Lean Leader GB Series 5 - Lead 5S

Your Gateway to Operational Excellence
© PSL 2010 All Rights Reserved
LEAN LEADER TRAINING PACKAGE
Module 5 - Leading 5S

5S – The key to Removing Waste in the
Workplace
Waste
Value
Addition(<5%)
Defects
Over Production
Waiting
Non-Effective Use
Of Staff Talent
Excessive
Processing
Motion
Transportation
Inventory
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From 5S to 6S
Many companies have also included safety as critical element of their 5S program. These are known
as 5S + 1, or 6S programs
When 5S programs are implemented properly they have a significant impact on the removal of
hazards and risk reduction.
Safety elements have been built into our programs
Time
1945 1955 1965 1975 1985 1995 2005
Introduction of 6S
programs
Sort, Set in Order Shine, Standardise Sustain Safety
LTIFR Reduction 45%
Productivity Increase 150%
Source: Japan Industrial Safety and Health Association. Survey on the relationship between Productivity and Occupational Safety and Health

5S Assessment
5S-Radar Chart
15
12
1010
8
0
5
10
15
20
Sort
Se-in-Order
ShineStandardise
Sustain
Score World-Class
0 1 2 3 4
1
All unneeded items and unsafe items are
removed from the work area. Eg, on work
benches, in side the cabinets, under
equipment and machinery, in storage areas
etc.
2
Is there any scrap and waste lying around in
the work area?
3
Are items that are not needed been removed
from the work area, eg, tools, jigs,
stationery, extra items etc?
4
Items that are not used on a regular basis
are kept away from the work area and can
be easily located
5
Check if materials, parts, and supplies in the
work area are currently needed for
operations. Only items that are required for
operations in the next 2 hours are in the
work place.
Total Out of 20
5S Assessment Work Area: Date:
Productivity Solutions Limited Your Gateway to Operational Excellence
By When?
Tick When
Completed
Scoring Criteria: 0 = No activity undertaken; 1 = Reviewed once a year; 2 = Reviewed once in 6 months; 3 = Reviewed every 4 to 8 weeks; 4 = Reviewed continuously
Sort
Score
Action Required By Who?
0 1 2 3 4
1
Materials, boxes, storage containers, and
other items are stored in the appropriate
place and well oriented for operations. Also,
they are secured safely.
2
Tool, jigs, attachments and fixtures are
organised so that they are in easy reach of
the operator. This also applies to any go/no-
go and measuring devices.
3
The use of visual controls, colour coding and
other visual aids are widely implemented.
Eg, labelling, marking etc
4
There is good work-flow to enable efficient
operations. Eg, unilateral flow is followed
and operators need not have to go in
different directions to perform their work.
5
There is a place for evrything and everything
is in it's place. All items, tools etc can be
retrieved easily.
Total Out of 20
Set-in-Order
Score
Action Required By Who? By When?
Tick When
Completed
0 1 2 3 4
1
The work plcae including floors, work
benches etc are neat and clean. Cleaning
schedules are in place. No stains are rubbish
can be found.
2
Fixtures, tools and attachements are kept in
clean areas and no risk of damage exists.
3
Workplace operations / processes are
streamlines to reduce wasted time in storage
and retrieval, processing and changeovers.
4
Spary shields and physical guards are in
active use to keep items and liquids getting
on the floor. All critical areas are maked to
protect staff.
5
All staff take active part in continuous
improvement activities.
Total Out of 20
Shine
Score
Action Required By Who? By When?
Tick When
Completed

Shine: Self-Assessment
0 1 2 3 4
1
The work plcae including floors, work
benches etc are neat and clean. Cleaning
schedules are in place. No stains are rubbish
can be found.
2
Fixtures, tools and attachements are kept in
clean areas and no risk of damage exists.
3
Workplace operations / processes are
streamlines to reduce wasted time in storage
and retrieval, processing and changeovers.
4
Spary shields and physical guards are in
active use to keep items and liquids getting
on the floor. All critical areas are maked to
protect staff.
5
All staff take active part in continuous
improvement activities.
Total Out of 20
3 Shine
Score
Action Required Who? When?
Tick When
Completed

Preparing for 5S
• Define a project;
• Setup a project board (Story Board);
• Set the boundaries of 5S area;
• Identify the key people (form a team);
• Gather the resources needed for 5S;
• Photograph the 5S area;
• Do an initial audit of the 5S area;
• Prepare a plan for carrying out 5S.

