1. 5S and Visual Control Superfactory Excellence Program™ www
5S and Visual Control Superfactory Excellence Program™
© 2004 Superfactory™. All Rights Reserved.

2. Disclaimer and Approved use
The files in the Superfactory Excellence Program by Superfactory Ventures LLC (“Superfactory”) are 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
All files in the Superfactory Excellence Program have been created by Superfactory and there are no known copyright issues. Please contact Superfactory immediately if copyright issues become apparent.
Approved Use
Each copy of the Superfactory Excellence Program 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 Superfactory for authorization to use the Superfactory Excellence Program at multiple locations.
The presentations and files may be customized to satisfy the customer’s application.
The presentations and files, or portions or modifications thereof, may not be re-sold or re-distributed without express written permission from Superfactory.
Current contact information can be found at:
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3. 5S and Visual Control 5 Elements of 5S Why 5S? Waste
Workplace observation
Sort
Straighten
Shine
Standardize
Sustain
Visual Factory
Summary
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4. 5 Elements of 5S Sort Straighten Shine Standardize Sustain
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5. Why 5S?
To eliminate the wastes that result from “uncontrolled” processes.
To gain control on equipment, material & inventory placement and position.
Apply Control Techniques to Eliminate Erosion of Improvements.
Standardize Improvements for Maintenance of Critical Process Parameters.
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6. Types of Waste Overproduction Delays (waiting) Transportation Process
Inventories
Motions
Defective Products
Untapped Resources
Misused Resources
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7. Elimination of Waste
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8. Waste Identification
What waste can be identified in the following photos?
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9. Waste Identification
What waste can be identified in the following photos?
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10. After 5S Clear, shiny aisles Color-coded areas Slogans & banners
No work in process
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11. Workplace Observation
Clearly define target area
Identify purpose and function of target area
Develop area map
Show material, people, equipment flow
Perform scan diagnostic
Photograph problem areas
Develop a project display board (area)
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12. Target Area Vision Safety
Current Condition
Desired Conditions
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13. Target Area Vision Product Quality
Current Condition
Desired Conditions
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14. Target Area Vision Equipment Maintenance
Current Condition
Desired Conditions
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15. Target Area Vision Work Efficiency
Current Condition
Desired Conditions
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16. Target Area Vision Inventory Levels
Current Condition
Desired Conditions
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17. Target Area Vision Information Flow
Current Condition
Desired Conditions
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18. Sketch of the Current Work Area
Show flow of people, equipment, and materials with arrows
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19. Workplace Scan Checklist
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20. Waste Radar Chart
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21. Sort When in doubt, move it out Prepare red tags
Attach red tags to unneeded items
Remove red-tagged items to “dinosaur burial ground”
Evaluate / disposition of red-tagged items
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22. Red Tag Inspection Sheet
Search
Floors
Aisles
Operation areas
Workstations
Corners, under equipment
Small rooms
Offices
Loading docks
Inside cabinets
Look for unneeded equipment
Machines, small tools
Dies, jigs, bits,
Conveyance equipment
Plumbing, electrical parts
Look for unneeded furniture
Cabinets
Benches, tables
Chairs
Carts
Search these storage places
Shelves
Racks
Closets
Sheds
Search the walls
Items hung up
Old bulletin boards
Signs
Other _________
Look for unneeded materials
Raw material
Supplies
Parts
Work in process
Finished goods
Shipping materials
Look for other unneeded items
Work clothes
Helmets
Work shoes
Trash cans
Other
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23. Red Tagged Items Log Needless Items # of Date Reason for Notes /
(describe)
items
Tagging
Disposition
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24. Disposition List
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25. 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.
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26. 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
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27. Shine Clean everything, inside and out Inspect through cleaning
Prevent dirt and contamination from reoccurring
Results in
Fewer breakdowns
Greater safety
Product quality
More satisfying work environment
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28. 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
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29. Shine Cleaning Plan
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30. Standardize Establish guidelines for the team 5-S conditions
Make the standards and 5-S guidelines visual
Maintain and monitor those conditions
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31. 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
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32. Sustain
Determine the methods your team will use to maintain adherence to the standards
5-S concept training
5-S communication board
Before and after photos
One point lesson
Visual standards and procedures
Daily 5-minute 5-S activities
Weekly 5-S application
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33. Visual Factory Implementation
Develop a map identifying the “access ways”(aisles, entrances, walkways etc.) and the “action” areas.
Perform any necessary realignment of walkways, aisles, entrances.
Assign an address to each of the major action areas.
Mark off the walkways, aisles & entrances from the action areas
Apply flow-direction arrows to aisles & walkways
Perform any necessary realignment of action areas.
Mark-off the inventory locations
Mark-off equipment/machine locations
Mark-off storage locations (cabinets, shelves, tables)
Color-code the floors and respective action areas
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34. Review and Summary List each of the 5-S steps.
Describe the “30-second test”.
Why is total employee involvement so important?
What is management’s role?
Briefly describe each step in the 5-S system.
How do you intend to use this information?
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