This document provides an overview of the 5S methodology for performance excellence. It discusses the five elements of 5S - systematic organization, visual placement, self-discipline/control, scrubbing clean, and standardizing control. The goals of 5S are to eliminate waste, improve organization and visual controls, and maintain standardized processes. Implementing 5S involves training, communication, identifying waste, and progressively enhancing organization, cleanliness and standardization.

1. A STRATEGY FOR PERFORMANCE EXCELLENCE 5s

2. Executive Overview Participant manual Tools Workbook Knowledge Breakthrough Lecture notes Lecture notes Performance Excellence Series Training Module Elements

3. Session 1.0 Introduction…….……...……………………. 3 Session 2.0 Waste Management ……………………….. 14 Session 3.0 5S Implementation…………………………. 20 Element 3.1 Systematic Organization…………………... 31 Element 3.1.1 Red Tag System……………………………. 47 Element 3.2 Sorting Visual Placement………………….. 33 Element 3.2.1 Visual Sign System………………………….. 66 Element 3.2.2 Visual Color System………………………... 76 Element 3.3 Scrubbing Clean……………………………. 40 Element 3.4 Standardizing Control……………………... 45 Element 3.5 Self Discipline Control……………………... 48 5s Table of Contents Knowledge Breakthrough

5. 5S Performance Excellence Model Systematic-Systematic Organization Scrubbing clean Self-Discipline- Control Customer Expectations Sorting Visual Placement Standardizing Control Improved Quality Improved Safety Reduced costs Consistent Deliveries Improved Product/ Service Options 5s

6. The Five Elements of 5S Systematic Systematic Organization - Identifying what items are required and which are not. Sorting Visual Placement- Items should be easily retrievable, easy to get, and visual-easy to see. Self-Discipline/Control- Ensuring that Systematic Organization, Visual Placement & Cleanliness are maintained. Scrubbing Clean- Keep the area free from debris, dirt, oil, items not needed. Standardizing Control- Maintain and continually improve the previous improvements. 5s

7. Tool Kit Comparison Major CPI Tools (6  ) Kaizen Lean Description Cp/Cpk  Process capability assessment DOE  Design of experiments SPC  Process control based on statistics and data analysis FMEA  Risk assessment tool Regression  Correlate effect one variable has on another Process Map    Map process steps to communicate and identify opportunities 5 whys /2 hows  Determination methods for root cause discovery Pareto    Column chart ranking items highest to lowest Fishbone    Cause / Effect Diagram 5S   Elimination waste Visual Mgmt   Emphasis on visual techniques to manage process Poka-Yoke   Error proofing techniques Spagetti Chart   Kanban   Material storage technique used to control process Takt Time   Determine pace or beat of a process Std Work   Evaluate tasks done during a process SMED   Single minute exchange of dies - Quick machine set up TPM  Integrate maintenance strategy with process Cellular Flow  Reduce inventory & cycle time thru process layout and pull production techniques Expand Process Improvement Program to Utilize Kaizen Tool Kit 5s

13. Elimination of Waste

14. Systematic Organization Cleanliness Visual Placement Standardization 5 S Implementation Plan Progressive Enhancements Step 1 Establish 5 S Implementation Team Step 2 Develop Specific Implementation Plan Step 3 Develop Communication Plan Step 4 Develop 5 S Training Plan Step 5 Implement 5 S Step 6 Verification of Effectiveness

19. Cleanliness involves cleaning every aspect of the Organization and the removal of dirt, dust,oil, scraps on the floor, & garbage. Key Deliverables A clean Systematic Organization results in increased safety and efficiency . Increased Safety Increased Efficiency

20. Step 2: Allocation: Assign resources to the specific tasks required to make 3S a habit.

26. Waste Identification Map

28. The Nine Wastes Percentage of Waste