5S Supply - Introduction to 5S - February 24 2010

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Introduction to 5SWe will be starting shortly

Please read

© 5S Supply 2010

Introduction to 5S

Wednesday, February 24th, 2010

12:00 pm – 1:00 pm (CST)

brought to you by 5S Supply

www.5Ssupply.com5S simplified. Everything you need… all in one place.



© 5S Supply 2010

Today’s Agenda“Behind all

workplace

successes

and failures

are the

5S’s.”

From “5 Pillars of the

Visual Workplace: The

Sourcebook for 5S

Implementation” by

Hiroyuki Hirano

• What is 5S

• Philosophy of 5S

• Benefits of 5S

• Explanation of each of the

S’s—Sort, Set-in-order,

Shine, Standardize, Sustain

• Q&A

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What is 5S?



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What is 5S?

• Five words that begin with the letter “S”

• Meaning workplace organization and

standardization

• Foundational building block of Lean

• Builds teamwork and discipline

• It’s NOT JUST CLEANING!

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Where did 5S Come From?

• A fundamental part of the Toyota

Production System (TPS)

• Need for a safe working environment,

respect for people

• Quality, cost and delivery



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Leadership

5SVisual

Standard Work

Batch Size Reduction Quick Changeover

Pull System & KanbanCellular & FlowTPM

V

S

M

Error-proofing

Teams

Problem Solving

Planning

Kaizen

POUS

Lean Enterprise

Layout

Building Blocks of a

Lean Enterprise

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Translation

Self-disciplineSustainDisciplineShitsuke

StandardizeStandardizeStandardizationSeiketsu

SweepingShineCleaningSeiso

Simplifying

accessSet in orderNeatnessSeiton

SortingSortOrganizationSeiri

*OtherConversionTranslationJapanese

* there are several other conversions



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Other Names

• 6S = 5S + safety

• 7S = 5S + safety +

security

• 5Cs

1. Clear Out

2. Configure

3. Clean & Check

4. Conform

5. Custom & Practice

• Others

• 5S is the most common

term

• Using other terms may

confuse people if they

see or read other

information about 5S

• If done correctly, safety

is automatically part of

5S

© 5S Supply 2010

Garage Story

• 5S is like cleaning out your garage

• Clear everything out, make piles

• Organize the things that you are going to keep

• Clean top to bottom, fix or repair as needed

• What happens 6 months later?



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Philosophy of 5S

Be a 5S learner, achiever and

thinker

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Why is 5S Necessary?

• Companies are like living

organisms, they must learn to

adapt and be flexible to survive

and thrive

• Customers, suppliers, people,

processes, materials,

technologies are continually

changing

• Deeply engrained processes,

culture, and customs are not

easily changed

“5S is easy,

getting

people to

change is

hard”



© 5S Supply 2010

5S Philosophy

• 5S is not about the cleaning

• 5S is not just the steps, it is how you go

about your job – are you a Lean

Thinker?

• Think about the 5Ss as being attributes

of the type of person you would want to

hire

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What do you think of this

maintenance area?



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Do you think that 5S applies to office,

common or support function areas?

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5S Dreamland

Fairies and robots

do not come out

in the middle of

the night and do

5S for you.

Who has to do it?



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Benefits of 5S

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Myths about 5S

• 5S takes too much time.

• There aren’t any benefits for doing 5S in the office.

• 5S means to clean and I wasn’t hired to clean!

• It doesn’t really matter how we store things.

• I like the way my desk is. I can find everything Ineed so why does it matter how I have my things?

• Doing 5S will take away from me doing my realwork.



© 5S Supply 2010

More Myths

• We’re clean and neat already.

• We have a cleaning crew so we don’t need to do 5S.

• We’re not idiots, we know what we are doing. 5S will just get in the way of us doing our jobs.

• We have so many problems here, why would you have us do 5S?

• There is no benefit for us to spend time to this 5S stuff.

© 5S Supply 2010

Benefits of 5S

• Teamwork

• Discipline

• More organized workplace

• Safer work environment

• Reduces stress

• Saves time

• Saves money

“Time is

money”



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Benefits of 5S

• Impresses customers or auditors

• Reduces waste

• Better handle on true costs

• More pleasant place to work and increase moral

• Supports the other Building Blocks of Lean

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Sort

“When in doubt, move it out!”



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Sort

• The first thing to do is to clear the clutter

out of the area

• Perform as a team

• Use the “30 day” rule

• Use the Red Tag technique

• Break the “just in case” mentality

• “When in doubt, move it out!”

© 5S Supply 2010

Sort

• Clearly distinguish

between:

– What is needed

currently and should

be kept

– What is not needed

and can be removed

Will be used

Will not be used

May be used

Keep

Red Tag

Discard



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Sort

• Red Tags are visual signal that something may not

belong in your target area

• Attach Red Tags to items that don’t belong in the

immediate area

• Move the items to the Red Tag Holding Area

• Use simple Red Tags

• Have Red Tags easily available

© 5S Supply 2010

5S Red Tags

Name _______________ Date________

Item ____________________________

Reason for Tagging ________________

________________________________

Your

Name

Today’s

date

What the

item is

Why did you

tag it?

