1. www.ManufacturingNZ.co.nz 5S Introduction – Workplace Organisation
Successful implementation of 5s into manufacturing processes (or business processes) has many advantages.
5S demonstrates that management has a commitment to change and improvement.
5S gets everyone involved in ‘doing’ something.
5S is a starting block and integral part of many other lean initiatives, such as TPM, Kaizen and SMED.
5S increases motivation of staff as it improves the working environment.
Costs are saved through efficiency and productivity improvements, freeing up space and reducing wasted time and resources.
5S creates a better impression with customers and suppliers or any external people.
5S can create funds by releasing unnecessary equipment that can be sold.
5S improves the safety of the workplace.
5S is a low cost, high impact activity to demonstrate the results that can be achieved through lean.
5S establishes a set of new practices and attitudes in the organisation workforce that will be needed to successfully implement a Lean culture.
Beth Smith Manufacturing Consulting 2009

2.
Definition
Workplace organisation is a visual and physical method of correctly organising the workplace.
It ensures that only the required material and equipment is present, that it is in good condition, and that it is stored in a manner that aids the efficiency of the production facility or workplace.
5S can be applied to a manufacturing cell, a production line, a support area such as maintenance, or administrative areas.
Beth Smith Manufacturing Consulting 2009

3. The 5 Steps of Work Place organisation
Main elements
The 5 Steps of Work Place organisation
Japanese English
Shitsuke
Seiketsu
Seiso
Seiton
Seiri
Sustain 5
Standardise 4
Shine 3
Set in order 2
Sometimes the 5Cs is used
Clear out
Configure
Clean and Check
Conform
Custom and practice
It is important that all Five disciplines are implemented as they are all interdependent upon each other.
Sort 1
Beth Smith Manufacturing Consulting 2009

4. These items should be immediately removed from the work area.
Step 1: SORT – clear out
Identify all items in the workplace which are not required to do the regular jobs, e.g.
Scrap material
Unused stillages
Unused Jigs and fixtures
Unnecessary tools
Obsolete components
Personal possessions
Etc.
These items should be immediately removed from the work area.
It is best if this exercise is carried out by the operators who work in the area along with their team leader.
The standardised work documentation should specify exactly what material and equipment is required to do the job. Anything else should not be in the work area
The team should compare the actual condition with that specified and remove any surplus.
A red tag campaign is often used, where any item that is not required is individually marked and removed to a quarantine are for a period before being scrapped or disposed of.
Use photos to record the before and after and display the after so all know the new required standard.
Two areas should be set up: one for the collection of unused items and one for items that are frequently used.
Beth Smith Manufacturing Consulting 2009

5. Example of “Sort” on the factory floor
Example of “Sort” on the factory floor
Many unnecessary items clutter the cell
All unnecessary items removed
Obsolete parts
Tables / benches
Tools and fixtures A F A F
Work in progress E E B B C F C F
Scrap material
This exercise has removed the unnecessary material. It is easier to see what is going on!
The “sort” or “clear out” should only leave the material and equipment necessary to do the current and common jobs.
This is only the first of 5 steps, DON’T STOP!
Machines
Containers of materials
AFTER
BEFORE
Beth Smith Manufacturing Consulting 2009

6. Example of :sort” on the desk
Example of :sort” on the desk
Things get hidden or lost
In-Tray
Room to work
Easy to find things
Looks professional
Cleaning the desk is now possible.
Things are easy to find
Important items cannot get missed.
With the completion of the first S you will instantly see three main results:
increased productivity – The purpose of individual work areas will be more apparent, leading to highly efficient workforce.
Workers will be more satisfied with their environment. Emplotee morale will increase as junk itmes or materials that are potetntil health hazards are identified and removed.
Much more full attention can be paid to production. Employees will no longer need to focus on tangential tasks such as locating tools and implementing their own organisation systems.
No room to work
Looks unprofessional
BEFORE
AFTER
Beth Smith Manufacturing Consulting 2009

7. Step 2: Set in order – create layout
Step 2: Set in order – create layout
Properly identify, arrange and locate the material & equipment that is necessary to do the job. E.g.
Production components
Tooling and fixtures
Hand tools
Containers
Etc.
All material and equipment required for the job should located as close s possible to the point of use
All material and equipment should have a clearly amrked and visual “home” positions , which make them easy to find and makes obvious any missing items.
Beth Smith Manufacturing Consulting 2009

8. Example of “Set in order” on the factory floor
Example of “Set in order” on the factory floor
Necessary item still with no home clutter up cell
All necessary items correctly located
Reduced congestion
Improved safety
Tools and fixtures
Tables / benches A F A F E B E B C F C F
The workplace was much tidier after the “sort” step – but efficient working was still obstructed by the inappropriate location of material and equipment.
The application of the “set in order” step has placed all the necessary material in the most appropriate locations – which are close to the point of use, but not in positions which impedes the movement of production material or operators.
Cleaning and maintenance will now be much easier
The risk of accidents and mistakes will be reduced
Containers of materials
Work in progress
BEFORE
AFTER
Beth Smith Manufacturing Consulting 2009

9. Example of “Set in order” in a storage area
Example of “Set in order” in a storage area
No easy visual idea of stock level
Each item has a specific location can be colour coded
No identification
Store location identification is used
Items stored randomly
Diagonal strip indicates correct sequence
Tool No 1234
Tool No 568
Material at a convenient height
Make sure there is a place for everything
All items to be put where it is easy to find them and access them
Frequently used items should be stored in the most convenient locations for easy and rapid retrieval.
Every location must have an identification label
Colour coding can be used to speed up identification
Use convenient height – shoulder to knee
To improve access look at raising shelves or removing doors
Stock reorder level can be marked on location
Part No. 356
Part No. 999
Beth Smith Manufacturing Consulting 2009

