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5S PROCESSTHE FOUNDATION FOR VISUAL MANAGEMENT

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This document contains the confidential and

proprietary information of Gregory Cochran

& Associates, LLC.

Any disclosure, use, copying or distribution of

the information within this document is

strictly prohibited without permission from

Gregory Cochran & Associates, LLC.

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Learn The Benefits Of 5S

Understand The Definition And Meaning Of The 5s

Learn The Proper Strategy For Implementing A 5S Program

Apply 5S In The Workplace

5S Objectives

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What Is 5S?• 5S Enables Anyone To Distinguish Between Normal And Abnormal

Conditions At A Glance

• 5S Is The Foundation For Continuous Improvement, Zero Defects, Cost

Reduction, And A Safe Work Area.

• 5s Is A Systematic Way To Improve The Workplace, Processes, And

Products Through Production Line Employee Involvement.

When And Why Use It?

• To Create And Maintain An Organized, Clean, Safe, And High-

performance Workplace.

Duration?

• .5 To 3 Days

5S - Overview

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What Is 5S?

Defined

5S Is Process To Ensure A Clean, Orderly, Safe And Productive Workplace.

5SSUSTAIN

5SSUSTAIN

1S

Simplify

4S

Stabilize

Straighten

2S

Scrub

3S

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Benefits Of 5S

There Are 3 Key Benefits To Implementing A 5S Program

1. Safety

Reduce The Number Of Lost Time Accidents, Workman’s Compensation

Claims And OSHA Recordables.

2. Quality

Eliminate The Possibility Of Using Previously Rejected Parts Or The Wrong

Tools. Eliminate Contamination And Assure Compliance To Standard

Procedures.

3. Productivity

Eliminate Wasted Time Looking For Tools. Reduce Cycle Time, Reduce

Equipment Downtime Through Regular Cleaning And Inspection.

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What Are The 5S?

Simplify

(Seiri)

Straighten

(Seiton)

Scrub

(Seiso)

Stabilize

(Seiketsu)

Sustain

(Shitsuke)

Clearly Distinguishing Between What Is Necessary And What Is Unnecessary

And Disposing Of The Unnecessary.

Organizing The Necessary Items So That They Can Be Used And Returned

Easily.

Cleaning Floors, Equipment, And Furniture In All Areas Of The Workplace.

Maintaining And Improving The Standards Of The First Three S’s.

Achieving The Discipline Or Habit Of Properly Maintaining The Correct 5S

Procedures.

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Simplify

Identify Truly Needed Items By Asking Several Key Questions.

What Is It For?

Why Do I Have It?

How Often Do I Use It?

Does Someone Else Have The Same Thing?

Clearly Distinguishing Between What Is Necessary And What Is

Unnecessary And Disposing Of The Unnecessary

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Things Which Should Be Reviewed

Cabinets

Components

Documentation

Gages

Machines

Packaging Material

Parts

Prints

Shelves

Supplies

Tables

Tooling

Towels

Trash

PRODUCTION AREAS

Books

Business Forms

Cabinets

Catalogs

Correspondence

Equipment

Magazines

Paper

Parts

Records

Samples

Shelves

Supplies

OFFICE AREAS

Simplify

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Red Tagging Is A Tracking Process To Provide

Visual Identification Of Unneeded Items.

After All Obvious Items Have Been Thrown

Away, Remaining Items Are “Red-tagged” To

Assure Proper Disposition.

Red Tagging

Simplify

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Sample Red Tag

CELL / AREA

RED TAGTAG NUMBER

CATEGORY

1. Raw Material2. WIP3. Finish Materials4. Tools

5. Supplies6. Equipment7. Furniture8. Office Materials

9. Books/Magazines10. Other:

TAG DATE TAGGED BY

ITEM NAME

QUANTITY

REASON TAGGED

DISPOSITION REQUIRED

1. Discard2. In Cells Storage3. Long Term Storage

4. Reduce Inventory5. Sell / Transfer6. Other:

ACTION TAKEN DATE

CELL / AREA

RED TAG LOCATORTAG NUMBER

Should Be Full Size

(8.5” X11”)

Bright Red To Promote

Visibility

Should Have Pre-printed

Sequential Tag Numbers

Perforated Lower Section To

Record Location Of Tag

Simplify

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Step 5

▪ Evaluate Red Tag Items

▪ Dispose Of Truly Unnecessary

Items

▪ Retain Red Tagged Material If

There Is Proper Justification

▪ Discard Any Material Which Has

Been Red Tagged After A Pre-

determined Time

▪ Complete All Red Tag

Information. Returned To The

Red Tag Coordinator

Red-Tagging Process

Step 4

▪ Explain Red Tag Criteria

To Teams

▪ Ensure A Good Cross-

section Of People

Tagging Items To

Prevent “I Might Need

That”

▪ Red Tag Work Area As

Rapidly As Possible

▪ Determine What

Criteria Will Used To

Distinguish A Needed

Item From An

Unneeded Item

▪ Example: Save Only

The Items Needed To

Conduct Business In

The Area

Step 3

▪ Identify Red Tag

Targets

▪ Determine Location

For All Red Tag

Items During Event

Step 2

▪ Select Members From

Various Teams

▪ Select A High Level

Manager To

Participate As A Team

Member

Step 1

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Red Tag Area

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Examine The Workplace

Identify Truly Needed Items

– What Is It For?

– Why Do I Have It?

– How Often Do I Use It?

– Does Someone Else Have It?