Use unknown,

Obsolete,

Not used here,

etc.



© 5S Supply 2010

Other Tag Issues

• Some companies

use additional color

tags for

maintenance or

safety issues

• Companies that use

Red Tags for quality

issues have to

determine which

color tag to use

• Make sure you have

wire, string or tape

to attach tags to the

item

• Make sure everyone

on the team has

tags and a pen

© 5S Supply 2010

Red Tag Area

• The Red Tag Holding Area is a temporary holding

area – meaning things can’t stay in there forever

• If other people or groups need items, they are

allowed to take things from the Red Tag Holding

Area

• Dispose of items periodically (rules will be setup

during “Standardize”)



© 5S Supply 2010

Notes on Red Tagging

• Avoid the “Pack rat” mentality

• Don’t worry about the “One thing”.

Focus on the benefits of clearing things

out of the immediate area.

• Just because an item is tagged, it

doesn’t necessarily mean that it is going

to be thrown away. We will make the

decision later if we need it or not.

© 5S Supply 2010

5S and Dilbert



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Benefits of Sort

• Clears out the things that you didn’t need in your work area

• Reclaim room and space

• Reduces search time

• Allows for other changes like moving items or changing the layout

• Safer place to work

• Let’s employees feel that they have control over their area, instead of the areas controlling them

© 5S Supply 2010

Set-in-Order

“A place for everything and

everything in its place!”



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Power of Set-in-order

• Now that the area has been cleared out

of unnecessary items, it is time to find a

“home” for items that will remain

• This is where fantastic results occur

• Reduces:

– Search time

– Stress

– Inventory and supplies

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Everyday Examples

• Kitchen

• Parking lots

• Highways

• Broom racks & Shine Carts



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Set-in-order

• Now that you have used Sort, decide where

the items that you will keep belong

• Decide how many and how to replenish

• Make it visual and obvious if something is

out of place

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Decide Where Things Belong

Guidelines

• If it is used often, keep close at hand

• Designated location & label

• Use systems like the “2-label” system

• Shadows, lines, color-coding

• Easy to get & put away (ergonomic and

safe)

• Get items off the floor & top shelves



© 5S Supply 2010

Other Set-in-order Issues

• Make it easy for

everyone to find and

use them – “30

second” rule

• Use “recoil”, getting

items back to where

they belong

• Make it obvious

when they are not in

there correct place

• Make items easy to

get and easy to put

away

© 5S Supply 2010

Benefits of Set-in-Order

• No guessing at where items belong and

how many

• No excess items

• Items are easy to find and put away

• Everyone passes the 30-second test

“A place for everything and

everything in its place!”



© 5S Supply 2010

Shine

”To clean and inspect.”

© 5S Supply 2010

Shine

• Shine = clean + inspect

• Perform as a team

• Must plan Shine

• Have the necessary items easily

available

• 5S is not just cleaning!



© 5S Supply 2010

Why Shine?

• Can prevent accidents or safety incidents

• People feel better when they work in a clean environment, this actually helps morale

• Working together helps build team work

• Impresses customers on tours

• Can spot potential problems with equipment before they occur

© 5S Supply 2010

Make it Fit Your Organization

• Even if you have a cleaning crew or service,

do they know exactly what you want and what

is expected of them? Is it followed?

• Wiping and cleaning common areas helps

reduce the spread of germs thus improving

sick-time related absenteeism

• Make it quick and simple - or better yet, think

of ways to prevent dirt from accumulating in

the first place!



© 5S Supply 2010

Initial Cleaning and Inspection

• Have to have a plan

• Start at the top and work down

• Clean and inspect major items first

• Be thorough, restore to “like new” condition

• Clean floors and aisle ways last

• Everyone has to participate

• Schedule it

• Take it Serious

© 5S Supply 2010

Planning Shine

Determine

• Task

• Location

• Who

• When

• Cleaning materials

needed

Supplies

NeededTeamArea

Desks

Equipment

Files/Storage

Common

Areas

Supplies



© 5S Supply 2010

Additional Ideas for Shine

• Prevent dirt in the first place or at least contain it

• Low cost solution versus breakdowns

• Plan ahead

• Everyone participates as a team

• Make it quick (and fun!)

• Have the right tools & supplies ready

© 5S Supply 2010

Benefits of Shine

• A more pleasant place to work

• Promotes a professional atmosphere

• People actually have the tactile sensation by touching their equipment, machines and work areas

• You are able to find small problems

before they become BIG problems

• Safer and cleaner workplace



© 5S Supply 2010

Standardize

“Make up the rules and follow and

enforce them!”

