Lean Champion Black Belt 8 - Manage 5S

Your Gateway to Operational Excellence
© PSL 2009 All Rights Reserved
Lean Champion Training Package
Module 7 - Manage 5S

5S – The key to Removing Waste in
the Workplace
Inventory Excessive Processing
Motion
Waiting
Non-affective use
of Resources
Over Production
Transportation
Defects
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5S Example – Machine Shop
Before After

Building Team Leader Capability
As a leader one of your roles is to
ensure that all your team leaders are
capable of promoting and implementing
5S activities.
How often do you meet to discuss 5S
with your team leaders?
One on one?
As a group?
What actions are required?

Developing Practices and Procedures
- Team Level 5S
Designated Areas/Responsibility for 5S Task Teams
* 2 weekly Rotation
Okuma AreaVisual Board MaintenanceSafe Work Place - Kevin
Machine maintenance - Steve
Tool Room - Shane
Assembly Area - Nev
CNC Area (clean machines, work benches, trolleys, machine leaks) - Dave
Deburring Area and Raw Material Racks (stock availability) - Sam
Machine Shop/Band Saw - Raul
General Cleaning - Jethro

Change Management Guide
WIIFM ResourcesVision SkillsAction Plan SUCCESS+ ++ =+
WIIFM ResourcesSkillsAction Plan CONFUSION+ ++ =+
ResourcesVision SkillsAction Plan
PUSH
CHANGE
+ ++ =+
WIIFM ResourcesVision Skills
FALSE
STARTS
+ ++ =+
WIIFM ResourcesVision Action Plan ANXIETY+ ++ =+
WIIFMVision SkillsAction Plan FRUSTRATION+ ++ =+

Embedding 5S
5S needs to become part of the way your
organization thinks and acts.
It needs to be locked into the way that
everyone works.

5S – How we do it? Sustain
Management commitment to 5S
Lead by example
Continuous Improvement Activities
Regular reviews
5S Progress Boards
Goal is to be “Tour Ready” for
potential customers at any time

Creating Workplace Ownership
The key to a good 5S program is to get
the 5S program ownership beyond the
Management Team and Team Leaders
and to have the team members “own” the
program.
Empowering the teams to look after and
manage the 5S programs can be a good
way of making work fun and improving
staff retention.
The role of the leader then becomes one
of channelling the energy and providing
good guidance and resources.

Embedding 5S
What actions are required to embed 5S
in your workplace to become a way of
working rather than a housekeeping
project?
Form groups of 2-3 people
Time allowed – 30 minutes
Use the sheet below to collate your answers

Improving 5S Activities
Set up quarterly reviews of progress
with your site steering committee, or
5S Champions Club.
Use this to compare performance
across your teams and develop action
plans to address any issues.
Celebrate the most successful 5S
team or the largest improvement from
a 5S activity.
When you recognise success you will
get more of it.This document is a partial preview. Full document download can be found on Flevy:

SOP template

Time allowed – 20 mins
5S – Sustainment Plan

Project Evidence – Part 2
Audit 5S Implementation
2.1 Undertake spot checks of compliance.
2.2 Review workplace for indicators of
compliance/non-compliance.
2.3 Encourage operators to routinely
suggest areas for improvement.
2.4 Discuss 5S routinely with team leaders
to seek ideas for improvement and
encourage identification of non-
conformance.

Wrap Up
• Participants identify one key item
that they will remember from
today’s session
• Don’t forget to bring your project
information to the next session for
presentations and assessment
• Good luck – go and make a
difference

Project Evidence – Is it Complete?
Action Plan
Photocopies of completed workbook pages
Other evidence

1
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