1. Visual Workplace - A Prerequisite To Becoming World Class
This module should be taught at the start of Day 2. Before beginning, be sure to review the Pulse Check summary from Day 1.
6S As A Tool To Create And Maintain The Visual Work Place

2. What Is 6S?
A process and method for creating and maintaining an organized, clean, high-performance workplace
A conditioning discipline for kaizen

3. What is Lean? A Thought Process!
A methodology that focuses on the identification
and elimination of waste. The relentless never ending attack on waste.
Relentless challenge of the status quo with
regard to the elimination of waste.
Customer satisfaction and continual improvement
Also known as the Kaizen process.
A different way of Thinking and Managing
A Thought Process!

4. Why Have a 6S Program? Places high value on safety
Creates proper environment for standard work
Prerequisite to perfect quality
Encourages visual control
Helps identify waste
Promotes employee satisfaction
Promotes customer satisfaction
It is essential for abnormality management

5. Housekeeping is only a small subset of 6S
The 6S Program
Step 1: Safety
Step 2: Sort – Segregate & Discard (Seiri)
Step 3: Separate – Arrange & Identify (Seiton)
Step 4: Shine – Clean & Inspect Daily (Seiso)
Step 5: Standardize – Revisit Frequently (Seiketsu)
Step 6: Sustain – Motivate To Sustain (Shitsuke)
This will be the only time the Japanese terms will be used (so the students will understand why it’s called 5S) – from here on out, stick with the English translations.
Housekeeping is only a small subset of 6S

6. Step 1: Sort – Segregate & Discard
“When in doubt, move it out, and throw it out.”

7. Step 1: Sort – Segregate & Discard
“When in doubt, throw it out.”

8. Step 1: Sort – Segregate & Discard
Survey the work area for unnecessary items, and move them out
Discard as much as possible
Organize the remaining necessary items
Use the Red Tagging process
Survey…
Conduct a red tag audit (see next slide for details).

9. Step 1: Sort – Segregate & Discard
Red Tagging: Helpful Hints
Identify a disposition area to put items removed
Train all participants in proper red tag procedure
Be fair—get all areas tagged
Don’t red tag people!
Don’t compromise: If in doubt, move it out!
Necessary items can be tagged if improvements are known or suggested
Don’t put multiple tags on any one item
Be reasonable about decorative items, family pictures, plants, etc.
Explain why the log is important:
Summary of what has been tagged
Location
Disposition status
Documentation
Make suggestions on where to place it.

10. Step 1: Sort – Segregate & Discard
Red Tag Examples
Production Areas
Office Areas
Cabinets / tool boxes
Components
Documentation
Gauges
Machines
Old Paint
Packaging Materials
Parts
Prints
Shelves
Supplies
Tables
Tooling
Trash
Books
Business
Forms
Cabinets
Catalogs
Correspondence
Equipment
Magazines
Paper
Parts
Samples
Shelves
Supplies
Digital files

11. Step 1: Sort – Segregate & Discard
Red Tag The Shelf!!!!!

12. Step 2: Separate – Arrange & Identify
Work In Process WIP
Cutting tools, gauges, & lubricants
Tools and jigs
Information
Discuss:
Opportunities for establishing SWIP and/or min/max levels
Footprinting opportunities
Silhouette opportunities (tool and part boards)
Labeling, etc.

13. Step 2: Separate – Arrange & Identify
Define item placement by frequency of use
Determine address system with part number and address
Label the container with part number and address
Note minimum and maximum quantity (if appropriate)
Make good arrangement a habit (follow steps 1–4)
Max Inventory (red)
Address
A-1
A-2
Part #
A-3 A 1 12 1 13 1 14
Min Inventory

14. Step 2: Separate – Arrange & Identify
Before
For Ease of Use
After
“A place for everything, and everything in its place”

15. Step 2: Separate – Arrange & Identify
For Ease of Use
A copy of the scissors is the shadow showing the
scissors in use
(Home location clearly identified)
“A place for everything, and everything in its place”

