Potential
Inappropriate Systems
Wasted Utility Resources
Wasted Materials

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

10. The Good – After 5S

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

12. 5S Examples
After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
Before 5S

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

14. Straighten Make it obvious where things belong Lines Labels Signs
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.

15. 5S Examples – Sort and Straighten
See the difference?
Sort - All unneeded tools, parts and supplies are removed from the area
Straighten - A place for everything and everything is in its place

16. Straighten 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

17. 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

18. 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.

19. 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

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

24. 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

25. 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
Red tags must be dispositioned within 30 days

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

27. Red Tag Inspection Sheet
Look for unneeded equipment
Machines, small tools
Dies, jigs, bits,
Conveyance equipment
Plumbing, electrical parts
Look for unneeded furniture
Cabinets
Benches, tables
Chairs
Carts

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

29. Red Tag Inspection Sheet
Look for other unneeded items
Work clothes
Helmets
Work shoes
Trash cans
Other
Look for unneeded materials
Raw material
Supplies
Parts
Work in process
Finished goods
Shipping materials

30. 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

31. Knowledge Check

32. Name the five “S” components. (Mark all that apply)
Sort
Straighten
Shine
Standardize
Sustain

33. Match the 5S component name with it's description by dragging the description to the name.
Sort
Straighten
Shine
Standardize
Sustain
Safety
Description
Training, daily activities
Clean everything, inside and out
A safety commitment in all activities
Establish policies and procedures to ensure 5S
Make it obvious where things belong
Remove all unnecessary materials and equipment F E B D A C

34. What are some ways in Straighten that you can make it obvious where things belong? (Mark all that apply)
Lines
Labels
Signs

35. Performing Shine results in which of the following
Performing Shine results in which of the following? (Mark all that apply)
Fewer breakdowns
Slower processing
Greater safety
Product quality
More satisfying work environment

36. What are some ways your team can Sustain 5S? (Mark all that apply)
5-S concept training
Before and after photos
Checklists, standards and procedures
Daily 5-minute 5-S activities

37. Strategy is sometimes called the sixth "S".
A) True
B) False

38. Which of the following are a part of the “red tag” activity
Which of the following are a part of the “red tag” activity? (Mark all that apply)
One-time activity to remove or disposition clutter
Identify clutter, unused equipment, etc
Fill out and attach red tag
Note in red tag log

39. What are some ways that you can maintain a Visual Factory
What are some ways that you can maintain a Visual Factory? (Mark all that apply)
Mark-off the inventory locations
Mark-off equipment/machine locations
Visually indicate amount of allowed inventory
Label all cabinets, shelves, etc with their contents

40. How can you implement 5S in your organization?

41. Congratulations!!! You have completed the course.
Please visit Superfactory ( for more information on manufacturing excellence.