3. What is 5S?
Sort - removal of unnecessary items
Set in Order - a place for everything and everything in its place
Shine - clean the workplace
Standardise - set standards
Sustain - sustainable standards
4. Why introduce 5S?
• 5S is one of the building blocks in the Operational Excellence Strategy
• A Lean Manufacturing tool that improves productivity by eliminating waste.
• Will enable us to continue on our journey to becoming World Class
• With a philosophy of, "A place for everything and everything in its place”.
5. Why introduce 5S?
• Proven studies have shown that if an employee has the right materials and
equipment to do his job, which are located close to the point of use, there will be an
improvement in Productivity.
• Time will not be lost by an employee having to go and look for a particular item.
• Effective deployment of 5S will also enable further improvements in Set Up Time
Reduction.
• Given the number of large number of SKUs produced, reducing the time from “Off
Product to On Product”
• A key initiative in driving productivity improvements.
6. Why introduce 5S?
• Engaging teams to develop and organise their own work environment
• Look for ways to further improve, creates a habit of continuous improvement
• Will lead to further improvements across all Key Performance Areas.
7. Why introduce 5S?
• The deployment of 5S will not only improve productivity
• But it will see a reduced risk of fire, safeguarding our people and property
• Reduce the number of work related injuries. Work areas will no longer be cluttered
and unsafe
• 5S will promote a safe and well organised working environment.
9. Sort
We only need what is needed, in the amount that it is needed and
when it is needed. if in doubt, throw it out
• Set Standards for necessary and unnecessary items
• Remove all unnecessary items
• Establish mechanisms to prevent unnecessary items from
returning
• Monitor and improve
10. Set In Order
“A place for everything, and everything in it’s place”
• Defined frequencies of use
• Defined storage locations
• Shadow Boards
• Having the materials and equipment to complete work
• Monitor and improve
11. Shine
Removal of all dirt, and identify potential and actual problems
• Remove all dirt – “Deep Clean”
• Eliminate sources of contamination
• Make it easier to clean the workplace
• Introduce cleaning schedules
• Monitor and improve
12. Standardise
Clear visible standards, so that everybody knows what is expected of
them
• Visual
• Clearly understandable
• Highlight abnormalities
• Monitor and improve
15. Chaos
• Focus on cleaning prior to VIP visit
• Workplace is cluttered
• Workplace is dirty
• No formal systems for storage
• No 5S standards
• No sustainable housekeeping
• No understanding of 5S principles
17. Sustain & Improve
• Sustained emphasis on 5S improvements
• Focus on reducing items in the workplace
• Sources of dirt continuously eliminated
• Storage of items continuously refined
• Standards are continuously refined
• Celebrating 5S improvements
• The team take ownership for refining 5S
18. The Benefits
• Improved productivity
• Worker ownership
• Set Up Time Reduction
• Reduced risk of fire
• Improved workplace organization
• Focussed Improvement
19. A3 Future State
SORT
Annual Red Tagging exercises in all workshops, with the removal of non
essential items
Designated areas in each dept for Red Tagged items
SET IN ORDER
Floor markings to identify storage areas
Full identification of Safety hazards
Shadow boards for tools and ancillary equipment located close to the areas
where use is required
Effective waste segregation
SHINE
“Clean as you go” approach to GMP
Scheduled cleaning activities by work area
Identification and root cause elimination of sources of dirt / recurring issues
20. A3 Future State
STANDARDISE
Visual standards in place in all depts
Designated person responsible for completing activities as per cleaning
schedule
SUSTAIN
Autonomous completion of cleaning activities
Departments to be “audit ready” at all times
Full adherence to cleaning schedules
