1. Chapter 4 5S

2. IT-465 Lean Manufacturing
What are the 5S’s?
They are the keys to workplace organization, housekeeping, and visual management.
Simple and produces:
Increase in quality
Increase in productivity
Cleaner workplace which produces a safer workplace
Earlier i.d. of abnormal business situations
IT-465 Lean Manufacturing

3. IT-465 Lean Manufacturing
Waste
Waste is anything other than the MINIMUM amount of people, time, equipment, material, parts, and space required to ADD VALUE to the product.
The 5S’s apply everywhere.
IT-465 Lean Manufacturing

4. The 8 General Types of Waste
Scrap/Rework/Remake
Transportation
Motion
Waiting Time
Inventory
Overproduction
Overprocessing
Underutilized Human Resources
IT-465 Lean Manufacturing

5. IT-465 Lean Manufacturing
The 5S’s
Sort
Proper arrangement
Straighten (Store)
Orderliness
Sweep (Shine)
Cleanliness
Schedule (Standardize)
Cleaned up, standardized.
Sustain
Discipline, practice and repeat.
IT-465 Lean Manufacturing

6. IT-465 Lean Manufacturing
The Origin of 5S
Step #
Japanese
Word
English
Translation
5S Word 1
Seiri
Proper
Arrangement
Sort 2
Seiton
Orderliness
Straighten 3
Seiso
Cleanliness
Sweep 4
Seiketsu
Cleaned Up
Schedule 5
Shitsuke
Discipline
Sustain
IT-465 Lean Manufacturing

7. IT-465 Lean Manufacturing
Lack of 5S
Hides safety problem
Creates waste
Limits a company’s ability to satisfy their customers.
You never get a second chance to make a first impression.
World class facilities develop beginning with the 5S’s, and facilities that fall, fall apart beginning with the 5S’s (Hiroyuki Hirano)
IT-465 Lean Manufacturing

8. IT-465 Lean Manufacturing
Implementing 5S
5S Implementation Steps Outline
Prelaunch
Step #1. Form, train, & develop 5S teams.
Step #2. Develop the 5S model
Launch
Step #3. Announcement
Step #4. Train the plant in 5S
IT-465 Lean Manufacturing

9. IT-465 Lean Manufacturing
Implementing 5S
Step #1. Form, Train, and Develop 5S Grading/Recognition Teams.
Rule #1: Leaders must lead. Everyone must be involved. Applies to the office and the shop floor.
Rule #2: Everyone must be trained in 5S
IT-465 Lean Manufacturing

10. IT-465 Lean Manufacturing
Implementing 5S
Step #2. Develop the 5S Models: The “Islands of Excellence” Using the Grading/Recognition Teams.
IT-465 Lean Manufacturing

11. IT-465 Lean Manufacturing
Implementing 5S
Step #3. Kick Off the 5S Implementation: Tell Your Entire Team About the Importance, Goals, and Vision of 5S.
Importance
Establish plant wide discipline & org baseline that supports all improvement activities.
Goals
Improve safety & pride in the work place. Improve quality and productivity.
Vision
“Islands of Excellence”, World Class Enterprise.
IT-465 Lean Manufacturing

12. IT-465 Lean Manufacturing
Implementing 5S
Step #4. Train the Entire Plant in 5S.
Sorting, proper arrangement.
Improved safety
Improved communication between team members
Smoother work flow
Improved quality and productivity
Clearly distinguish between what is needed and what is not needed.
“When in doubt, move it out”
Rule #3. Facility environmental, health, and safety procedures must be followed at all times in the cleaning, moving, and disposal of equipment and material.
IT-465 Lean Manufacturing

13. IT-465 Lean Manufacturing
Implementing 5S
Step #4 Continued.
Sorting using the Red Tag system
A method used to i.d. items that are found in the work area, but their use and need are unknown.
Red Tag Procedure
Dedicate a red tag storage site
Look at all items critically, then place tags
Record all tags on log sheet
Give all users and shifts 48 hours to review
Move items to red tag storage site
Management review in one week
Make a list of tools that are required, but not available.
Rule #4. The Red Tag System is for one-time use only; it is not an ongoing crutch for future clean-ups.
IT-465 Lean Manufacturing

