21. 5S for the Workplace
Training and
Sourcebook
for
5S Worksheets
22. How to Use This Manual
The continuous improvement tools that are presented in Sections
1-10 of this manual are shown in order of use. These forms
MUST be completed in the order presented in this manual. Each
section contains a brief description of the tool, its purpose, when
to use it, who should use it, how to use it, and the expected
results.
Remember to focus on the elimination of waste.
Strive to maximize yields and obtain cost reductions
from existing machinery and equipment before
“buying solutions”. Improve current systems and
techniques before automation. Automating a system
or practices without first having an understanding of
the process will not solve underlying process
problems.
Perhaps the most important point to remember is that
we must understand a process before we make any
attempt in changing it. “No Tampering” is the first rule
of continuous improvement. We can not tamper with
a process without understanding it.
By using these tools, we will all share a common and
systematic approach for questioning, analyzing,
proposing solutions, experimenting, and finally,
implementing proven changes.
“The problems that exist in the world
today
cannot be solved by the same level of
thinking
that created them.”
Improvement
Identify waste
Measurement
5S
Template
23. Table of Contents
Section 1 Development of 5S “To Do” Plan: Establishment of the 5S team focused on
the development, training, and implementation of the company’s 5S program.
Deliverable includes action plan and associated tasks with the 5S
implementation. ………………………………………………………………………… 4
Section 2 Waste Identification Map: Identification of the 9 wastes associated with
production of products and services. A detailed map of each major work area is
developed describing the major types of wastes in each area. These wastes are
the improvement opportunities that exist prior to
5S………………………………...
The overall wastes is calculated for all the work areas and identified on the 9
Waste Radar Chart
7
Section 3 5S Action sheet: Establishing baseline key performance metrics in terms of
key deliverables, photographs, and current conditions of the “before” 5S
implementation phase. Deliverable includes the 5S action
sheet………………….
11
Red Tag Strategy: The utilization of “Red Tags” to visually identify items which
are not needed or used infrequently…………………………………………………..
14
Section 5 Visual Color Sheets: Utilization of colors to identify specific work actions,
inventory locations, access areas within the work environment. Initialization
begins with development of Visual Color
Sheets…………………………………….
17
24. Section 6 Visual Sign Sheets: Utilization of signs to identify machine, equipment, tooling,
inventory, safety, hazard and work center locations. Sample Sign
Sheets……….
20
Section 7 Standard Cleaning Work Sheet: A cleaning matrix identifying the work area
responsibilities, supplies, and schedules for cleaning. …………………………….. 23
Section 8 Cleaning “To Do List”: A action list identifying specific cleaning tasks for each
work area identified on the Standard Cleaning Work Sheet……………………….. 27
Section 9 5S Status Report: A report identifying implementation effectiveness of each 5S
steps applied. A variable metric ranging from 0-5 is established for each step
implemented…………………………………………………………………………….. 30
Section 10 Waste Identification Map: Identification of the 9 wastes associated with
production of products and services. A detailed map of each major work area is
developed describing the major types of wastes in each area. These wastes are
the improvement opportunities that exist prior to 5S……………………………
9 Wastes Radar Chart: After the completion of 5S, the results of the waste reduction
is recorded, charted and compared to the initial 9 Waste Radar Chart.
33
26. Manager or Team Leader (Section A) Area or Process Name (Section B) Person Preparing This Sheet (Section C)
Over production Delays
Transportation
Process
Inventory
Motion
Defective Product
Defective
Untapped
Resources
Mis-used
Resources
Waste Identification Map
27. 9 Waste Radar Chart
% of Waste Before 5S
% of Waste After 5S
0
D e f
ec ti
ve P roduc t
T ranspo rt
a ti
on
D e l
ays
R esou rces
M i
s -used
P rocess
10
M o ti
on
I
nven t
o ry
U n t
apped
R esou rces
90
70
20
30
40
50
60
80
100
O ve rp roduc ti
on
28. Overproduction Delays Transportation Inventory M
otion Processes Defective
Products
Untapped
Resources
M
is-Used
Resources
Before After Before After Before After Before After Before After Before After Before After Before After Before After
100
90
80
70
60
50
40
30
20
10
0
The Nine Wastes
Percentage
of
Waste
29. Waste Identification Map
Purpose Used to create a visual picture of a work area to assess waste in work place
organization, office/cell layout and crewing. Shows the type of each waste in
section/division of the organization. Also utilized to indicate equipment type,
size, and distances within each work area.
When To Use The Waste Identification Map should be used after the 5S “To Do” plan is
completed. A map should be developed for each department or focus area
of the 5S program. Do not attempt to develop a single Map for an entire
organization, it will become too busy to be effective.
Who Should Use It The Waste Identification Map can be used by anyone involved in continuous
process improvement.
Expected Benefits The Waste Identification Map will provide information about work waste in
each department, work sequence, equipment layout and distances. The
Waste Identification Map not only provides actual waste, but also provides a
visual layout of the interrelationship of the waste.
30. How To Use It 1. Referring to the 5S “To Do” Plan, identify each respective area 5S will
be implemented. Develop a Waste Identification Map for each area or
department and complete sections A, B, C, with the necessary
information. Note you may have multiple Maps for the entire 5S
implementation program.
2. For each work department, fill in the equipment, access areas,
storage areas, inventory locations etc. on the Map. It is best to draw
these to scale.
3. Next identify the processes for each area on the Map.
4. Next, list the products and services at each applicable workstation.
5. Next, identify the product/service flow through the respective
processes & work stations.
6. Establish time trials for each major activity and when completed
document the time for each major activity within the department.
7. Document the type of waste and time associated with each waste at
each activity, process, equipment, inventory, storage, and office
location.
8. For each type of waste identified, complete the waste matrix section on
the bottom of the 9 Waste Radar Chart in the “before” column. Note:
The y-axis list % of waste, use whatever metric makes sense i.e.
time, $, labor hours, productivity etc. Remember that your goal is
to reduce these wastes as a result of the 5S Program.
Chart the % waste value for each type of waste on the Radar Chart.
Connect each of the values on the radar chart. This is extremely important,
this is your baseline metric and will be used to determine the magnitude of
your improvements.
Next Step You are now ready to move to the next step, the Action Sheet.