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5S Facilitator’s Guide
Using 5S to help achieve a Visual Workplace.




                                               SORT




            SUSTAIN                                              SET

                                               5S


                        STANDARDIZE                      SHINE




 VISUAL WORKPLACE, INC.
 7381 Ardith Ct.
 Byron Center, MI 49315
 PH: 616.583.9400
 FX: 616.583.9409                                 You won’t GET LEAN...
 www.visualworkplaceinc.com
 info@visualworkplaceinc.com                           until you GET VISUAL!
GBMP
            everybody • everyday




                             SORT




SUSTAIN                                        SET

                              5S


      STANDARDIZE                      SHINE




                                   2                 5S Facilitator’s Guide
5S Facilitator’s Guide   3
Japanese “S“                      Japanese Meaning                              Anglicized
                                                                                     Version
	    1. Seiri      	   Remove all items from the workplace that are             	   Sort
                   	   not immediately needed for the work.
	    2. Seiton     	   Place needed items (material, information,               	   Set in Order
                   	   tools) in a location that supports the worker.
	    3. Seiso      	   Make the workplace spotless, free of                     	   Scrub, Sweep,
                   	   contaminants, dirt and foreign material.                 	   Straighten
	    4. Seiketsu   	   Create a standard means for keeping the                  	   Standardize
                   	   workplace clean and orderly.
	    5. Shitsuke   	   Make a commitment to order and cleanliness.              	   Sustain




                                                                        	
  
                                                      5S Red Tags

                                                                               5S Red Tag Area Sign




                                                  4                                                 5S Facilitator’s Guide
 




5S Facilitator’s Guide   5
6   5S Facilitator’s Guide
5S Facilitator’s Guide   7
8   5S Facilitator’s Guide
5S Facilitator’s Guide   9
10   5S Facilitator’s Guide
5S Facilitator’s Guide   11
Improvement Opportunity                            5S Achievement
   S1: Sort                            Exceptional Workplace Organization Exists!

                                       Notes/Comments:
   S2: Set in order

   S3: Scrub, sweep, straighten


Notes/Comments:




                                  12                                5S Facilitator’s Guide
7	
  Deadly	
  Wastes
                                                                        !oca%on of Waste
                                                                             Date:
              Improvement	
  Team:




                          Describe	
  the	
  waste/problem	
  area.                   Describe	
  the	
  improvement	
  made	
  along	
  with	
  	
  
                                                                                                any	
  cost	
  and	
  %me	
  savings.



                               Over	
  Produc3on        Over	
  Processing                  ?ow	
  much	
  3me	
  is	
  spent	
  moving	
  A	
  searching	
  dailyB	
  
                                                                                            Min/day	
  ÷	
  60	
  min=	
  Non	
  Value	
  Added	
  hrs/day	
  
                               Transporta3on            Wai3ng                              (e.g.	
  10	
  min/60min	
  =	
  .17	
  hrs/day)	
  

                               Inventory                ;o3on                               Calculate	
  the	
  cost	
  of	
  waste/year:	
  
                                                                                            $/hr	
  ×	
  hrs/day	
  ×	
  working	
  days/yr	
  =	
  Cost	
  of	
  waste/yr	
  
                               Defect                   Other                               Example:	
  $15.00/hr	
  ×	
  .17	
  hrs/day	
  ×	
  253	
  days	
  =	
  $645.15
           1093-V0710




5S Facilitator’s Guide                                                         13
14   5S Facilitator’s Guide
PROJECT CHECKLIST
       Organize your 5S teams, assign responsibilities and set completion deadlines.
       Select your 5S team; list names:




       Sort                                                                                                  Owner                Due Date   Complete
       1.   Set boundaries for the area
       2.   Identify a Red Tag Area within close proximity to the work area
       3.   Take BEFORE pictures of the area
       4.   Develop sorting and disposition rules
       5.   Sort, tag and remove unneeded items
       6.   Take AFTER pictures of the area
       Waste can be hiding as:
       Excess tools & equipment (totes, bins, shelves)             Unnecessary furniture (carts, desks, chairs, cabinets)
       Outdated information (documents, manuals, samples)          Obsolete or excess material/inventory