14. IT-465 Lean Manufacturing
Implementing 5S
Step #4 Continued.
Straighten, orderliness. (Store)
Improved safety
Improved quality
Improved productivity
A place for everything, and everything in its place.
Rule #6. Use a ceiling-down strategy. The first straighten and sweep begins with the ceilings, walls, and floor.
IT-465 Lean Manufacturing

15. IT-465 Lean Manufacturing
Implementing 5S
Step #4 Continued.
Straighten, orderliness. (Store)
Organize everything that remains
Make locations visible and self-explanatory.
Designate storage locations for everything
Tools
Gauges
Cleaning supplies
Job aides, information sheets, etc.
Keys to organization
Visual controls
Immediate retrieval
Immediate return
IT-465 Lean Manufacturing

16. IT-465 Lean Manufacturing
Implementing 5S
Step #4 Continued.
Sweep, cleanliness. (Shine)
Improved safety
Improved team morale and ownership
Improved quality
Reduced equipment downtime
Sweep the floors, wipe off equipment, paint if necessary, and make sure everything stays clean.
IT-465 Lean Manufacturing

17. IT-465 Lean Manufacturing
Implementing 5S
Step #4 Continued.
Sweep, cleanliness. (Shine)
Three Phases of Shine
Daily cleanliness
Cleanliness inspections
Cleanliness Maintenance
Attach a maintenance card (or TPM Card) to identify the problem.
Keys to Cleanliness
Must be done on a regular basis
Cleaning tools and supplies available at point od usage
Assign specific individuals to tasks
Designate specific cleaning time
IT-465 Lean Manufacturing

18. IT-465 Lean Manufacturing
Implementing 5S
Step 4 Continued:
Schedule, Cleaned up. (Standardize)
Improved safety
Improved team morale and ownership
Pave the path to step #5, Sustain.
Standardize and maintain the use of sort, straighten, and sweep.
Develop 5S activity checklists for all mfg and office areas.
Rule #7. Have regular inspections.
Rule #8. Have recognition and reward programs
IT-465 Lean Manufacturing

19. IT-465 Lean Manufacturing
Implementing 5S
Step 4 Continued:
Schedule, Cleaned up. (Standardize)
Develop and implement best practices
Use a 5S checklist to i.d. what will be done, who is responsible and when the task is to be done.
Visual Workplace – Color-coded Zones
Red – Inventory too low, re-order
Green – Inventory level ok
Yellow – Inventory too high, stop production
Visual Standards
Quality board to record problems
Pictures representing types of defects
Everyone can easily identify defects
IT-465 Lean Manufacturing

20. IT-465 Lean Manufacturing
Implementing 5S
Step #4 Continued.
Sustain, Discipline
Improved safety through better housekeeping
Improved team morale and ownership
Reduced overhead costs.
Practice and repeat these procedures until they become a way of life throughout the entire company.
“Sustain” is the discipline or rope that ties the other 4S’s together.
Rule #9. 5S has to be self sustaining.
IT-465 Lean Manufacturing

21. IT-465 Lean Manufacturing
Implementing 5S
Step 4 Continued:
Sustain, Discipline
Continue to sort, store, shine, standardize, and sustain the work area.
Companywide promotion of discipline
Make properly maintaining correct procedures a habit:
Use inspections/audits by top managers to evaluate each workstation and to provide feedback.
Chart the audit scores on a visual display board to show progress/deterioration
IT-465 Lean Manufacturing

22. IT-465 Lean Manufacturing
Implementing 5S
Chart production schedules and team improvements
5S Benefits
Eliminates excess equipment & inventory
Reduced absenteeism
Fewer equipment breakdowns & longer life
Better understanding of equipment conditions
Fewer defects and higher quality
Defects are made obvious
Efficient and effective organization
Saves time, cost, and makes workplace easier to maintain
Improves production schedules
Motion and waste reductions
IT-465 Lean Manufacturing

23. IT-465 Lean Manufacturing
Implementing 5S
Summary
Improve Visuals
Brainstorm better visuals
Photograph completed area
Create a “to do” list
Conduct final 5S Audit using scorecard
Assign ownership of completed area
IT-465 Lean Manufacturing