This is the slide deck from our a free webinar presented on February 24, 2010 "Introduction to 5S" from 5S Supply.

1. 5S Supply Webinar Series
Welcome to
Introduction to 5S
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Our formal presentation will run from 12:00 pm - 12:45 pm CDT. The final
15 minutes will be dedicated to your Questions & Answers.
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© 5S Supply 2010
Introduction to 5S
Wednesday, February 24th, 2010
12:00 pm – 1:00 pm (CST)
brought to you by 5S Supply
www.5Ssupply.com
5S simplified. Everything you need… all in one place.
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2. 5S Supply Webinar Series
“Behind all Today’s Agenda
workplace
successes
• What is 5S
and failures
are the • Philosophy of 5S
5S’s.” • Benefits of 5S
From “5 Pillars of the • Explanation of each of the
Visual Workplace: The
Sourcebook for 5S S’s—Sort, Set-in-order,
Implementation” by
Hiroyuki Hirano Shine, Standardize, Sustain
• Q&A
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What is 5S?
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3. 5S Supply Webinar Series
What is 5S?
• Five words that begin with the letter “S”
• Meaning workplace organization and
standardization
• Foundational building block of Lean
• Builds teamwork and discipline
• It’s NOT JUST CLEANING!
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Where did 5S Come From?
• A fundamental part of the Toyota
Production System (TPS)
• Need for a safe working environment,
respect for people
• Quality, cost and delivery
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4. 5S Supply Webinar Series
Building Blocks of a
Lean Enterprise
Lean Enterprise
TPM Cellular & Flow Pull System & Kanban
Error-proofing Batch Size Reduction Quick Changeover
V Standard Work Teams Layout POUS
S
M Problem Solving Kaizen Visual 5S
Planning Leadership
© 5S Supply 2010
Translation
Japanese Translation Conversion *Other
Seiri Organization Sort Sorting
Simplifying
Seiton Neatness Set in order
access
Seiso Cleaning Shine Sweeping
Seiketsu Standardization Standardize Standardize
Shitsuke Discipline Sustain Self-discipline
* there are several other conversions
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5. 5S Supply Webinar Series
Other Names
• 6S = 5S + safety • 5S is the most common
• 7S = 5S + safety + term
security • Using other terms may
• 5Cs confuse people if they
1. Clear Out see or read other
2. Configure information about 5S
3. Clean & Check • If done correctly, safety
4. Conform is automatically part of
5. Custom & Practice 5S
• Others
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Garage Story
• 5S is like cleaning out your garage
• Clear everything out, make piles
• Organize the things that you are going to keep
• Clean top to bottom, fix or repair as needed
• What happens 6 months later?
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6. 5S Supply Webinar Series
Philosophy of 5S
Be a 5S learner, achiever and
thinker
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Why is 5S Necessary?
• Companies are like living
organisms, they must learn to
adapt and be flexible to survive
and thrive
• Customers, suppliers, people,
“5S is easy, processes, materials,
technologies are continually
getting
changing
people to
• Deeply engrained processes,
change is culture, and customs are not
hard” easily changed
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7. 5S Supply Webinar Series
5S Philosophy
• 5S is not about the cleaning
• 5S is not just the steps, it is how you go
about your job – are you a Lean
Thinker?
• Think about the 5Ss as being attributes
of the type of person you would want to
hire
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What do you think of this
maintenance area?
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8. 5S Supply Webinar Series
Do you think that 5S applies to office,
common or support function areas?
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5S Dreamland
Fairies and robots
do not come out
in the middle of
the night and do
5S for you.
Who has to do it?
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9. 5S Supply Webinar Series
Benefits of 5S
© 5S Supply 2010
Myths about 5S
• 5S takes too much time.
• There aren’t any benefits for doing 5S in the
office.
• 5S means to clean and I wasn’t hired to clean!
• It doesn’t really matter how we store things.
• I like the way my desk is. I can find everything I
need so why does it matter how I have my
things?