Time for action – Sort
Time allowed – 1 hr

Tools and Templates
1. 5S Assessment Forms
2. Improvement Opportunity Sheet
3. Action Plan
4. 5S Tags

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 review
and assessment
• Good luck – go make a difference

Set in Order – How we do it
Arranging needed items so that they are readily accessible and labeled so that
anyone can easily find them and put them away again
Once we have sorted out the
necessary from the unnecessary,
we can then decide where it
should all go, how much is needed
and how we will know if it is
missing.
“A place for everything and everything in its place”

Point of Use Storage
Point of Use storage is used to store items that are used frequently – at least daily.
Items should be stored within the natural reach of a person and at the actual
workplace. Ideal reach is between the waist and shoulders, heavier items should be
stored at lower heights.
Once you have completed Set in Order you should be able to retrieve any item within
30 seconds from your immediate work area, or 2 minutes from within your
department.

Set in Order – Replenishment signals
Replenishment signals are a method of determining when to re-order
material, or bring the next batch of stock for processing

Improved use of the shadow board can be obtained through the use of
colour coded discs, key ring holders or velcro dots.
Set in Order – Shadow Boards
peter

Set in Order – Colour Coding
Use of colour to denote items and levels of safety are set by government. The internationally
accepted standards are defined by ANSI (Z535.1-1998) and appear below.
Red: Immediately identifies fire protection equipment and apparatus, including fire alarm boxes, fire
blanket boxes, fire extinguishers, emergency stop bars, buttons and switches.
White, Yellow or Black (solids or diagonal strips): These are the basic colors for lane marking.
Yellow or Yellow/Black Diagonal Stripes: Used for marking physical hazards, such as low pipes,
beams, handrails, pillar posts and fixtures that extend into work areas. Yellow is also used to warn
against using equipment that is under repair.
Orange: Identifies dangerous machine and equipment parts that may cause serious injury. Orange
should be used to mark hazardous parts when enclosure doors are open or guards are removed.
Green: Designates safety and first aid equipment, such as fire tanks, eye washes and first-aid kits.

Set in Order – Floor Markings
Picture #1
Picture #2
Picture #3

Cleaning a work area produces an
opportunity to visually inspect
equipment, tooling, materials and
work conditions.
A clean work area highlights any
leakage, spillage or other defects.
The goal is to be proud of the
workplace and have it “Tour
Ready” all the time. Many
companies will paint floors and
equipment.
How we do it? – Shine

Time for action – Set in Order / Shine
Before
After
Time allowed – 45 mins

5S Standards
• Set standards for storage
• Restocking
• Workflow
• Cleanliness

5S Standards - Examples
Use the sheet below to collate your answers

5S – How we do it? Sustain
• Continue self-assessment process – identify
what is needed, who will do it, involve the
whole team, monitor progress
• Set a 12 week target
• Goal is to be the industry Leader – World
Class, something to be proud of!

5S – How we do it? Sustain
Site Recognition
• Bronze Award – more than 50% of
the site is world class
• Silver Award – more than 70% of
• Gold Award – more than 90% of

Project Evidence – Part 1
Facilitate 5S in the
Workplace
1.5 Assist the team to develop 5S
schedules
1.6 Ensure procedures reflect 5S
1.7 Assist team to achieve the
required level of skill

Recommended Reading and Resources
Books Websites
www.strategos.com
www.lean.org

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