10.
Step 3: Shine
All tools and equipment associated with the process must be thoroughly cleaned and then checked for:
Leaks
Wear
Loose fittings
Incorrect settings
Etc.
“shine” must also be applied to the whole workplace, i.e. Floor and other factory fixtures and fitting including lights and heating.
Any concerns identified should be formally logged and followed up until resolved.
Where concerns logged an identification alert tag should be adde to the equipment. Regular reviews should pick up where action is not being taken.
Everyone in the work team should be involved in the “shine”
Each work team member should be responsible for activity in their own area.
All areas must eventually have a “shine” owner
Beth Smith Manufacturing Consulting 2009

11. Example of “shine” in equipment
Example of “shine” in equipment
Poor equipment condition
Dirt hides problems
Problems become apparent
Drives resolution of problems
Orderly cleaning will often identify problems in the production process.
Fluid leaks are often difficult to pin point on dirty machines
Particles such as swarff and filings get onto work areas and often damage products and equipment.
Dirty filters often lead to early failure and quality problems
Clogging cn occur when using dirty coolant.
Dust can get into processes such as painting
Safety first. Untidy areas are not safe and create fire hazards.
BEFORE
AFTER
Beth Smith Manufacturing Consulting 2009

12.
Step 4: Standardise
The systemised approach of maintaining high standards of workplace organisation at all times by:
Recording requirements
Allocating responsibilities
Determining frequencies
Display of instructions and guidelines.
Standardisation is necessary to make sure Workplace organisation becomes a way of life.
Standardisation must be applied to the following elemenets: Sort, set in order and shine
Details of the individual tasks, responsibilities for those tasks, the required frequency and the circumstances under which each task should be carried out must be recorded within standard documents and displayed.
Basic posters reminding people of what is expected, help.
Beth Smith Manufacturing Consulting 2009

13. Example of “standardise”
Example of “standardise”
Standard process sheet can be simple or detailed, openly displayed and include pictures to show requirements and standards
Workplace organisation document
Team member Joe Bloggs
Floor plan
Areas of responsibility:
1 Weld subassemblies
2 Machine centre 1
3 Work bench 1
Tasks to be completed Frequency
Empty dustbins Daily
Clean out swarf Daily
Clear bench top Daily
Empty metal scrap bin Days
Check machine maintenance monthly
WB 1
MC 1
The tasks involved in maintaining Workplace Organisation standards are just as important as those for the production process.
All Workplace organisation tasks should be captured on the normal work instruction charts type documentation
Visual management methods help team members and team leaders maintain workplace organisation standards
The use of good quality notice boards displaying colourful diagrams, tables, photographs and other messages will help provide effective communication
Visual aids must be placed where the team members find them easy to use and read, not just where visitors can see them!
Display and explanation of more infrequent tasks can help ensure continuity
Weld Subs
Beth Smith Manufacturing Consulting 2009

14. Stap 5: Sustain – training and discipline
Stap 5: Sustain – training and discipline
Workplace Organisation is an important part of any Best Practice system.
Everyone involved in operating the system must understand the principles and processes.
Formal structured training and on the job coaching is essential if good Workplace Organisation practice is to become part of “business as usual”.
Simple effective visual management methods should be used to assist the team members and team leaders to follow the processes and maintain standards.
All tasks, systems, locations and areas should be apparent and clear for strangers to be able to understand.
Workplace organisation supports the operation of the whole Best Practice system
Poor workplace organisation will inhibit the effective operation of the system
Workplace organisation must be part of the overall training and induction plan
On the job training and coaching by team leaders forms an important part of this plan
Visual management methods can help to make good workplace organisation a way of life
All production management must understand the importance of good workplace organisation and must immediately challenge any examples of poor discipline.
Train people to devise and implement their own solutions
Use team meetings to highlight success.
Beth Smith Manufacturing Consulting 2009

15. Example of Training and discipline
Example of Training and discipline
Workplace Organisation Monitor Board
March
Month _________
Team Members
Work centres
Fred Smith
Mark Doyle
Steven London
David Connell
Front of card
Rear of card To
be done
Mark Black
Completed
Sam Davies
The use of a workplace organisation monitor is invaluable as method of visual management.
A simple visual system can help the whole team become accustomed to the requirements of the system,
Such a system can provide an instantly obvious status of the workplace organisation process
Regular audits should also be carried out by team members.
Karen Jones
Beth Smith Manufacturing Consulting 2009

16. Importance of Workplace organisation- 5S
Summary
Importance of Workplace organisation- 5S
A workplace that is
Well organised is
Safe to work in
High in productivity
High in Quality
Low in cost
Consistent in delivery
High in Morale
Sustain
Standardise
The five disciplines of Workplace organisation are well-recognised method of improving the working environment that is used extensively around the world.
Workplace organisation
Defines workplace standards
Defines organisation processes
Defines roles and responsibilities
Defines monitoring methods
Workplace organisation helps to:-
Reduce stress
Reduce absenteeism
Improve quality
Improve interpersonal relations
Better use the equipment available.
Shine
Take all five steps to success!
Set in order
Sort
Beth Smith Manufacturing Consulting 2009