5S presentation for sanitation and cleaning program of a food production facility, including lean manufacturing and six sigma

1. October 22nd, 2018
Sanitation Program Enhancements
(5S system and color coded cleaning tools
overview)

2. 5S SYSTEM OVERVIEW
ORIGEN -
Its early beginning can be traced to management methods developed and applied
during the American Industrial Revolution. Many early methods were later
improved upon in Japan during post WWII reconstruction.
WHAT IS IT? -
5S system is one of a number of Lean Manufacturing tools designed to help improve workplace efficiency through facility organization.
5S TERMS TRANSLATED
JAPANESE TERMS TRANSLATION 5S TERMS DEFINITIONS
Seiri Tidiness Sort Clean up, and identify needs for the immediate
work space
Seiton Orderliness Set in Order Organize items, designate storage locations, and
define procedures for use.
Seiso Cleanliness Shine Clean and maintain the area’s appearance and
establish preventative maintenance
Seiketsu Standardization Standardize Set roles and responsibilities to ensure efficient
process improvement
shitsuke Discipline sustain Maintain and reinforce involvement in achieving
goals

3. HOW THE 5S SYSTEM WORK?
The 6th S
☑ SAFETY - Safety is often referred to as the 6th ‘S’
because it is a primary concern in the workplace.
FiveS activities incorporate safety by identifying and
eliminating hazards for a zero-accidents, injury-free
work environment
HOW DOES IT WORK 5 Steps engages people
through the use of 'Standards' and ‘Discipline'. It is not
just about housekeeping, but concentrating on
maintaining the standards & discipline to manage the
organization - all achieved by upholding & showing
respect for the workplace every day.

4. WHERE SHOULD WE IMPLEMENT THE 5 STEPS FOR SUCCESS?
EVERYWHERE; 5s begins with the creation of an internal committee team.
Individuals with strong leadership skills should be considered as top
candidates for this team.
☑ BETTER DATA COLLECTION
BENEFITS
☑ PROPER STORAGE/SEGREGATION
☑ IMPROVE WORKPLACE APPARIENCE
☑ ENHANSE SAFETY & DECREASE INJURES

5. 5s - A FOOD SAFETY ENHANCER!
5
ACCOUNTABILITY
Having a place for
everything allows
easier tracking of
items on the
production floor
making them
traceable to where
they should be
WHY 5S FOR FOOD PRODUCTION.
3
AUDIT READY
5S helps you stay audit
ready, knowing
everything is in its place
at all times. In addition,
auditors and clients will
see immediately that you
are going above and
beyond in your food
safety efforts
1
HACCP
5S benefits your
HACCP program by
supporting the
segregation of your
color Code System
and helping control
high risk items.
2
FOREIGN OBJECT RISK
5S can greatly reduce the
risks of foreign particle
contamination caused by
tools, defective
equipment, or other items
used in and around
production by ensuring
they are in place and not
at risk of getting into the
product.
4
EFFICIENCY & WASTE
REDUCTION
5S will make waste more
obvious giving you the
opportunity to become
more efficient. Change-
over times will improve
and you will spend less
time training staff.

6. AMERISAN – ANOTHER CLEANING TOOLS SELLING COMPANY…
Amerisan A company that offers a variety of color
coded tools, PPE in different colors, custom made
signs and more. They believe that visual
communication is one of the most effective ways in
achieving and sustaining 5S Lean manufacturing
goals.

7. LEAN SIX SIGMA: 8 WASTES
DEFECTS
Any rework that
results in scrap or is
substandard to quality
performance
OVERPRODUCTION
Producing more
than what is needed
for a job or
schedule
WAITING
Idle time that can
be spent doing
something
productive
NON-UTILIZED TALENT
Not utilizing all knowledge,
ideas, skills and available
resources
employees have to offer
TRANSPORTATION
Handling more than once,
delays in moving materials or
unnecessary handling during
the completion of tasks
INVENTORY
Any surplus supplies or
tools that are
unnecessary to the job
at hand
MOTION
Any action or
movement that adds
no value to the final
product
EXTRA-PROCESSING
Extra actions or
operations that are
performed outside the
scope of the customers
needs

8. 5S OPTIONS
Create Visually Organized Floor Layouts with
Flexibility
With the rise in popularity of organizational systems like Lean and
5S, many companies are realizing gains in efficiency from color
coding and labeling their workspaces. With Superior Mark™, you
can label away without committing to a permanent layout. Because
it is removable, companies have the freedom to practice
“Continuous Improvement,” changing floor layouts to best
accommodate their most efficient work flows.
Endless Customizable Options
Superior Mark™ can be custom printed with any message,
graphics, or even photos! Because it is reverse printed, the ink is
protected from surface damage. From hazard stripes to bar codes,
clearly communicate the importance of safety and organization with
our crisp prints!
US 8,883,290B2

9. 5S OPTIONS
Armor Stripe offers an extremely durable system to aid in floor layout, sorting and
workflow for 5S Lean manufacturing standards.
These markers are made from a through-color solid 0.055” thick rigid polyethylene
surface with an ultra tacky heavy coat weight adhesive backing. They will adhere to
most any clean smooth surface with a very high tack bond while offering a low residue
removal from most applications.
Available in an assortment of stock sizes and colors with custom options available.