       Set in Order                                                                                          Owner                Due Date   Complete
       1.   Team members that work in the area set locations for the value-added items
       2.   Place needed items in locations that eliminate unnecessary motion
       3.   Think ergonomics and safety
       4.   Create a border and address for each item that casts a shadow
       5.   Measure and document the improvements made
       6.   Take AFTER pictures
       Look for improvements and demonstrate the power of workplace organization:
       Missing information                                       Time spent searching
       Eliminating obsolete information                          Walking or bending

       Shine                                                                                                 Owner                Due Date   Complete
       1.   Team identifies opportunities to improve cleanliness
       2.   Cleaning supplies/tools are gathered
       3.   Sources of contamination are identified and eliminated
       4.   Area is cleaned
       5.   Develop daily/weekly/monthly checklists to maintain cleanliness
       6.   Create standard work instructions for all cleaning processes
       7.   Create a smart place for cleaning items that include borders and ID labels
       8.   Take AFTER pictures
       Cleanliness must become a part of our standard work and should include:
       Transportation equipment                                    Work surfaces
       Racks, desks, chairs, walls and lights                      Equipment, tools, fixtures

       Standardize                                                                                           Owner                Due Date   Complete
       1.   Develop a standard 5S tool kit/cart
       2.   Create standard work instructions and train team on all workplace processes
       3.   Develop 5S audit procedures (who, what, where, when, and how?)
       4.   Implements management feedback system to evaluate adherence to standards
       5.   Establish a visual display to communicate 5S progress and current levels
       Tool Kits should include products for maintaining borders, ID labels, work instructions and cleanliness.
       Abnormal conditions should be visible at a glance.
       A formalized feedback system with ownership and accountability will encourage continuous management participation.

       Sustain                                                                                               Owner                Due Date   Complete
       1.   Create a 5S area map and assign owners for accountability
       2.   Create a storyboard to illustrate the workplace organization journey
       3.   Benchmark ideas from other departments, divisions and industries.
       4.   Schedule quarterly team meetings to review current state and identify progress
       5.   Display all 5S communications, audits and feedback locally in each area
       Management support/communication is crucial to the sustainment of an organized workplace; use many means to communicate:
       Newsletters                                                Dedicated 5S facilitators
       Employee feedback and suggestion programs                  Benchmarking




5S Facilitator’s Guide                                                   15
7381 Ardith Ct.
Byron Center, MI 49315
PH: 616.583.9400
FX: 616.583.9409




           GREAT REASONS TO MAKE
           YOUR WORKPLACE VISUAL
        Abnormal conditions are immediately
        identified and corrected.
        Missing information and time spent
        searching are eliminated.
        Injury frequency is drastically reduced.
                                       1101-V0910
        Work is standardized and process changes are
        instantly communicated.
        Key performance indicators reveal opportunities
        for improvement.

    You won't GET LEAN... Until you GET VISUAL!




Visit us online at
www.visualworkplaceinc.com                                1101-V0312

