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55S BASICS BASICTRAININGTRAINING

What isWhat is 5 5S and why do weS and why do wewant to do it?want to do it?

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What isWhat is 5 5S and why do we want toS and why do we want to

do it?do it?55S is short for: Sort, Set in Order, Shine, StandardizeS is short for: Sort, Set in Order, Shine, Standardize

and Sustainand Sustain

55S representsS represents 5 5 disciplines for maintaining adisciplines for maintaining a visualvisualworkplaceworkplace (visual controls and information systems).(visual controls and information systems).

These are foundational to Kaizen (continuousThese are foundational to Kaizen (continuous

improvement) and a manufacturing strategy basedimprovement) and a manufacturing strategy based"Lean Manufacturing" (waste removing) concepts."Lean Manufacturing" (waste removing) concepts.

55S is one of the activities that will help ensure ourS is one of the activities that will help ensure ourcompanys survival.companys survival.

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55SS11. Sort. Sort -- All unneeded tools, parts and supplies areAll unneeded tools, parts and supplies are

removed from the arearemoved from the area

22. Set in Order . Set in Order - - A place for everything and everything isA place for everything and everything isin its placein its place33. Shine. Shine -- The area is cleaned as the work is performedThe area is cleaned as the work is performed44. Standardize. Standardize - - Cleaning and identification methods areCleaning and identification methods are

consistently appliedconsistently applied

55. Sustain. Sustain -- 55S is a habit and is continually improvedS is a habit and is continually improved

Also Also -- Work areas are safe and free of hazardous or Work areas are safe and free of hazardous or dangerous conditionsdangerous conditions

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Some New WordsSome New WordsR ed TagR ed Tag- -Process for tagging, removing and disposing of Process for tagging, removing and disposing of items not needed in the work area.items not needed in the work area.Lean ManufacturingLean Manufacturing- -concepts that seek continuousconcepts that seek continuous

improvement by removing waste in processesimprovement by removing waste in processesSome Japanese words you need to know:Some Japanese words you need to know:KaizenKaizen- -(pronounced ki zen)(pronounced ki zen) - - improvementimprovement

Kaizen Event andKaizen Event and 5 5S EventS Event- -Planned improvements toPlanned improvements to

aspecific area or process (usually takeaspecific area or process (usually take 3 3 toto 55 days).days).55S Events focus on makingS Events focus on making 5 5S improvements.S improvements.

MudaMuda- -(pronounced moo da)(pronounced moo da) - - wastewaste

GembaGemba- -(pronounced gim ba)(pronounced gim ba) - - workplaceworkplace

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SomeSome 5 5S ExamplesS Examples

BeforeBefore 55SS

AfterAfter 55SS -- Cleaned,Cleaned,organized and drawersorganized and drawerslabeled (less time andlabeled (less time andfrustration hunting)frustration hunting)

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55S ExamplesS Examples - - Sort, Set inSort, Set in

Order Order

See the difference?See the difference?

11. Sort. Sort - - All unneeded tools, parts and supplies areAll unneeded tools, parts and supplies areremoved from the arearemoved from the area22. Set in Order. Set in Order - - A place for everything and everything isA place for everything and everything isin its placein its place

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55S ExamplesS Examples - - StandardizeStandardize

44 . Standardize. Standardize - - Cleaning and identification methodsCleaning and identification methodsare consistently appliedare consistently applied

Departments have weeklyDepartments have weekly 5 5S toursS tours

Every job has duties that use Sort, Set in OrderEvery job has duties that use Sort, Set in Order

and Shineand ShineWe all have common duties to do our part to keepWe all have common duties to do our part to keepall areas of the plant in shapeall areas of the plant in shape - - breakroom,breakroom,restrooms, locker area, parking lot, etcrestrooms, locker area, parking lot, etc

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55S ExamplesS Examples - - SustainSustain

5. SustainSustain - - 55S is a habit and is continually improvedS is a habit and is continually improved

55S is a simple concept with powerful results.S is a simple concept with powerful results.

You will get additional information onYou will get additional information on 5 5S so that youS so that youwill be well equipped.will be well equipped.

Our experience is that the more we doOur experience is that the more we do 5 5S the betterS the betterthe work environment becomes: cleaner, safer, morethe work environment becomes: cleaner, safer, more

organized, the work is easier, less confusion and lessorganized, the work is easier, less confusion and lessstress.stress.

Use theUse the 55S (work S (work\ \homehome\\play)play) -- The more you use itThe more you use itthe easier it becomes and life just gets better andthe easier it becomes and life just gets better and

better.better.

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The Good, Bad and the UglyThe Good, Bad and the UglyF irst the Bad and the Ugly - Life Without 5S

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The GoodThe Good

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What is Waste (Muda)?What is Waste (Muda)?Some of the main forms of waste are:Some of the main forms of waste are:

OverproductionOverproduction

Waiting for materials, machines, or instructionWaiting for materials, machines, or instruction

Transportation or movementTransportation or movement

Excessive inventoryExcessive inventory

Inefficient machine processing and/or operationInefficient machine processing and/or operation

Producing defectsProducing defectsPart or line changeover or machine setupPart or line changeover or machine setup

Inadequate housekeepingInadequate housekeeping

Miscommunication or inadequate instructionMiscommunication or inadequate instruction

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Improvement (Kaizen)

PrinciplesGet rid of all old (false) assumptions.Get rid of all old (false) assumptions.Don't look for excuses, look for ways to make it happenDon't look for excuses, look for ways to make it happen

. . Don't worry about being perfect. . Don't worry about being perfect - - even if you onlyeven if you onlyget itget it half right start NOW!half right start NOW!It does not cost money to do KAIZEN.It does not cost money to do KAIZEN.If something is wrong Fix it NOW.If something is wrong Fix it NOW.Good ideas flow when the going gets tough.Good ideas flow when the going gets tough.Ask "WHY" five timesAsk "WHY" five times - - get to the root cause.get to the root cause.Look for wisdom from Ten people rather than one.Look for wisdom from Ten people rather than one.Never stop doing KAIZEN.Never stop doing KAIZEN.

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SummarySummary

55--S is for you.S is for you.

CleanClean- -up and organize your work area every day soup and organize your work area every day sothat each new day is easier and safer than the daythat each new day is easier and safer than the daybeforebefore

Share your input with your leaders so that the tools youShare your input with your leaders so that the tools youneed will be available to you, increasing your efficiency.need will be available to you, increasing your efficiency.

Volunteer to help with theVolunteer to help with the 5 5S tours andS tours and 5 5S events.S events.

Take a good look around...Imagine zero waste/zeroTake a good look around...Imagine zero waste/zeroconfusion!confusion!