Lean - 5S Workplace Organization

Work Place Organization
A Guide to Implementing 5S
Prepared by :- Nitin Joshi

What are the Components of 5S
Sort
Eliminate unnecessary
items
Introduction
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What are the Components of 5S
Sort
Eliminate unnecessary
items
Introduction
Set
Place items in
the appropriate
locations
Shine
Clean all
items
Create a
consistent
process

Introduction
Where would you Implement 5S?
Warehouse
Maintenance
Production
Offices
Shipping yard
Quality Assurance
Everywhere!

Sort
The Benefits of Sort
Creates additional space in the facility
Eliminates movement of unnecessary items during normal operations
Prevents using wrong or broken parts/materials during operations
Unnecessary items can create unsafe working conditions
Minimizes time in finding correct items
Excess materials “mask” other issues
Allows you to improve the over-all process flow

Sort
How to Conduct a Red Tag Event
1. Determine the area that you want to conduct the Red-Tag
2. event in
3. Develop a team that will apply the Red-Tags
4. Create a temporary “parking-lot” for items that need further
5. evaluation
6. Determine the criteria for Red-Tagging an item
7. Determine the final Decision-Maker for further evaluation items
8. Launch the Red-Tag Event
9. Document the results of your Red-Tag EventThis document is a partial preview. Full document download can be found on Flevy:

Sort
Criteria for Red-Tags
The four main factors used in determining the disposition of an item are:
1. Is the item necessary to the operation where it is located
2. Is it a high or low frequency used item
3. How much of the item is really necessary
4. Are we ever going to use this item again?

Red Tag Event
Sort

The Power of Sort
Sort

The Process of SET
- This is the process of arranging items in the facility in the optimum location.
− In this process we analyze the item loca+on and quan+ty.
− We convert the old adage of “A place for everything and everything in its place” to “The best
place for necessary items and necessary items in the best place”
SET
Set

Set
How to Conduct the SET Eve
Create a pre-5S map of the area you want to organize.
Create a process flow on the pre-5S map indicating process/work flow
− Indicates high traﬃc areas and parts/equipment that is most frequently used.
Determine areas on your map where high congestion occurs
Create a new 5S map to trial new lay-outs that minimize movement
Implement this new lay-out with temporary markings
Verify with the team that the new lay-out is optimum
Permanently mark the locations and place the parts accordingly.

Set
Creating Your Trial 5S Map
When creating your new map, make sure you consider the following:
− Does your design op+mize movement so that the least amount of travel is required for high-
frequency use items.
− Are the parts stored at op+mum heights and easy to acquire
− Are carts and tables adequately sized for the parts you have on them
− Does your new design allow for visual aids to highlight loca+ons for ease of iden+ﬁca+on and
retrieval

Post-SET Exercise
After you have placed all equipment and parts, allow the team to trial this in “real-time”
Make any changes the team determines is necessary
Edit your Visual-Aids accordingly
Once the correct position is determined for all equipment or carts, remove the tape and use paint and
stencils to permanently mark locations
Set

Agenda
Introduction
Sort
Set
Shine
Standardize
Sustain
SummaryThis document is a partial preview. Full document download can be found on Flevy:

Shine
Implementing SHINE
Determine SHINE areas
Determine who is responsible for the cleaning
Determine the methods required for cleaning
Ensure you have the tools and supplies necessary for cleaning
Start to SHINE!

Shine
Your SHINE methods should include when the activities take place:
− Before the shiK starts
− During the shiK
− AKer your shiK is completed
Define what will be cleaned during each activity
Identify defects when conducting your daily cleanings and create a work request where
necessary
Define the tools and procedures needed
A Master Cleaning Schedule is a useful tool when implementing SHINE
Determining the SHINE Methods

Shine
Materials You Will Need for Shine
Cleaning Materials
− (1) roll of black arrows on yellow tape (ﬂow indicators)
− Camera
− Spray bo8les for each person
− Cleaning solu+on (strong and mild) for equipment cleaning
− (1) bo8le spray bo8le for each person with soap & water
− Degreaser
− WD-40
− Toothbrushes for each person
− Steel wool brushes
− Bristle brushes for every other person
(long-handled scrub brushes)
− 1” and 2” scrapers or pu8y knives
for every other person
− Cleaning rags (12-14) per person
− Safety locks for each person
(and several multi-linking hasps)
− Duck Tape or Maskin Tape

Shine
“Shining” Examples

Standardization
5S Maps
Master Cleaning Schedules
5S Scorecard
Tools Needed for STANDARDIZATION

Standardization
Utilize the Master Cleaning Schedule the same way you would a Preventive Maintenance schedule
− Verify that work has been accomplished
“Wander” the area and utilize the shadowboxed aids to determine that all is where it
should be
Integrating Sort, Set, and Shine into Regular Work Schedules

Sustain
How to Implement SUSTAIN
The process of implementing Sustain is not a measurable indicator. However, we
implement by providing the culture and conditions that illustrate our vision

Summary
5S in Conclusion
5S is the cornerstone of all future continuous improvement initiatives
While difficult to start, once you achieve momentum, it is difficult to stop
5S requires support from all levels of the organization
5S results in positive consequences across Safety,Quality, Productivity and Flexibility

JH + PM= Improved Reliability
Improved Equipment Reliability

Clean & Well maintained Workplace

Summary
Examples of 5S in Action

Writing of Non-conformities
•Non-conformities must be based on objective evidence
Requirement Failing Evident

Internal Audits Procedure
Purpose
Scope
Responsibility
Procedure in detail
Audit Checklist
Intimation of Audit
Audit procedure
Frequency of Audit
ReviewThis document is a partial preview. Full document download can be found on Flevy:

Plant Auditor team

3) When you complete an S, add the number of times you checked each column by the
column score weight then add up all your subtotal numbers and write that number in
the category subtotal box.
4) Continue this process throughout each S
5) Add up each category subtotal to obtain your final score.
6) Post the score in a visible location in the target area using the 5S Score Sheet.
How to Use This Form cont..
Area to be audited :- Area Owner's Name :-
Auditor's Name :- HOD's Name :-
Date of Audit
5'S Sr.No Check Points Discreption Score 0 ~ 4 Remarks
1 Material Or Part
Does the inventory or in process inventory
indicates any unwanted material or part,,?
2 Machines or Other Equipment
Are there unused machines or equipment
around..?
3 Tools and equipment
Are there any unneeded tools, equipments or
similar items around.?
4 Visual Control
It is obvious which items have been marked
as unnecessary..?
5 Written standard
Are there clear standards for elimination of
excess items and there disposal?
5'S Audit Sheet
SEIRI(SORT)

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