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5S Facilitator Guide

  • 1. 5S Facilitator’s Guide Using 5S to help achieve a Visual Workplace. SORT SUSTAIN SET 5S STANDARDIZE SHINE VISUAL WORKPLACE, INC. 7381 Ardith Ct. Byron Center, MI 49315 PH: 616.583.9400 FX: 616.583.9409 You won’t GET LEAN... www.visualworkplaceinc.com info@visualworkplaceinc.com until you GET VISUAL!
  • 2. GBMP everybody • everyday SORT SUSTAIN SET 5S STANDARDIZE SHINE 2 5S Facilitator’s Guide
  • 4. Japanese “S“ Japanese Meaning Anglicized Version 1. Seiri Remove all items from the workplace that are Sort not immediately needed for the work. 2. Seiton Place needed items (material, information, Set in Order tools) in a location that supports the worker. 3. Seiso Make the workplace spotless, free of Scrub, Sweep, contaminants, dirt and foreign material. Straighten 4. Seiketsu Create a standard means for keeping the Standardize workplace clean and orderly. 5. Shitsuke Make a commitment to order and cleanliness. Sustain   5S Red Tags 5S Red Tag Area Sign 4 5S Facilitator’s Guide
  • 6. 6 5S Facilitator’s Guide
  • 8. 8 5S Facilitator’s Guide
  • 10. 10 5S Facilitator’s Guide
  • 12. Improvement Opportunity 5S Achievement S1: Sort Exceptional Workplace Organization Exists! Notes/Comments: S2: Set in order S3: Scrub, sweep, straighten Notes/Comments: 12 5S Facilitator’s Guide
  • 13. 7  Deadly  Wastes !oca%on of Waste Date: Improvement  Team: Describe  the  waste/problem  area. Describe  the  improvement  made  along  with     any  cost  and  %me  savings. Over  Produc3on Over  Processing ?ow  much  3me  is  spent  moving  A  searching  dailyB   Min/day  ÷  60  min=  Non  Value  Added  hrs/day   Transporta3on Wai3ng (e.g.  10  min/60min  =  .17  hrs/day)   Inventory ;o3on Calculate  the  cost  of  waste/year:   $/hr  ×  hrs/day  ×  working  days/yr  =  Cost  of  waste/yr   Defect Other Example:  $15.00/hr  ×  .17  hrs/day  ×  253  days  =  $645.15 1093-V0710 5S Facilitator’s Guide 13
  • 14. 14 5S Facilitator’s Guide
  • 15. PROJECT CHECKLIST Organize your 5S teams, assign responsibilities and set completion deadlines. Select your 5S team; list names: Sort Owner Due Date Complete 1. Set boundaries for the area 2. Identify a Red Tag Area within close proximity to the work area 3. Take BEFORE pictures of the area 4. Develop sorting and disposition rules 5. Sort, tag and remove unneeded items 6. Take AFTER pictures of the area Waste can be hiding as: Excess tools & equipment (totes, bins, shelves) Unnecessary furniture (carts, desks, chairs, cabinets) Outdated information (documents, manuals, samples) Obsolete or excess material/inventory Set in Order Owner Due Date Complete 1. Team members that work in the area set locations for the value-added items 2. Place needed items in locations that eliminate unnecessary motion 3. Think ergonomics and safety 4. Create a border and address for each item that casts a shadow 5. Measure and document the improvements made 6. Take AFTER pictures Look for improvements and demonstrate the power of workplace organization: Missing information Time spent searching Eliminating obsolete information Walking or bending Shine Owner Due Date Complete 1. Team identifies opportunities to improve cleanliness 2. Cleaning supplies/tools are gathered 3. Sources of contamination are identified and eliminated 4. Area is cleaned 5. Develop daily/weekly/monthly checklists to maintain cleanliness 6. Create standard work instructions for all cleaning processes 7. Create a smart place for cleaning items that include borders and ID labels 8. Take AFTER pictures Cleanliness must become a part of our standard work and should include: Transportation equipment Work surfaces Racks, desks, chairs, walls and lights Equipment, tools, fixtures Standardize Owner Due Date Complete 1. Develop a standard 5S tool kit/cart 2. Create standard work instructions and train team on all workplace processes 3. Develop 5S audit procedures (who, what, where, when, and how?) 4. Implements management feedback system to evaluate adherence to standards 5. Establish a visual display to communicate 5S progress and current levels Tool Kits should include products for maintaining borders, ID labels, work instructions and cleanliness. Abnormal conditions should be visible at a glance. A formalized feedback system with ownership and accountability will encourage continuous management participation. Sustain Owner Due Date Complete 1. Create a 5S area map and assign owners for accountability 2. Create a storyboard to illustrate the workplace organization journey 3. Benchmark ideas from other departments, divisions and industries. 4. Schedule quarterly team meetings to review current state and identify progress 5. Display all 5S communications, audits and feedback locally in each area Management support/communication is crucial to the sustainment of an organized workplace; use many means to communicate: Newsletters Dedicated 5S facilitators Employee feedback and suggestion programs Benchmarking 5S Facilitator’s Guide 15
  • 16. 7381 Ardith Ct. Byron Center, MI 49315 PH: 616.583.9400 FX: 616.583.9409 GREAT REASONS TO MAKE YOUR WORKPLACE VISUAL Abnormal conditions are immediately identified and corrected. Missing information and time spent searching are eliminated. Injury frequency is drastically reduced. 1101-V0910 Work is standardized and process changes are instantly communicated. Key performance indicators reveal opportunities for improvement. You won't GET LEAN... Until you GET VISUAL! Visit us online at www.visualworkplaceinc.com 1101-V0312