• Doing 5S will take away from me doing my real
work.
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10. 5S Supply Webinar Series
More Myths
• We’re clean and neat already.
• We have a cleaning crew so we don’t need to do
5S.
• We’re not idiots, we know what we are doing. 5S
will just get in the way of us doing our jobs.
• We have so many problems here, why would you
have us do 5S?
• There is no benefit for us to spend time to this 5S
stuff.
© 5S Supply 2010
Benefits of 5S
• Teamwork
• Discipline
• More organized workplace
• Safer work environment
• Reduces stress
“Time is • Saves time
money” • Saves money
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11. 5S Supply Webinar Series
Benefits of 5S
• Impresses customers or auditors
• Reduces waste
• Better handle on true costs
• More pleasant place to work and
increase moral
• Supports the other Building Blocks of
Lean
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Sort
“When in doubt, move it out!”
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12. 5S Supply Webinar Series
Sort
• The first thing to do is to clear the clutter
out of the area
• Perform as a team
• Use the “30 day” rule
• Use the Red Tag technique
• Break the “just in case” mentality
• “When in doubt, move it out!”
© 5S Supply 2010
Sort
• Clearly distinguish Will be used Keep
between:
– What is needed Red Tag
May be used
currently and should
be kept
– What is not needed Will not be used Discard
and can be removed
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13. 5S Supply Webinar Series
Sort
• Red Tags are visual signal that something may not
belong in your target area
• Attach Red Tags to items that don’t belong in the
immediate area
• Move the items to the Red Tag Holding Area
• Use simple Red Tags
• Have Red Tags easily available
© 5S Supply 2010
Your
5S Red Tags Today’s
date
Name
Name _______________ Date________
What the
item is
Item ____________________________
Why did you
tag it?
Use unknown, Reason for Tagging ________________
Obsolete, ________________________________
Not used here,
etc.
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14. 5S Supply Webinar Series
Other Tag Issues
• Some companies • Make sure you have
use additional color wire, string or tape
tags for to attach tags to the
maintenance or item
safety issues • Make sure everyone
• Companies that use on the team has
Red Tags for quality tags and a pen
issues have to
determine which
color tag to use
© 5S Supply 2010
Red Tag Area
• The Red Tag Holding Area is a temporary holding
area – meaning things can’t stay in there forever
• If other people or groups need items, they are
allowed to take things from the Red Tag Holding
Area
• Dispose of items periodically (rules will be setup
during “Standardize”)
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15. 5S Supply Webinar Series
Notes on Red Tagging
• Avoid the “Pack rat” mentality
• Don’t worry about the “One thing”.
Focus on the benefits of clearing things
out of the immediate area.
• Just because an item is tagged, it
doesn’t necessarily mean that it is going
to be thrown away. We will make the
decision later if we need it or not.
© 5S Supply 2010
5S and Dilbert
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16. 5S Supply Webinar Series
Benefits of Sort
• Clears out the things that you didn’t need in
your work area
• Reclaim room and space
• Reduces search time
• Allows for other changes like moving items or
changing the layout
• Safer place to work
• Let’s employees feel that they have control
over their area, instead of the areas
controlling them
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Set-in-Order
“A place for everything and
everything in its place!”
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17. 5S Supply Webinar Series
Power of Set-in-order
• Now that the area has been cleared out
of unnecessary items, it is time to find a
“home” for items that will remain
• This is where fantastic results occur
• Reduces:
– Search time
– Stress
– Inventory and supplies
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Everyday Examples
• Kitchen
• Parking lots
• Highways
• Broom racks & Shine Carts
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18. 5S Supply Webinar Series
Set-in-order
• Now that you have used Sort, decide where
the items that you will keep belong
• Decide how many and how to replenish
• Make it visual and obvious if something is
out of place
© 5S Supply 2010
Decide Where Things Belong
Guidelines
• If it is used often, keep close at hand
• Designated location & label
• Use systems like the “2-label” system
• Shadows, lines, color-coding
• Easy to get & put away (ergonomic and
safe)
• Get items off the floor & top shelves
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19. 5S Supply Webinar Series
Other Set-in-order Issues
• Make it easy for
everyone to find and
use them – “30
second” rule
• Use “recoil”, getting
items back to where • Make items easy to
they belong get and easy to put
away
• Make it obvious
when they are not in
there correct place
© 5S Supply 2010
Benefits of Set-in-Order
• No guessing at where items belong and
how many
• No excess items
• Items are easy to find and put away
• Everyone passes the 30-second test
“A place for everything and
everything in its place!”
