5S Training SessionBy: Carlos Sanchez

TOPIC Slides 5S History & Benefits 03 What are the 5S? 04-19 How to implement 5S 20-21 5S Audits 22-23

Agenda

6S Training 2

Born in Toyota (No kidding!) Why?

◦ To create a sense of ownership and responsibility to the workers for their workplace

What are the Benefits of 5S?◦ High Quality products & Services ◦ Little or no Waste◦ High productivity◦ Better controlled inventories◦ Better work culture◦ Less accidents & Absenteeism

5S History & Benefits

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S1. Sorting

S2. Straighten

S3. Shine

S4. Standardize

S5. Sustain

S6. Safety (New S)

What are the 5S?

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5S Training

Sorting is the identification of the optimal organization of the workplace

How? By sorting out unnecessary items in the workplace and discarding them using these tools:◦ Stratification Management◦ Need vs. Want◦ “One is Best” principle

S1:Sorting

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Stratification Management

S1: Sorting

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Usage Frequency of Use Storage Method

Things not used in the past year Throw them out Things used once in last 6-12 months Store at a distance

Things used once in last 2-6 months Store in central area Things used more than once a month Keep in workplace

Things used once a week Store in the work-

Things used every day place or carry by the

Things used hourly person.

LOW

HIGH

AVG.

5S Training

Need vs. Want When? For LOW usage items

◦ If the item is not needed…Get rid of it!◦ If the item is needed…Keep only the quantity that

is needed and get rid of the rest.◦ If the item is borrowed…Return it!

S1: Sorting

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“One is Best” principle◦ One set of tools◦ One page Inspection form◦ One page Memo◦ One location file◦ One place for stationary◦ One place for spare parts

S1: Sorting

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Straighten is the process by which the optimal organization identified in S1 is put to use.

How?◦ Arrange things so they can be accessible◦ All things have a defined name & place◦ Decide how things should be put away◦ Define put away rules for things…and follow

them!

S2: Straighten

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5S Training

Arrange Things so they can be accessible How?

◦ Analyze how people get things out and put them away, and measure the time. The goal is to reduce this time to the minimal.

Typical reasons for excessive time delays:◦ Not sure where things are kept◦ Not sure of what things are called (No labelling)◦ Storage site is too far◦ Several storage sites◦ Unclear if things are in stock◦ Things are too big/heavy to move around

S2: Straighten

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All Things have a defined name & place (Visual Factory)

How?◦ Develop criteria for deciding where Things belong◦ If a Thing has several know names; choose only

one!◦ Identify similar Things with unique name or code◦ Make a diagram of the area, locating each Thing◦ Take pictures of how the area should look like and

each Thing in its place

S2: Straighten

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Decide how things should be put away How?

◦ Think of storage of Things with retrieval in mind◦ Label each storage location with the Thing’s name◦ Each Thing must have a location associated with

it◦ Frequently used Things need to be retrieved

easily◦ All heavy Things should be stored near the floor◦ Make it comfortable for the person (Ergonomics)

S2: Straighten

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Define put away rules for things How?

◦ Always put things back where they belong (really?)

◦ Manage inventories to avoid stock out◦ Have an indication of who is using the thing and

when it’s expected back◦ Make it obvious that the thing is missing (Shadow

outlines)◦ Take a picture of the area with all its things in

place for visual reference (Poster)

S2: Straighten

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Shine is about cleanliness How?

◦ Identify each area of the company and assign responsibilities to keep it clean.

◦ Everyone is responsible for S3 Why is it so important?

