1. "5S" A3 OVERVIEW Author: David Devoe Lean.for.6S@gmail.com
I BACKGROUND V Steps 1 - 3 Sort – Step One
• First used by Toyota in 1970s.The Japanese 5S words: •Separating items into categories: those that are necessary to do the job those that are not
Seiri, Seiton, Seison, Seiketsu & Shitsuke. •Unnecessary items are removed from the work area
•There are 5 primary phases of 5S: sorting, straightening, systematic cleaning, standardizing, & sustaining.
Recently, an additional 6th. phase 'Safety' has become popular. Set in Order –Step Two
• 5S at RIE began in the summer of 2006. 5minutes was set aside at the end of each day for 5S cleanup
activities. . RED Tag (explained below) events were held in the fall of 2006. • Properly arranging and aligning tools & mat'ls that are
•The TPS 5S Training Module consists of a 37 Power Point slide presentation. determined to be necessary to do the job.
• If necessary tools are disorderly and/or not conveniently
II PURPOSE OF 5S A3 located for ease of use, it will add unnecessary work
movements. • Sorting helps to build in quality.
• Provide an overview of 5s philosophy
• Explain the purpose and application of each of the 5S steps.
• Get better understanding of: Elements of Set in Order
What is 5S, What are the steps of 5S, Why implement 5S, What are the benefits of 5S. •Set in Order and Standardization: Standardize the processes and guidelines for the company to follow when
doing this step
II WHAT IS 5S •Visual Controls: Devices or methods which show, at a glance, how work should be done and/or where items
should be placed (painting lines on floor, shadow boxes, pictures, etc)
• 5S is a key lean tool for waste removal. •Principles of Deciding Locations: Get rid of unnecessary motion: “motion improvement.”. Get rid of whole
• A process for creating and maintaining an organized, clean, and high performance work place operations: “radical improvement.”
• Reduces waste of motion
Shine – Step Three
•Machinery and equipment dirtied by shavings ,burrs, grease, etc. is not only unsafe but causes
mechanical breakdowns.
Housekeeping: Separate needed items from unneeded. Keep only what is immediately necessary VI Step 4
item on the shop floor. Standardize – Step Four BEFORE 5S
Workplace Organization: Organize the workplace so that needed items can be easily and quickly •Establish guidelines for maintaining Sort, Set in Order, and Shine.
accessed. •Standardize methods to ensure the improvements become a way of life.
Cleanup: A place for everything and everything in its place. •Create or revise check sheets and operator instructions.
•Scan the work place.
Cleanliness: Sweeping, washing, and cleaning everything around working area. Keep everything
clean for a constant state of readiness. Standardizing Control
•Maintaining and controlling continual improvement achievements
•Ensuring that systematic organization, sorting, and scrubbing clean are AFTER 5S
III WHY IMPLEMENT 5S
synchronized
• Eliminatethe waste that result from uncontrolled processes –Why, Who, What, When, Where, How, How much –Plan, allocate, act, verify
–Step 1: Planning •Who does what and when
• Gain control over equipment, material, & inventory
–Step 2: Allocation •Assign resources to tasks
• Standardize improvements for maintenance –Step 3: Act •Perform tasks and integrate into daily operations
• Improve delivery consistency –Step 4: Verify •Ensure effectiveness
•Improve quality, safety, & reliability Sustain – Step Five
VII Step 5
IV THE RED TAG PROCESS Sorting Items for Removal •Ongoing renewal and improvement. •Teams build on earlier accomplishments.
•Employees make a habit of using correct procedures.
Ask 3 questions about each Item: •Organization creates disciplines to sustain improvements. For ex: –Audits –Recognition –Accountability
1) Is it needed within one week, one month, etc?
•Red tags will be Key points to maintain discipline of the 5s system: 1. Each new employee is trained in 5S 2. 5S begins
used to id the items to 2) In what quantity? immediately on new equip. 3. Standards change to continually challenge the employee, dept.,& the company
be removed. 3) Where should it be Located?
•Id items to be red
tagged
•Machines &
VIII RESULTS Expected Results: WORK STATION 5S CHECK LIST
•Attach tags
equipment
•Enter item to be removed into the Red Tag log
•Tools •No unneeded items in work area •All needed items will be visibly identified •All tools & fixtures are
Explain why it is being removed, Where product should go next:
•Inventory neatly organized at shift end. •Parts modules, carts stored neatly & in proper location •Machines, fixtures
Back to stock or Removal from area
•Shelves,cabinets, & railings are wiped clean •No personal belongings visible in work area •Computer terminals & stations
•Documentation required
files,desks wiped clean •All work station floor space is swept •5S housekeeping stations contain all necessary items