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20. 5S Supply Webinar Series
Shine
”To clean and inspect.”
© 5S Supply 2010
Shine
• Shine = clean + inspect
• Perform as a team
• Must plan Shine
• Have the necessary items easily
available
• 5S is not just cleaning!
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21. 5S Supply Webinar Series
Why Shine?
• Can prevent accidents or safety
incidents
• People feel better when they work in a
clean environment, this actually helps
morale
• Working together helps build team work
• Impresses customers on tours
• Can spot potential problems with
equipment before they occur
© 5S Supply 2010
Make it Fit Your Organization
• Even if you have a cleaning crew or service,
do they know exactly what you want and what
is expected of them? Is it followed?
• Wiping and cleaning common areas helps
reduce the spread of germs thus improving
sick-time related absenteeism
• Make it quick and simple - or better yet, think
of ways to prevent dirt from accumulating in
the first place!
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22. 5S Supply Webinar Series
Initial Cleaning and Inspection
• Have to have a plan
• Start at the top and work down
• Clean and inspect major items first
• Be thorough, restore to “like new” condition
• Clean floors and aisle ways last
• Everyone has to participate
• Schedule it
• Take it Serious
© 5S Supply 2010
Planning Shine
Supplies
Area Team
Needed
Determine
• Task Supplies
• Location Common
Areas
• Who
Files/Storage
• When
• Cleaning materials Equipment
needed Desks
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23. 5S Supply Webinar Series
Additional Ideas for Shine
• Prevent dirt in the first place or at least contain it
• Low cost solution versus breakdowns
• Plan ahead
• Everyone participates as a team
• Make it quick (and fun!)
• Have the right tools & supplies ready
© 5S Supply 2010
Benefits of Shine
• A more pleasant place to work
• Promotes a professional atmosphere
• People actually have the tactile
sensation by touching their equipment,
machines and work areas
• You are able to find small problems
before they become BIG problems
• Safer and cleaner workplace
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24. 5S Supply Webinar Series
Standardize
“Make up the rules and follow and
enforce them!”
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Standardize
• Standardize means to set up the rules for
Sort, Set-in-order and Shine
• Have the 5S teams and 5S Design Teams set
the standards
• Standards must be simple and easy to follow
• Use audits to help maintain the standards
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25. 5S Supply Webinar Series
Standards for Sort
One-point Lesson
Red Tag Rules Description: How to fill-out a Red Tag
• When to Red Tag W rite in your name
1
Fill-in date tagged
2
• How to Red Tag 5S Red Tag
3 Name ______________ Date __________
• What’s go on the Red W rite in the Item ______________________________
name or
Tag description
of the item
__________________________________
Reason for Tagging __________________
• more… __________________________________
4
Rules for the Red Tag W rite in the reason for tagging
(obsolete, needs repair, not
Holding Area needed, scrap, use unkown, etc.) 5
Attach tag using
• When to clear out wire, tape, string,
or other method
• How to dispose of items 6 Move item to the Red Tag Holding Area
• more…
© 5S Supply 2010
Standards for Set-in-Order
• Which items, where, how many
• Who replenishes
• Return all items… and What to do when items are
missing
• Visual standards – signs, lines, labels and color
coding
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26. 5S Supply Webinar Series
Standards for Shine
• Clean and Inspect (C&I) Schedule
• Show the task, person responsible,
items needed, frequency, the time
element and the desired state
• Where to keep cleaning supplies, how
to replenish
© 5S Supply 2010
5S Clean and Inspect Schedule