16. Step 2: Separate – Arrange & Identify
Information

17. Step 3: Shine – Clean & Inspect Daily
Identify cleaning activities and routine maintenance required
Provide well equipped cleaning supply stations
Have painting and marking supplies available
Identify individual ownership for all areas
5S standard operations which impact on “clean & inspect daily” include:
Operator Daily 5S Checklist (customized for each operator)
Supervisor Daily 5S Checklist
5S audit score sheet
5S audit schedule
Note: Examples of these documents are on subsequent slides.
Stress the importance of shift-to-shift communication.

18. Step 3: Shine – Clean & Inspect Daily
"A clean workplace enhances quality, safety, and pride"

19. Step 3: Shine – Clean & Inspect Daily
"If it doesn't get dirty then it doesn't need to be cleaned"

20. Step 4: Standardize – Revisit Frequently
Set-up daily shift hand-off rules
Identify normal state
Conduct weekly 6S audits to uncover 6S abnormalities
Determine root cause(s) of any 6S abnormalities
Implement countermeasures for abnormality prevention
A sample audit form is on the next slide.
Recommended audit frequencies:
First line supervision – weekly
Mid-level management - monthly
Upper management – monthly / quarterly
Countermeasures may include:
Improving daily 5S checklists to ensure full implementation of “segregate & discard”, “arrange & identify”, or “clean & inspect daily”, as needed.
Reinforcing/retraining use of daily checklists.
Establishing a 5S audit schedule.

21. Step 4: Standardize – Revisit Frequently

22. Step 5: Sustain – Motivate To Sustain
Implement a 6S performance board
Everyone sets the 6S example:
Daily checklist reviews conducted
All levels participate in audits
All levels ensure countermeasures are implemented
Promote positive results in company communications
A 5S performance board provides visual control for maintaining 5S discipline. It consist of”
The most recent 5S weekly audit
5S audit score tracking graph
5S kaizen newspaper or countermeasures list
Leadership participation in the process of monitoring (I.e., the daily review and weekly audit process) is crucial.
“Promote positive results…” includes linking kaizen success to 5S success (I.e., establish that there’s a bottom line that goes beyond housekeeping).
"If you drop it, pick it up“
“If you spill it, wipe it up”

23. Step 5: Sustain – Motivate To Sustain
Everyone needs to be involved
Integrate 6S principles into daily work requirements
Communicate need for 6S, roles of all participants, how it is implemented
Be consistent in following 6S principles in all areas
Follow through—6S takes effort and persistence
Link 6S activities with all other kaizen initiatives
Remember, 6S is a foundation for world class

24. 6S Develop a 6S audit schedule Determine 6S standard work details
Develop a standard clean-up checklist
Develop the implementation plan
6S Standard Work Development Exercise (allow 1 hour 30 minutes):
Have the group develop 6 audit schedule:
What is the audit frequency?
Who will do the audit (for each participant’s work area; for example, they may choose to pair off into “mutual audit” teams)?
Use the blank form in the appendix at the end of this module.
Use the sample in the appendix at the end of this module as a guide.
Have the group determine other standard work details:
Where will scores and the kaizen newspaper be posted?
Who sets 6S targets?
Who is responsible for auditing the newspaper for uncompleted items?
How will middle and senior management be involved?
Have the group develop an operator daily 6S checklist for one operator in the delta site.
Note: The delta site supervisor should use this as a template for developing checklists for all the other operators and a checklist for himself.
Mention to the students that there are blank “6S Audit Schedule” and “6S Daily Checklist” forms in Addendum 1 (for their later use).
Summarize the standard work consensus, and arrange with the KPO for the process and forms to be ready for the Day 4 5S audit (if you do one; at a minimum, the should be ready for use next week).

25. Thank You. Let’s get started!
This module should be taught at the start of Day 2. Before beginning, be sure to review the Pulse Check summary from Day 1.