The document discusses Lean Manufacturing and 5S training. It defines Lean Manufacturing as eliminating waste to improve value for customers. 5S is an organizational method for workplace tidiness and efficiency. The 5S include Sort, Set in Order, Shine, Standardize, and Sustain. Implementing 5S through visual controls and labels can help eliminate waste and improve safety. Sustaining 5S requires ongoing audits, employee involvement, and management support.

1. 5S Training

2. What is Lean Manufacturing?
 Lean Manufacturing is the continuing process of
analyzing, then improving, the flow of information
and materials in order to eliminate waste and
enhance value to the customer.
 In simpler words:
Cut out the waste of non-value activities.
Illustration:
Like a lean piece of Filet Mignon.

3. WHY Go “Lean”?
 Uses less of everything compared with mass
production.
 Less human effort
 Less space
 Less tool investment
 Less inventory
 Less defects
 Reduces costly internal “Wastes”
Being Wasteful Helps
the Competition!!

4. Elements of Lean
 Philosophy of Excellence in becoming a
World Class Company
 Elimination of Waste
 Synchronization to Customer Demand
 Employee Involvement
 Continuous Improvement

5. What Is Waste?
 Waste is everything we do that takes
time, adds cost, and has no value in
the eyes of the customer.

6. 7 types of Waste (Muda)
1) Overproducing
2) Waiting
3) Moving
4) Downtime
5) Excess Inventory
6) Motion
7) Scrap

7. CAS Medical System’s
Route to World Class Manufacturing
Minimum
6 Investment
Lean Sigma
Building Tools
Value Stream 5s Flexible Small Lot Rapid Response
TQM
Mapping Evaluation Work Force Production to Change
Waste
Layout Visual Setup One Piece Short Cycle Highest
Elimination
Changes Controls Reductions Flow Manufacturing Quality
(Muda)
Standard Pull
Suggestion Quick
Work Takt Time Systems Kaizen
Program Delivery
Instructions (Kanban)
TPM
Best Process
Reliability

8. What is 5s+1
 It’s Housekeeping at the
highest level that’s measurable

9. WHY 5S?
To prepare the workplace so the end
result is a clear, clean, orderly, and safe
environment:
• Eliminates waste from unorganized and/or
uncontrolled processes
• Gains control on equipment, material, and
supplies
• Allows us to work safely
• Helps us to easily & quickly find people, parts,
tools, places, supplies, and information you need
in order to do your job

10. Early Years of 5s
1. Scrounge
2. Steal
3. Stash
4. Scramble
5. Search

11. Do you know your 5S’s +1?
 S1: Sort Sort out the clutter. Get rid of items
not needed to make your product
 S2: Scrub Scrub & Shine your work area. Paint if needed. Don’t
rely on someone else to clean your mess
 S3: Select Select locations for materials, supplies & equipment.
Anything that takes up real estate needs to have a
designated location
 S4: Set Set locations by using borders, ID labels, shadow boards
 S5: Safety Prevent Safety hazards caused by clutter, garbage, spills,
and disorder. Increase safety through visual
order.
 +1:Sustain Sustain the 5’s habit. Conduct management audits
and report cards.

12. SORT - The 1st & Most Important“S”
Purpose of Sort - get rid of the junk
 Sort through items in the area
 Keep what is needed
 Eliminate what is not needed
 Reduce the number of items to the
quantity required at any given time
** Don’t be a Pack-Rat

13. “Red Tag” Unnecessary Items
Red tagging is a visible way to identify items that are
not needed or in the wrong place:
 Identify unneeded, misplaced items
 Attach red tags
 Move the items to the holding area
 Dispose of unneeded items
Ask yourself:
Does it have a function in this area?
Is it needed? How often? By whom?
If we remove it, will it really matter?
Is it in the way? Does it take too much
space? Should it be smaller?