Item: ID:
Key: Clean & Inspect activity required Cleaning activity completed
Frequency of C&I
Team Time
No Task Requirement MON TUE WED THUR FRI
Min
Member
1 Technician Wipe down equipment Cleaner & Wipes 1
Cleaner, rags,
2 Operator Clean or replace filter
filter (if required) 3
3 Helper Sweep floor Broom 2
4 Supervisor Inspect safety guards Visual 1
Complete Diagnostic Post results on 5S
5 Manager
Checklist Display Board 5
6 All 5S Weekly Meeting Agenda, ½ hour max 30
7
8
9
10
Total 42
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27. 5S Supply Webinar Series
Key for Standardize
• Make the rules, then follow and enforce them
• People usually think 5S fails at Sustain, but it
typically fails at enforcing the rules
• Policies drive behaviors
• Make the rules simple and easy to follow
• Use immediate correction
• Lead by example
• Do not allow 5S to take a backseat to other
things
© 5S Supply 2010
Benefits of Standardize
• Everyone knows the rules
• Easy to understand and to follow
• You have to have a standard in order to
know that you have improvement
• Sets the foundation for successful 5S
implementation and Sustain
• Allows you move on to “Sustain”
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28. 5S Supply Webinar Series
Sustain
“Make 5S part of everyday life.”
© 5S Supply 2010
5S Discipline
• Management’s support – without this 5S
will never work!
• 5S is not something extra, it’s part of
everyday work
• Get everyone involved – teamwork
• Helps set the base for other Lean efforts
• Creative ways to prevent Standardize
from deteriorating
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29. 5S Supply Webinar Series
Ways to Make 5S a Habit
• On-going • Lead by example
communication – • 5S promotions
newsletters,
communication boards,
posters, short meetings
• Field trips,
benchmarking
• Reward and recognition
• Use immediate
correction
© 5S Supply 2010
More Ways to Make 5S a Habit
• Training and additional • Continued 5S Audits
“Booster” training once • Contests
or twice per year • 6-week photos
• Brainstorm problems • “Extreme 5S Makeover”
and solutions video
• Study groups • 5S Campaign boards
• Capture Lessons 5S Campaign Week of XX/XX
5S Item Team
Learned, share Best Sort Check Red Tags Jim, Bob
Practices Set-in-Order Check missing items Jennifer, Ralph
Shine Check lights Homer, Marge
Standardize Update audit schedule Eileen, George
Sustain New Contest All
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30. 5S Supply Webinar Series
Additional Information for
Success
• Everyone has to participate
• Promote participation
• Keep at it, even when it isn’t easy
• Make sure everyone understands what
5S is and why it’s needed
• Remember, 5S is a low cost solution
• 5S is essential for Lean
© 5S Supply 2010
Q&A
Please submit your questions at
this time
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31. 5S Supply Webinar Series
Developer
Anthony Manos
• Tony Manos is a Professional Business Advisor with expertise in
Lean. Trained and certified by the Department of Commerce,
National Institute of Standards and Technology (NIST) in Lean
principles and as a trainer in Lean courses. He is an international
trainer and speaker on Lean topics.
• Mr. Manos is a Senior Member of ASQ, SME and AME and is a
Shingo Prize examiner
© 5S Supply 2010
5S Garage: An Recommended
Introduction to
5S and Lean
Resources
Principles “5S Pillars of the Visual Workplace: The
Sourcebook for 5S Implementation” by
Hiroyuki Hirano
“5S for Operators: 5 Pillars of the Visual
Workplace” by Productivity Press
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32. 5S Supply Webinar Series
Additional Resources
Group 5S Supply
© 5S Supply 2010
Q&A
If we don’t get a chance to answer your
question today, please send it to:
webinar@5Ssupply.com
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33. 5S Supply Webinar Series
Upcoming Events
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