Throw Away Anything You Know You Can

Use Red Tagging For Items That You Are Unsure Whether Or Not

They Are Needed

Strategy

5SSUSTAIN

5SSUSTAIN

1S

Simplify

4S

Stabilize

Straighten

2S

Scrub

3S

Simplify

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Examples

Simplify

Before

After

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Straighten

Organize The Necessary Items So That They Can Be Used

And Returned Easily

Place All Necessary Items In The Best Location And Visually Organize The

Area

First Decide Where All Items Should Be So That The Organization Is Easy To Use And

Understand

Choose Proper Storage Methods That Minimize Inventory And Promote Visual

Management

Visually Indicate Locations So Items In Use Can Be Returned And Missing Items Are

Easily Identified

Make Sign Boards That Clearly Explain Inventory, Equipment, And Other Items So Anyone

Can Understand The Workplace

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Proper Locations

Storage Methods

Location Marking

Shadow Boards

Sign Boards

Straighten

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Identify Critical Items, Parts, And Areas Within Factories With Common Colors

Which Provides For A Common Understanding For Any Associate Or Visitor.

Standard Color Guide Purpose

Straighten

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Safety

International Green

Quality

International Blue

Standards

Federal Safety Yellow

Defects

Federal Safety Red

Maintenance

Pure White

Safety Equipment, First Aid, Safety Posters,

Notices

Inspection Points, Quality Notices & Instructions,

Gauging

Operation Standards, Location Marks, New

Tooling, Good Part Storage

Scrap, Bad Parts, Warranty Materials, Dull Tools

Repair Tools, TPM Materials, Machinery,

Cleanliness

Standard Color Guide

Straighten

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Straighten

Organization Of A Packing Area Makes Packing

Parts Easier And Faster – Everything Has A

Designated Location

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Before After

Straighten

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Cleaning Floors, Equipment, And Furniture In All Areas Of The

Workplace

Establish A Clean Workplace.

– Clean Up The Area.

➢ Sweep & Wash Floors

➢ Clean In, Under, And Around Equipment And Furniture

➢ Eliminate All Trash From Workplace

– Keep In Mind: How Do Things Get Dirty? - Fix The Root Cause Of The Dirt.

Scrub

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Examples

Scrub

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Eliminate Excess Storage Areas And Flat Surfaces

Make Changes To Equipment That Make It Easy And Quick To Clean And

Eliminate Dirt And Leaks At Their Source

Use Check List To Establish Daily Cleaning And Organization Activities

Institute 5S Patrols To Monitor 5S Progress

Maintaining And Improving The Standards Of The First Three S’s

Stabilize

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ExamplesStabilize

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Develop A Habit Of Simplifying, Straightening, Scrubbing And Stabilizing

Your Workplace

Everyone Has To Accept 5S As A Personal Goal

People Follow Examples (Good And Bad); Set A Good Example

Achieving The Discipline Or Habit Of Properly

Maintaining The Correct 5S Procedures

Sustain

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Examples

Sustain

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28

Before After

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Summary – 5S Implementation

Clean The Workplace Thoroughly

Simplify

Straighten

Scrub

Stabilize

Sustain Make 5S A Part Of Our Daily Life

Sort Everything In The Work Area

Organize The Entire Work Area

Make Changes To Maintain The First Three S’s

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Summary

5S Is A Foundation For Improvement

Visual Management Is The Ultimate Goal

It Is Up To Each And Every One Of Us To Make 5S A Personal

Goal

Get Help on Your Continuous Improvement Journey

One of the things you will find as you move along your Lean journey is that

going it alone is much harder than if you had a coach. A good coach will push

you to greater and greater levels of self-sufficiency. Regardless of where you

are on your journey, we can help.

If you are just beginning your concerted continuous improvement efforts, we can

help you chart your course and teach you what you need to know to start

leading change on your own. For those who are further along your journey, we

can help by teaching you more advanced topics, reviewing what you are already

doing, and helping you improve your improvement processes.

© Gregory Cochran & Associates, LLC. All Rights Reserved. For the exclusive use of Gregory Cochran & Associates ,

LLC with no reproduction or distribution permitted without the permission of Gregory Cochran & Associates , LLC

Ways We Support Our Clients

On-site Coaching / Consulting: In this traditional form of consulting, we come to

you and work hand-in-hand with you to bring about change in your organization.

Lean assessments, Kaizen facilitation, and policy / strategy deployment

coaching are popular ways to use this form of support.

Remote Coaching / Consulting: Remote consulting puts technology to use so we

can help you in a variety of ways. Need a quick answer? Want a charter

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Ways We Support Our Clients Continued

Lean Help in the NE Ohio Area: There are a lot of factors that go into choosing a

coach. Getting a good fit is the most important. But there are some special

benefits to having a continuous improvement expert right in your own back yard.

▪ Just in Time training. Want to do a large scale kaizen? No problem! But, having a local Lean coach

also allows you to do smaller, Just in Time projects as well. These mini improvement events can

yield big gains, but more importantly they require less planning time on your part and have less

impact on your team’s production than a traditional kaizen.

▪ You save on travel expenses. No airfare. No lodging. Using a local coach saves you money.

▪ You can get help on much shorter notice. When your Lean coach is nearby you don’t have to wait

for the help that you need. There is no need to work around airline schedules or worry about

weather causing delays for your consultant.

www.GetLeanCoach.com For More Information And Free Tools

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LLC with no reproduction or distribution permitted without the permission of Gregory Cochran & Associates , LLC