This document provides an overview of 5S and how it can be implemented to promote workplace safety, productivity and organization. It defines the 5S principles of Sort, Set in Order, Shine, Standardize and Sustain. The benefits of 5S include improved safety, quality, productivity and equipment reliability. A 5S implementation process and critical success factors are outlined. Audit tools and maturity levels are provided to assess 5S implementation. The document aims to teach attendees how to apply 5S concepts and launch a successful 5S initiative.

1. © Lean & Mean Consulting. All rights reserved. 2015© Lean & Mean Consulting. All rights reserved. 2016
06/ 16
5S & Safety
Promoting High Workplace Safety &
Productivity
World-Class Standards & Best Practices of Operational Excellence

2. 2
Objectives
 Understand the benefits of working in a safe, 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
 Learn how to use 5S Tools and Standard Templates

3. 3
 Introduction to 5S
 5S Provides a Solid Foundation
to Lean Implementation
 Types of Waste in the
Workplace
 What is 5S?
 Benefits of 5S
 Implementing 5S
 Critical Success Factors
Training Agenda
 5S Audit System
 5S Principles - Step By Step
 5S for the Operations:
Safety
Quality
Productivity
Equipment Reliability
 5S in the Office
 5S Maturity Model

4. 4
Introduction to 5S
 5S is a structured process to
enhance workplace safety,
quality, efficiency, order and
standardization
 5S represents the disciplines for
maintaining a visual workplace
that supports our safety culture
of zero injuries & world class
quality
 5S is a foundation for
Continuous Improvement
5S

5. 5
5S Lays the Foundation for Continuous
ImprovementProductivity
5S
Leveling 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:
Superior service,
lowest cost, shortest lead times
Involvement

6. 6
5S Helps to Identify and Eliminate the 8 Types of
Waste
Motion
Extra physical /
mental motion that
doesn’t add value
Waste
Waiting
Employees waiting
for another process
or information
Over
production
Producing more
than what the
customer needs
Intellect
Not using
employees full
intellectual
contribution
Over
processing
Adding excess value
when the customer
does not require it
Defects
Reprocessing, or
correcting work Inventory
Building and storing
products the
customer has not
ordered
Transportation
Moving from one
place to another

7. 7
Principles General Description
1S Sort
Remove what is not needed and keep what is
needed
2S Set in Order
A place for everything and everything in its
place. Arrange items in order for easy access
3S Shine
Keep things clean and tidy; no garbage or dirt in
the workplace. Eliminate the source of dirt for
repeating issues
4S Standardize
Use standards and guidelines to maintain a clean
workplace
5S Sustain
Make 5S a habit and teach others to adhere to
established standards
5s + Safety Safety is integrated into all of the above S’s
What Is 5S

8. 8
Benefits of 5S
 5S supports our total safety culture
 5S delivers world-class quality
 5S promotes colleague engagement
 5S increases customer satisfaction
 5S immediately makes abnormal
conditions visible
 5S improves productivity

9. 9
5S Implementation Process
Step 5: Implement 5S
Step 1: Establish the 5S Focus Area
Step 2: Define a 5S Implementation Plan
Step 3: Develop 5S Criteria and Standards
Step 4: Provide 5S Education
Step 6: Audit, Evaluate & Follow-Up
5S

10. 2
Promoting High Workplace Safety & Productivity
Module. 06
5S

11. 5S

12. 12
1S: Sort
 Guiding Principle:
 Clutter elimination
 Safe environment
 Meaning:
 Distinguish between the necessary
and unnecessary
 Get rid of what you do not need
 “When in doubt, move it out”

13. 13
1S: Sort
 The first step in 5S is to get
rid of what we do not need
 Go through all the tools,
equipment, materials,
drawers, cabinets etc. in
the plant and work areas
 Keep only essential items
 Everything else is stored away,
discarded, or red tagged

14. 14
Attach Red Tags
 Fill in everything except disposition
 Perform tagging swiftly
 Place tags on all items in question
 Move “tagged items” to a RED ZONE
NOTE: if you know the item is to be disposed of, do it directly – only
tag items that need to be dispositioned.
Other items you might need:
• A log book
• Boxes for small items (Tag the box instead of tagging each
small item individually)

15. 15
Red Tag. Example
A tool to prepare Red-
Tags is available!

16. 16
Red Zone Details
 Red Zone Requirements:– must be bordered in red and labeled
“RED ZONE”
 Red Zone must be in a predominate location and visited by
Management Team on a regular basis IE. Daily Walk Around
 Red Zone items must be dispositioned within 48 hrs
 For all assets follow the fixed asset disposal, impairment, and
transfer policy
 Prepare and print red tags:
Use the template from Lean Management Academy

17. 17
How to Sort:
Starting the 5S Sort
 During the sort event look for any obvious safety issues and
resolve them immediately. You may find trip hazards or
leaking equipment that was covered up.
 If there is any doubt that something is required identify item
with a red tag
 Some employees will be resistant and want to keep items not
needed. In this situation, refer to guidelines on slide 22
At the end of the sort event each workstation should only contain a small amount of
work-in-process and the tools and supplies needed to do the work.