◦ Lack of cleanliness could cause Things falling of carts and getting damaged Dust and grime contaminating key processes Dust getting into electrical contacts causing shorts Garbage accumulating near electrical equipment

causing fires Computer malfunction due to dust accumulation

S3: Shine

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Standardize is the system we put in place to maintain the first three S’s Sorting, Straighten, & Shine

How?◦ Set a high standard of workplace housekeeping◦ “Visually Manage” the workplace◦ React quickly when any of the S’s are not followed◦ Create color coding and label areas and things

Some tools:◦ Labels, Tags & Marking◦ Transparent Windowing◦ Visualizing Conditions◦ Trouble Maps◦ Measure & Show

S4: Standardize

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Labels, Tags & Markings Examples

S4: Standardize

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Type of Label/Tag/Mark RemarksLubricating oil label Indicate the type, grade, color, and where is it used

Annual inspection label Should be attached to all equipment

Temperature label Indicates abnormality or overheat

Responsibility label Shows who is responsible for what

Identification label Tells people what things are

Safety label Remind people of special safety considerations

Zone label on meters Normal / danger zones should have different colors

OK mark OK mark indicates that the part is acceptable5S Training

Transparent Windowing◦ Make covers transparent or take them off. Let

everyone see what is stored and how good or bad things look. Avoid the “Out of sight-Out of mind”

Visualizing Conditions◦ Highlight the condition of a process, like:

Put windows in drainpipes so people can see effluent flowing

Tie ribbons to fans so people can “see” the breeze Trouble Maps

◦ Show emergency exits, fire fighting equipment on a map of the workplace and post it everywhere.

Measure & Show◦ Measure the process and display the statistical

analysis, identify the limits and mark deviations

S4: Standardize

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Sustain is the strategy used to keep everyone engaged with the practices of the previous 4 S’s

How?◦ Discipline, Discipline, and more Discipline◦ Make it a habit◦ Walk the talk◦ Audit the workplace and make it visible which

areas are Great, which are Good, and which are Not so Good

◦ Don’t punish…re-train and follow up◦ It never ends

S5: Sustain

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Safety must precede everything we do, it’s no use to have an organized workplace if it’s not safe for the people working on it

How?◦ Identify all required Personal Protective

Equipment (PPE) in all the visual documentation◦ Perform risk assessments to processes and

establish controls to assure the safety of the person

◦ Post visual alerts to potential work hazards (Temperature, Speed, Safe distances, etc.)

◦ Include safety in the workplace audits of 6S, and react immediately to any unsafe conditions identified.

6S: Safety

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5S requires commitment from Everyone in the plant.

5S requires a person to lead the implementation process, typically its called the 5S Champion or 5S Leader

Steps:◦ Implementation Plan◦ 5S Awareness training for Everyone in the plant◦ Promote the plan when ever possible◦ Choose pilot area to start◦ Showcase the results with the rest of the plant◦ Replicate the process◦ Audit, Audit, and keep auditing ◦ Take Before-After pictures

How to implement 5S

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5S Training

Once implementation starts its good to have some targets in order to create a sense of satisfaction and purpose. These are known as 5S Levels:◦ Level 1: Plant has a 5S implementation plan and

its training their people in 5S◦ Level 2: 5S committee is meeting regularly and

it’s aware and is implementing prototype areas in 5S

◦ Level 3: 5S committee has full participation from all areas of the plant in 5S. Initial 5S audits are done

◦ Level 4: 5S committee is reacting to 5S audits and making improvements to all areas

◦ Level 5: 6S is obvious to everyone in the plant, it has become part of the operations day to day business

How to implement 5S

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5S Audits are the self regulating mechanisms that will provide accurate feedback of how effective the 6S implementation has been

5S Audits should be performed by the 5S Leader with the Plant Manager, this way it will show to everyone that Top Management is really committed to the success of the initiative.

All 5S Audit finding should be documented, addressed, and verified. These are key lessons to be learned and shared with the rest of the organization

5S Audits

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5S Training

This is an example of a 5S Audit Worksheet:

5S Audits

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Audit No: ……………………… Date: ……………………… Time: …………………………

Dept. / Location Audited: ……………………………………………………………………………

Name of Auditor (s): …………………………………… Signature (s): ……………………………

Name of Auditee (s): …………………………………… Signature (s): ……………………………

No. Activity / Practices Audited Audit Finding Score Remarks

5S Audit Work Sheet