5S Techniques by Operational Excellence Consulting

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The 5S workplace organization system applies a set of basic management principles that many companies widely adopt to maximize productivity and organization. As a cornerstone of Lean management, 5S improves workplace morale, safety and efficiency.

In this training presentation, you will learn how to mobilize and align your management team to launch or improve a 5S and Visual Management implementation in your organization. The presentation covers 5S and Visual Management best practices, step-by-step implementation guidance, and the best ways to integrate lean 5S into the organization's culture to achieve sustainable world-class excellence.

LEARNING OBJECTIVES

1. Understand the benefits of working in a clean and neat environment
2. Define the 5S principles, and identify visual tools
3. Explain how to apply the 5S principles and visual tools to enhance workplace organization
4. Learn how to kick start and launch a 5S initiative
5. Define the critical success factors for 5S implementation

CONTENTS

Introduction & Overview
5S Lays the Foundation for a Lean Enterprise
5S Establishes a Baseline for Kaizen Activities
5S as a Cornerstone of Employee Engagement
5S Helps to Eliminate Waste
What is 5S?
What is the Purpose of 5S?
Benefits of 5S
5S Principles - Step by Step
How to Conduct a Red Tagging Exercise
5S Visual Management
5S Applications
5S Implementation
Starting & Launching 5S
5S Audit System & Maturity Levels
Supporting Lean Tools for 5S
Critical Success Factors​

To download this complete presentation, please go to: http://www.oeconsulting.com.sg

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5S Techniques by Operational Excellence Consulting

