A basic introduction to the world of 5s with visual examples and simple explanations.

1. 5s
An introductionBy Sarah Bridge

2. Objectives
 To understand the importance of 5s to our Lean
initiatives.
 To know what the 5S’s are and know the key
benefits of each.
 To be able to participate in group and individual
5s activities.

3. What is 5s?

4. The Average Factory Environment

5. Sort
• Everything at the workplace should be related to
the work being done there.
• Leave only what is needed, in the amounts
needed.
• Remove all items that are not needed for current /
regular production.

6. Benefits of sort
• Keeps the work area clean and clutter free.
• Reduces the risk of accidents and near misses.
• Creates extra work space where necessary items
can be placed.
• Reduces the time spent searching for tools and
equipment.
• Less clutter results in a more pleasant working
environment.

7. • A method of identifying potentially unneeded
items in the work area.
• Ensures that no needed items are accidentally
disposed of.
• Allows us to evaluate the usefulness of an item
by segregating it when we are unsure of it’s use.
Red Tagging

8. • The three questions to ask
- Is this item needed?
- If it is needed, is it needed in this quantity?
- If it is needed, is this the best location for it?
• Holding areas
- A safety net between questioning whether
something is needed and getting rid of it.
- Items are held for a set time (30 days?).
- Notices are put out for unknown items so that they
may be claimed by anybody who has a genuine
need for them.
After the allocated time, unwanted items are disposed of.
Red Tagging

9. • Define the necessity of the item in order to perform
the work required on a day to day basis.
- If it isn’t needed it should be disposed of.
• Determine the frequency with which the item is
needed.
- If it’s needed infrequently it can be stored away from the work
area.
• Decide the quantity of the item required to perform the
regular work.
- Excess items can be disposed or stored away.
Red Tagging Aims

10. • Establish red tag holding area.
- An area is set aside to store tagged items which need
further evaluation
• Red tag items.
- the 5s team goes through the 5s area and red tags all
items they believe can be removed from the area or
disposed of.
- Any items that we are unsure of are also red tagged.
- All tagged items are listed on a log sheet with a
location and description.
- this log is circulated throughout the company so that
anybody may claim an item if it is required.
Red Tagging Steps

11. • Evaluate the red tagged items.
- Decide if items should be disposed of, or kept for a period to
determine their necessity.
• Remove questionable items to the red tag holding
area.
- Assign responsibility of the area to the team.
- Circulate item log.
- After 30 days the items should be reviewed a final time. Log
any items which have been removed back to the work area
due to being required.
- Dispose of, store away from the area, or sell any items left
after the time period has passed.
Red Tagging Steps

12. • Defective tools or inventory.
• Obsolete tooling, jigs, inventory.
• Worn out tools.
• Broken equipment.
• Outdated posters, signs & notices.
• Excessive quantities of materials, tools, supplies.
• Excessive personal items.
Examples of Unneeded Items

13. After Sorting

14. • Everything that remains after Sort should have a
place.
• Arrange things so that they are easy to use, and
label them so that anyone can find them and put
them away.
• Place frequently used items closer to you than
those used less often.
Set

15. • For every item in the workplace we will need to:
- Identify it.
- allocate a place to store it.
- Determine how much / how many to store at the
workplace.
- Create a visual marker for it.
Set

16. • Decide where to keep needed items.
- Keep frequently used items at point of use.
- Screwdrivers next to screws, order of use.
• Organise items in a way that makes sense.
- Make it easy for anyone to find them, use them and put them
back after use.
- Make it obvious when items are not in their correct place.
- Use visual indicators such as area photos to show the area
in it’s correct state.
Set

17. • Safety is improved.
- Ergonomic storage of tools and materials.
- Clean, clutter free floors and walkways.
• Tools and parts are stored properly so there’s less
damage.
• Less waste of motion – reduced searching for
materials, tools & supplies.
• Reduced inventory of materials, supplies, leaving
more free space.
• A more pleasant working environment.
Benefits of Set

18. • Standardisation
- Creating a consistent method of carrying out tasks and
procedures.
• Visual controls
- Used to identify standards.
- Examples;
• Where items belong and how many belong there.
• Standard procedures.
• Area photographs.
• Colour coding
• Restock markers
Keys to Set