10. 5S OPTIONS
FREEZER TAPE: SUPERIOR
MARK™ TAPE FORMULATED
FOR USE IN EXTREME COLD
Our freezer floor marking tape is a variation
of Superior Mark floor marking tape that
utilizes a special adhesive formulation
crafted for exceptional durability and
performance in extreme cold and low
temperatures.

11. 5S Shadow Boards – a visual Communication
FDA Compliant | Plant Safe
The Shadow Boards are custom built to meet the specific needs.
They offer unlimited sizes, colors, and configurations. Choose from
magnetic boards, wall & wheel mounted and options as well as
multiple board materials

12. 5S Shadow Board Type
A transparent shatter proof
laminated material of high
strength and versatility. The
most durable option available,
ideally suited for harsh
environments like
Food Processing and
Pharmaceutical facilities.
Food
Safe
Shatter
Proof
Moisture
Resistant
Chemical
Safe
UV
Stable
Scratch
Resistant
Aluminum composite consisting
of two thin sheets of
aluminum enclosing a Polyethylene
core.Highly versatile and resilient
medium duty option, ideally suited
for standard applications in Food
Processing and Pharmaceutical
facilities.
PVC or ‘Poly’ based material
available in both rigid and flexible
forms. A lightweight option for use
in specific plant locations, suited
to light duty applications in any
Food Processing and
Pharmaceutical plants.
UV
Stable
Light
Weight
Moisture
Resistant
Recyclable
STORSHIELD STORLAM STORPLAS
Food
Safe
Shatter
Proof
Moisture
Resistant
Chemical
Safe
UV
Stable

13. Introduction
#3
Proof Process
✓ Acquire needed
high res logo
artwork from client
✓ Design and submit
proofs for all
boards
✓ Customer Approval
#2
Preliminary
Layout/Pricing
✓ Determine board
size based on tool
count
✓ Submit design ideas
✓ Submit pricing for
each board
✓ Approve design
concept and pricing
#1
Analysis
✓ Identify areas that
require 5S
organization to
improve safety and
efficiency
✓ Determine type of
board – wall mount
or mobile
✓ Determine what
tools will be stored
in that location
#4
Production/
Delivery
✓ Boards produced,
hardware, tool, and
detailed
instructions for
installation
✓ Delivery to client
Shadow Board Process

14. 5S Shadow Boards – before and after
BEFORE 5S EXERCISE
AFTER 5S EXERCISE

15. Non-compliance
Non Compliance with Current Color Code Standard and
5S Standards “Sort” and “Set in Order”
Color Area Utensil
White Food Contact Brushes, Squeegees
Green Non-Food Contact (“Clean
Rooms”)
Brushes, Squeegees
Green with Black Stripe Non-Food Contact (“Clean
Rooms”) - FLOORS ONLY
Brushes, Squeegees
Blue Non-Food Contact (“Dirty
Rooms”)
Brushes, Squeegees
Blue with Black Stripe Non-Food Contact (“Dirty
Rooms”) FLOORS ONLY
Brushes, Squeegees, Mop,
Mop Wringer
Red Restrooms Mop, Mop Wringer, Bowl
Brush
Black Drains Brushes, Buckets

16. Non-compliance
Non Compliance with 5S Standard “Shine”
Unattended Tools and Messy Areas:

17. Non-compliance
Sub Standard Tools:
Broken handle Bent handle Repaired handle Chipped paint on handle

18. Non-compliance
Condensation Issue:
Non Compliance with 5S Standard “Shine”

19. Corrective Action Report
Update the color code program
Remove all sanitation tools with wood handles
Remove all sanitation tools with fiberglass handles
Remove all sanitation tools that are in
disrepair - broken, chipped paint.
4
3
2
1

20. Corrective Action Report
Post signage that reinforces the color code program
and a high standard of excellence at Flying Foods JFK
Drive compliance by implementing manager
shift checks for each shift and location
Remove all sanitation tools that do not comply with
color code or have mixed colors
Prevent tool disorganization by installing shadow
boards in accessible areas
Train all personnel on the benefits of 5S, updated
color coded program
9
8
7
6
5

21. Reference: https://www.amerisanusa.com
Thank You!