  1. 1. © Operational Excellence Consulting. All rights reserved. Sort Set In OrderShine Standardize Sustain
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Objectives • Understand the benefits of working in a clean and neat environment • Define the 5S principles, and identify visual tools • Explain how to apply the 5S principles and visual tools to enhance workplace organization • Learn how to kick start and launch a 5S initiative • Define the critical success factors for 5S implementation NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: http://www.oeconsulting.com.sg
  3. 3. © Operational Excellence Consulting. All rights reserved. 3 Outline • Introduction to 5S • 5S Provides a Solid Foundation to Lean Implementation • Types of Waste in the Workplace • What is 5S? • Benefits of 5S • 5S Principles - Step By Step • How to Conduct a Red Tagging Exercise • Creating a Visual Workplace • Applying 5S to:  Safety  Quality  Equipment Reliability  Productivity • 5S in the Office • How to Implement 5S • How to Sustain 5S • 5S Audit System • Supporting Lean Tools for 5S • Critical Success Factors
  4. 4. © Operational Excellence Consulting. All rights reserved. 4 Introduction to 5S • 5S is a structured program to implement workplace organization and standardization • 5S represents five disciplines for maintaining a visual workplace • 5S is a foundation to Kaizen and Lean implementation, e.g. TPM Sort Set In OrderShine Standardize Sustain
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 5S Lays the Foundation for a Lean Enterprise Productivity 5S Heijunka Standardized Work Kaizen Just-In-Time • Continuous flow • Takt time • Pull system • Flexible workforce Jidoka • Separate man & machine work • Abnormality Identification • Poka yoke •Visual Control Goals: highest quality, lowest cost, shortest lead times Involvement
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 5S establishes a baseline for Kaizen activities Standardize Standardize StandardizeKaizen Kaizen Kaizen P DC A Kaizen (改 善) = Continuous Improvement Plan DoCheck Act
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 5S Suggestion System Continuous Improvement Teams 5S is a cornerstone of Employee Engagement
  8. 8. © Operational Excellence Consulting. All rights reserved. 8 5S Helps to Eliminate Waste Over-production Producing more than what the customer needs Inventory Building and storing extra services/products the customer has not ordered Transportation Moving product from one place to another Rework Reprocessing, or correcting work Over-processing Adding excess value when the customer does not require it Motion Extra physical/mental motion that doesn’t add value Intellect Not using employees full intellectual contribution Waiting Employees waiting for another process or a machine/tool Waste
  9. 9. © Operational Excellence Consulting. All rights reserved. 9 What is 5S? Principles General Description 1S Sort Remove what is not needed and keep what is needed 2S Set in Order Arrange essential items in order for easy access 3S Shine Keep things clean and tidy; no trash or dirt in the workplace 4S Standardize Establish standards and guidelines to maintain a clean workplace 5S Sustain Make 5S a habit and teach others to adhere to established standards
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 What is the purpose of 5S? Immediately make problems visible
  11. 11. © Operational Excellence Consulting. All rights reserved. 11 Benefits of 5S • 5S makes our workplace more pleasant • 5S improves work efficiency • 5S and safety go hand-in-hand • 5S leads to better customer satisfaction and higher productivity
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 1S : Sort • Principle  Stratification management  Dealing with the causes • Meaning  Distinguish between the necessary and unnecessary  Get rid of what you do not need  “When in doubt, move it out”
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 1S : Sort Degree of Need Frequency of Use Storage Method Low • Things you have not used in the past year • Things you have used once in the last 6-12 months • Throw them out • Store at a distance Medium • Things you have only used between 1-6 months • Store in a central place in the workplace High • Things used once a week • Things used daily • Things used hourly • Store near the work site or carry on the person
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 2S : Set In Order • Principle  Functional storage  Search elimination • Meaning  Arrange essential items in order for easy access  A place for everything  Everything in its place after use
  15. 15. © Operational Excellence Consulting. All rights reserved. 15 2S : Set In Order - Examples
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 2S : Set in Order - Office Desk An office desk before and after conducting 5S Sort, Set In Order and Shine. Clutter and unused items have been removed leaving only what is needed. Before After
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 3S : Shine • Principle  Cleaning as inspection  Degrees of cleanliness • Meaning  Eliminate the sources of dirt and filth  Cleaning as a form of inspection  Clean everything, inside out  Shine check sheet
  18. 18. © Operational Excellence Consulting. All rights reserved. 18 3-Step Approach to Cleaning Common areas, walls, ceilings, lights, storage areas, toilets, “junk yards”, shelves, filing cabinets, etc. Individual workstations, chairs, drawers, computers, cabinets, shelves, etc. Clear away things underneath your table! Measuring instruments, e.g. micrometer, gauges, vernier calipers, contact surfaces, etc.
  19. 19. © Operational Excellence Consulting. All rights reserved. 19 4S : Standardize • Principle  5S standardization  Visual management • Meaning  Establish guidelines  Make standards and guidelines visual  Make standards so that any abnormality becomes visible  Use visibility tools