18. 5S

19. 5S

20. 5S

21. 5S

22. 22
How to Sustain 5S?
 Get commitment from all levels
 Get everyone involved
 Support 5S across the organization
 Do it all the way
 “Gemba” (Shop Floor) walk by Plant Management
 Conduct 5S audits and leverage successes
 Use 5S to capitalize on Continuous Improvement programs and
initiatives
 Ensure action items are being tracked and completed in a
timely manner
5S
Continuous
Improvement
Teams
Suggestion
System

23. 23
How to Sustain 5S?
 Conduct monthly audits (minimum):
 Include operations, offices and support areas
every month
 Immediately address and fix issues
 Use housekeeping criteria, IE. 5S Audit, Shine
Schedule, Red Tag procedure, WCO
Assessment to evaluate each zone
 Post ‘expected standard’
pictures in the areas and hold
everyone accountable to the
‘standard’
 Post results of ‘before’ and ‘after’

24. 24
5S Audit & Results
• Record action items and
assign owner
• Zone Champions track
and monitor all items to
ensure timely closure
• Location of Audit:

25. 25
5S Effect on Safety, Quality, Productivity, and
Equipment Maintenance
5S
Safety
Quality
Productivity
Equipment
Maintenance

26. 26
5S + Safety = 6S
 Wear appropriate PPE (Personal
Protective Equipment)
 Install guarding as necessary and inspect
existing guarding to ensure it is in safe,
functional order
 Ensure warning signs are predominately
located:
 Emergency Exits, High Voltage,
Slippery/Wet floor, etc.
 Use “Tag-Out/Lock-Out” Procedure

27. 27
 Document all instructions
clearly and include pictures
when possible
 Specify clear process
standards
 Safety
 Quality
5S and Quality

28. 28
 Enter Work Order and/or report
equipment/machines that require
repair
 Use ‘Lock-Out/Tag-Out’ procedure
 Remove/replace tools, gauges and
equipment that are damaged, broken
or past calibration date
5S and Equipment Maintenance

29. 5
Promoting High Workplace Safety & Productivity
Module. 06
5S

30. 30
Desks, Cabinets, Shelves
 Dispose of any unnecessary items
from your desk drawers, cabinets
and shelves. Arrange necessary
items neatly
 Do not place anything on top of
cabinets
 Label contents in each cabinet on
outside, and label each file
 At the end of your work day, leave
your work area clean and organized
Poor Workstation Organization
Good Workstation Organization

31. 6
Promoting High Workplace Safety & Productivity
Module. 06
5S

32. 32
5S Audit
Workplace Scan Checklist
1. One-page audit questionnaire
2. It takes up to 20 minutes to
complete it per 5S zone
3. It is an Excel file with auto-
scoring function
4. It can be easily modified to
meet individual preferences
and expectations

33. 33
5S Maturity Levels- Where Are You?
5
Continuous
Improvement
Cleanliness problem
areas are identified and
mess prevention actions
are in place
Needed items can be
retrieved in 30 seconds
with minimum steps
Potential problems are
identified and
countermeasures
documented
Proven methods for
area arrangement and
practices are shared
and used
Root causes are
eliminated and
improvement actions
include prevention
4
Focus on
Reliability
Cleaning schedules and
responsibilities are
documented and
followed
Minimal needed items
arranged in manner
based on retrieval
frequency
Work areas cleaning,
inspection, and supply
restocking done daily
Proven methods for
area arrangement and
practices are used in the
area
Sources, frequency of
problems are noted with
root cause and
corrective actions
3
Make It
Visual
Initial cleaning is done
and mess sources are
known and corrected
Needed items are
outlined, dedicated
locations are labeled in
planned quantities
Visual controls and
indicators are set and
marked for work area
Agreements on labeling,
quantities, and controls
are documented
Work group is routinely
checking area to
maintain 5S agreements
2
Focus on
Basics
Necessary and
unnecessary items are
identified; those not
needed are removed
Needed items are safely
stored and organized
according to usage
frequency
Key area items are
marked to check and
required level of
performance noted
Work group has
documented area
arrangement and
controls
Initial 5S level is
established and is
posted in the area
1
Just
Beginning
Needed and not needed
items are mixed
throughout the area
Items are randomly
placed throughout the
workplace
Key area items checked
are not identified and
unmarked
Work area methods are
not always followed and
are not documented
Work area checks are
randomly done and
there is no 5S
measurement
Sort Set In Order Shine Standardize Sustain

34. 34
5S Routine Checklist

35. 35
5S Level Execution Audit. Example Level 2

36. 36© Lean & Mean Consulting. All rights reserved. 2016