© 5S Supply 2010

Standardize

• Standardize means to set up the rules for

Sort, Set-in-order and Shine

• Have the 5S teams and 5S Design Teams set

the standards

• Standards must be simple and easy to follow

• Use audits to help maintain the standards



© 5S Supply 2010

Standards for Sort

Red Tag Rules

• When to Red Tag

• How to Red Tag

• What’s go on the Red Tag

• more…

Rules for the Red Tag Holding Area

• When to clear out

• How to dispose of items

• more…

Description: How to fill-out a Red Tag

One-point Lesson

5S Red Tag

Name ______________ Date __________

Item ______________________________

__________________________________

Reason for Tagging __________________

__________________________________

Write in your name

1

Fill-in date tagged

2

Write in the

name or

description

of the item

3

Write in the reason for tagging

(obsolete, needs repair, not

needed, scrap, use unkown, etc.)

4

Attach tag using

wire, tape, string,

or other method

5

Move item to the Red Tag Holding Area6

© 5S Supply 2010

Standards for Set-in-Order

• Which items, where, how many

• Who replenishes

• Return all items… and What to do when items are

missing

• Visual standards – signs, lines, labels and color

coding



© 5S Supply 2010

Standards for Shine

• Clean and Inspect (C&I) Schedule

• Show the task, person responsible,

items needed, frequency, the time

element and the desired state

• Where to keep cleaning supplies, how

to replenish

© 5S Supply 2010

5S Clean and Inspect ScheduleItem: ID:

Key: Clean & Inspect activity required �� Cleaning activity completed ��

Frequency of C&I

No Team Member

Task Requirement MON TUE WED THUR FRI TimeMin

1 Technician Wipe down equipment Cleaner & Wipes � � � � � 1

2 Operator Clean or replace filter Cleaner, rags, filter (if required) � � � � � 3

3 Helper Sweep floor Broom � � � � � 2

4 Supervisor Inspect safety guards Visual � 1

5 Manager Complete Diagnostic

Checklist Post results on 5S Display Board � 5

6 All 5S Weekly Meeting Agenda, ½ hour max � 30

7

8

9

10

Total 42



© 5S Supply 2010

Key for Standardize

• Make the rules, then follow and enforce them

• People usually think 5S fails at Sustain, but it

typically fails at enforcing the rules

• Policies drive behaviors

• Make the rules simple and easy to follow

• Use immediate correction

• Lead by example

• Do not allow 5S to take a backseat to other

things

© 5S Supply 2010

Benefits of Standardize

• Everyone knows the rules

• Easy to understand and to follow

• You have to have a standard in order to

know that you have improvement

• Sets the foundation for successful 5S

implementation and Sustain

• Allows you move on to “Sustain”



© 5S Supply 2010

Sustain

“Make 5S part of everyday life.”

© 5S Supply 2010

5S Discipline

• Management’s support – without this 5S

will never work!

• 5S is not something extra, it’s part of

everyday work

• Get everyone involved – teamwork

• Helps set the base for other Lean efforts

• Creative ways to prevent Standardize

from deteriorating



© 5S Supply 2010

Ways to Make 5S a Habit

• On-going

communication –

newsletters,

communication boards,

posters, short meetings

• Field trips,

benchmarking

• Reward and recognition

• Use immediate

correction

• Lead by example

• 5S promotions

© 5S Supply 2010

More Ways to Make 5S a Habit

• Training and additional

“Booster” training once

or twice per year

• Brainstorm problems

and solutions

• Study groups

• Capture Lessons

Learned, share Best

Practices

• Continued 5S Audits

• Contests

• 6-week photos

• “Extreme 5S Makeover”

video

• 5S Campaign boards

Sort

Set-in-Order

Shine

Standardize

Sustain

Check Red Tags

Check missing items

Check lights

Update audit schedule

New Contest

Jim, Bob

Jennifer, Ralph

Homer, Marge

Eileen, George

All

5S Item Team

5S Campaign Week of XX/XX



© 5S Supply 2010

Additional Information for

Success

• Everyone has to participate

• Promote participation

• Keep at it, even when it isn’t easy

• Make sure everyone understands what

5S is and why it’s needed

• Remember, 5S is a low cost solution

• 5S is essential for Lean

© 5S Supply 2010

Q&A

Please submit your questions at

this time



© 5S Supply 2010

Developer

Anthony Manos

• Tony Manos is a Professional Business Advisor with expertise in

Lean. Trained and certified by the Department of Commerce,

National Institute of Standards and Technology (NIST) in Lean

principles and as a trainer in Lean courses. He is an international

trainer and speaker on Lean topics.

• Mr. Manos is a Senior Member of ASQ, SME and AME and is a

Shingo Prize examiner

© 5S Supply 2010

Recommended

Resources5S Garage: An

Introduction to

5S and Lean

Principles “5S Pillars of the Visual Workplace: The

Sourcebook for 5S Implementation” by

Hiroyuki Hirano

“5S for Operators: 5 Pillars of the Visual

Workplace” by Productivity Press



© 5S Supply 2010

Additional Resources

Group 5S Supply

© 5S Supply 2010

Q&A

If we don’t get a chance to answer your

question today, please send it to:

[email protected]



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Upcoming Events

• March 2010 – 5S for the Office

Don’t forget to visit us at

www.5Ssupply.com888 4 LEAN 5S

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5S Supply - Introduction to 5S - February 24 2010

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Transcript of 5S Supply - Introduction to 5S - February 24 2010