14. Scrub - The 2nd “S”
 Definition of Scrub - Clean everything inside and out.
 Why cleaning is inspection – It helps us notice pre-
failure conditions, and makes a good impression to
our customers & visitors.
 Clean floors are the first thing customers & visitors will
notice.
 Establish daily housekeeping list.
 Allow time at end of shift for cleaning & organizing. 5
minutes is maximum time needed if everyone chips in.

15. Daily Housekeeping Check List
Associate √
(To be completed before you leave for the day)
Floors are clean & free of debris. (check underneath
your work bench)
Clean all bench tops & equipment from dust, oils &
debris
Turn off all equipment, computers, lights
Return all tools, parts, and supplies to designated
locations.
All kanban cards are handed in and properly placed
with the item
Chemicals & cleaning supplies are stored in proper
locations
Dispose all cardboard
Work stations are clutter free and well organized
Nothing is in the aisle ways

16. Select Locations - 3rd “S”
 Definition of Selecting location - a place for everything &
everything in its place.
 Considerations for deciding locations - point of use storage,
how often is it used, space constraints.
 A few guidelines - Don’t select locations for things you don’t
need (S1), Standardize & consolidate, watch personal items.
Don’t fret mistakes; try making it better –
worst case scenario you can always put it back the way it was!
“JUST DO IT”.

17. Set Locations - 4th“S”
 Definition of Setting locations- Identifying your selected
location so everyone knows where it has to go.
 Location Identifiers - signs, labels, colored tape, shadow
boards, floor borders
 3 actions needed
1) Put taped border around moveable items.
2) Put an ID label with each border.
3) Put an ID label on each item.

18. Safety - 5th“S”
 Everyone is accountable for having a safe operation and
work environment. Get involved.
 Improve safety through visual order.
 Safety committee is established for CAS. Help to
implement committee findings.
 S1 – is your biggest contributor toward a safe
environment. (Statcorp Pallet story)

19. Cardinal Rule for 5s
Implementation
Follow the 5s Methodology
**Do not do S3 or S4 before doing S1
(Trident story)

20. +1 Sustain - The 6th “S”
 Purpose of +1: Is to recognize, reward, and strengthen adherence to the
first 5S’s. It provides feedback for Continuous Improvement.
 Make 5S’ part of the culture - Empower workers to manage and control
their area.
 5 Techniques for sustaining the 5s Program
1) 5s Audit Report Card
2) Review of report card with employees
3) Develop daily housekeeping activities
4) Employee Ownership
5) Include in annual performance review.
 Reasons for inadequate implementation:
1. Lack of understanding & training
2. Not supported by management
3. Little or no employee involvement

21. Review of 5’s +1 Audit Report Card

22. Keys To Success
• Management Driven
• Management Involvement
•Gather baseline information
• Get everyone involved
•Audit your results
•Take action – “Just do it”
• Keep it simple!

23. Total Employee Involvement
PEOPLE ARE THE KEY!

24. 5’s
Dept. Photos
&
Hall of Fame Best Practices

25. 5s Quiz
 1) Can you name the 5s+1 order of methodology?
Sort
Scrub
Select
Set
Safety
Sustain
 2) Of the five 5S’s which is the most important?
Sort
 3) What are the 5 techniques we will use to Sustain (+1) the 5s program?
Audit Report Card
Employee Review of Report Card
Daily Housekeeping List of Duties
Employee Ownership
Performance Reviews

26. 5s Quiz Continued
 4) What do we use for setting locations (S4)?
Signs
Labels
Tape Borders
Shadow Boards
 5) Why is S2 – Scrub so important to do?
It helps to notice pre-failure conditions.
It makes a strong impression to our customers & visitors.
 6) What’s the Cardinal rule for 5’s Implementation?
Follow the Methodology
Don’t do S3 & S4 before doing S1

27. Bonus Quiz Question
What are the 7 types of Muda?
 1) Overproducing
 2) Waiting
 3) Moving
 4) Downtime
 5) Excess Inventory
 6) Motion
 7) Scrap