  20. 20. © Operational Excellence Consulting. All rights reserved. 20 Standardization is the Way to Sustain the Gains Present state Future state Without standardization, all my improvements will roll back with time… STANDARDIZATION Standardization is a tool that will ensure your improvements will be sustained.
  21. 21. © Operational Excellence Consulting. All rights reserved. 21 Foundations of Standardized Work Simplify the Work Site
  22. 22. © Operational Excellence Consulting. All rights reserved. 22 5S : Sustain • Principle  Habit formation  Disciplined workplace • Meaning  Training  ‘Before’ and ‘after’ photos  Daily 5S five-minute activities  Self-discipline
  23. 23. © Operational Excellence Consulting. All rights reserved. 23 How to Sustain 5S? • Get management commitment • Get everyone involved • Get authorization from management for 5S activities • Promote 5S in the organization • Do it all the way • Gemba walk by CEO • Conduct monthly review by 5S committee • Use 5S as a platform to launch other continuous improvement programs/initiatives
  24. 24. © Operational Excellence Consulting. All rights reserved. 24 5S Audit Checklist & Results
  25. 25. © Operational Excellence Consulting. All rights reserved. 25 Creating a Visual Workplace • 5S can be enhanced by the use of visibility tools • Use 5S visibility tools to help you monitor results and look for things easily and quickly Note: Visual management IS NOT decoration
  26. 26. © Operational Excellence Consulting. All rights reserved. 26 Everyday Visual Management
  27. 27. © Operational Excellence Consulting. All rights reserved. 27 3 Types of Visual Management • Label to make it perfectly clear where things belong and what the procedures are Visual Display • Quantify the path to targets for success • Graphs and Pareto charts Visual Metrics • Create an error-proofed environment to promote easy adherence to standards Visual Controls
  28. 28. © Operational Excellence Consulting. All rights reserved. 28 Example of Visual Metrics Process Costs Product Profitability 100% Revenue Rework On TimeCycle Time Reduction WIP Backlog Internal Quality Customer Complaints
  29. 29. © Operational Excellence Consulting. All rights reserved. 29 5S and Safety, Quality, Productivity & Equipment Maintenance 5S Safety Quality Productivity Equipment Maintenance
  30. 30. © Operational Excellence Consulting. All rights reserved. 30 5S and Safety 1 • Wear protective clothes, goggles and shoes in the lab • Install protective covers on equipment and machines • Label warning signs prominently  High voltage, Radiation, Slippery/Wet floor, etc.  ‘Under Test – Do Not Switch Off’
  31. 31. © Operational Excellence Consulting. All rights reserved. 31 5S and Quality 1 • Train staff on 5S • Provide on-the-job training for new staff  Use ‘Training Within Industry’ (TWI) methods for coaching • Educate/Train staff to recognize and prevent mistakes
  32. 32. © Operational Excellence Consulting. All rights reserved. 32 The One-Is-Best Campaign • One-page memos • One-hour meetings • One-location files • One-day processing
  33. 33. © Operational Excellence Consulting. All rights reserved. 33 5S Implementation Process Step 5: Implement 5S Step 1: Establish a 5S Committee Step 2: Define a 5S Implementation Pan Step 3: Develop 5S Publicity Materials Step 4: Provide 5S Education Step 6: Audit, Evaluate & Follow-Up Sort Set In OrderShine Standardize Sustain
  34. 34. © Operational Excellence Consulting. All rights reserved. 34 5S : Getting Started 1 • 5S publicity materials  Booklets, badges, brochures, cups, pens, etc. • 5S training and education  Provide 5S training to managers and staff  5S pamphlets • 5S notice boards/intranet  5S news  ‘Before’ and ‘After’ photos
  35. 35. © Operational Excellence Consulting. All rights reserved. 35 Launching a 5S Day 1 • Set aside half a day for this event  Best on Fridays or before a festive season or public holiday  Everyone in casual attire, e.g. T-shirts • Prepare sufficient cleaning equipment, detergents, paints, etc. • Speech by CEO on importance of 5S to all staff
  36. 36. © Operational Excellence Consulting. All rights reserved. 36 Supporting Lean Tools for 5S Zone 1 Zone 3 Zone 4 Zone 2 Chores John Mark Sue Jim Pack Table Restocking X X X Supply Shelf Restocking X X X Handling Incompletes X Equipment Maintenance X File Organizing X X X X Visual Charts X X X Cleaning X X X X 1. Zone Chart 3. Cross-training Matrix Before After 2. ‘Before’ & ‘After’ Photos
  37. 37. © Operational Excellence Consulting. All rights reserved. 37 Critical Success Factors • Top management commitment • Involvement of all staff • Sufficient resources, manpower, admin, training, publicity, etc. • Link with productivity and quality initiatives • Regular 5S Audit and management review • Recognition and reward for good 5S practices
  38. 38. © Operational Excellence Consulting. All rights reserved. About Operational Excellence Consulting
  39. 39. © Operational Excellence Consulting. All rights reserved. 39 About Operational Excellence Consulting • Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. • One of our unique strengths is going beyond a tools-focused approach to seamlessly integrate people, processes, technology and continuous improvement initiatives to suit the specific needs and situations of our clients. • We provide corporate learning programs and management advisory services to assist our clients to achieve breakthrough in business performance and effectiveness. Our aim is to support our clients in designing, managing and executing lasting beneficial change.
  40. 40. © Operational Excellence Consulting. All rights reserved. To download this presentation, please visit us at: www.oeconsulting.com.sg END OF PARTIAL PREVIEW

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