19. • Used for identifying locations on floors and
walkways.
• Segregate working areas from walkways.
• May show:
- Flow direction.
- Storage location.
- Hazards or safety devices.
- Areas to be kept clear.
Painting / Marking

20. • Colour coding
- Shows which parts, tools etc are used for which purpose, or
which items are used together.
- Used for storage containers.
- Used to set items to a specific work area.
• Outlining
- Shows what parts and tools go where.
- Shadow boards.
• Cross hatching
- Areas to be kept clear.
Painting / Marking

21. Examples of Set

22. After Set

23. • Clean the area
- Remove all dust, dirt
- Floors clean
- Work surfaces clean
- Inside all cupboards, drawers etc clean
- All tools clean
• A clean workplace suggests quality work!
Shine

24. • Safety
- No debris, fluids or materials on floor to cause slips, trips or
falls
• Morale
- Dirty workplaces are unpleasant to work in.
- Clean workplaces foster pride in what we do.
• Customer service / satisfaction
- Customers touring a clean and organised factory are more
likely to see us as a quality driven business and want to
work with us.
Benefits of Shine

25. • Machine reliability
- Easier to identify issues on clean machines, meaning they
can be addressed sooner.
- Cleaning is a form of inspection.
• Equipment / Tools
- Clean equipment functions more effectively.
- Easier to spot damage or wear on clean equipment and
tools than on dirty ones.
Benefits of Shine

26. After Shine

27. • All procedures, practices and activities
established with the first 3s’s occur consistently
and at regular intervals.
- There is no point in going through Sort, Set or Shine
if we are going to let things go back to the way they
were.
• Makes implementing Sort, Set and Shine a daily
habit so that conditions are maintained at the
desired level.
Standardise

28. • Safety
- Walkways and floors are kept clear and hazard free.
• Efficiency
- Storage areas remain organised.
- Materials, tools and equipment remain organised and cared
for.
• We maintain all the benefits gained from Sort, Set
and Shine.
• We have a template for expanding the 5s area
across the whole plant.
Benefits of Standardising

29. • Decide who is responsible for each activity / area.
- Activity charts, Checklists, Schedules.
• Integrate 5s into daily work activities.
- 5 minute 5s, daily cleaning / inspection.
• Ensure 5s conditions are being maintained.
- 5s audits, 5s walk rounds.
Establishing the Habits

30. After Standardise

31. • 5s Audits.
- Checking the level of effectiveness of the first 3s’s.
- Use traffic light system, green, amber, red, to display
current state of area.
- To be conducted routinely by operators, managers and
directors.
• 5s Walk rounds.
- Weekly tours by managers / directors to note
improvements made and to encourage any further
improvements that can be made.
Monitoring

32. • Having the discipline to maintain the correct
standards over time.
• Creating conditions, and an atmosphere that
encourages the constant practice of good habits,
and the elimination of bad ones.
• Creating a culture which constantly looks for
improvement opportunities.
Sustain

33. • A workforce that is trained and aware of the
benefits of 5s.
• Time allowed to practice and maintain.
• Organised, focussed effort.
• Management support and drive.
• Efforts that are recognised, and appreciated.
• All improvements need to be beneficial and
purposeful.
Keys to Success

34. After Sustain

35. Recap

36. • Sort – To put things in order.
- Remove what is not needed.
• Set – Arrange for ease of use.
- Place things in a way that they are easily accessible whenever they
are needed.
• Shine – Clean.
- Keep area clean and free from rubbish.
• Standardise.
- Best practices to be used throughout.
• Sustain – Commitment and self discipline.
- Develop a culture of 5s and improvement.
The 5S’s

37. • Reduced set-up
times.
• Reduced searching
times.
• Increased floor space.
• More pleasant
working area.
• Employees enabled to
lead improvements.
• Less frustration.
• Less wasted labour.
• Better equipment
reliability.
• Higher quality.
• Lower cost.
• Safer working area.
• & many, many other
benefits.
Benefits

38. • Challenge traditional ideas.
• Find ways to make the impossible possible.
• Don’t accept excuses.
• Go for the simple solution, don’t overcomplicate
things.
• Correct mistakes right away.
• Involve everybody.
• Improvement never ends!
Keys to Success

39. Questions?