Important Lean Concepts • The 7 Wastes and Others • The Value Stream Concept • The Hidden Factory • Elimination of Waste and Loss with 5S • Our 5S Training Objectives Purpose of 5S • 5S Creates a Visual Factory • The 5S Cycle • 5S Activities Explained • The Purpose and Payoff of 5S • Remove the Roadblocks in the Way • 5S Program Overview 5S Program Steps • Workplace Observation • Set a Target Area Vision • The Power of a Shared Vision • What You See Before 5S • What You See After 5S • After 5S – Easy to Find, Easy to Do • One-Day Work Area Log Sort • Sort – keep only what is needed Today • Red Tag Process • Red Tag Inspection List Red Tagged Items Log Decide What to do With Dispossessed Items Straighten • Straighten – find it fast; faster • Put Order and Sense into the Workplace • Set-in-Place to Make Life Easy • Visual Control of Tool Storage • Visual Management of Inventory and Stock • Straighten the Workflow • Straighten Check Sheet Shine • Shine – see problems when they are small • 5S Examples – Shine • Shine Check Sheet • Plan Who, What, How to Clean Standardize • Standardize – the same rules for all • Set Standards for Condition and Use of Tools and Equipment • Being Visual – know exactly what is happening • Use Visual Management to Show Status • What Visual Management Would Help Here? Sustain • Sustain – ‘this is how we do it here • Weekly and Monthly Feedback on Performance • Workplace Measurement Checklist – tracking your performance weekly • Tracking Your Performance Monthly 5S Implementation • What of Your 5S Implementation? • Plan/Prepare 5S Kaizen Blitz Workshop Exercises • 5S Experiment – Sort, Straighten, Shine • 5S Experiment – Refine the Layout • 5S Experiment – Fastest Process • 5S Experiment – Standardise and Sustain
5S is workplace management where the work area and workplace are organised and ritualised to minimise the loss of time and the use of movement. Originally part of Lean manufacturing philosophy (also known as
the Toyota Production System), its principles for eliminating wasted time and unnecessary motion are
universally applicable to everyone and every business.
5S is much more than ‘a place for everything and everything in its place’. 5S comprises five principles to
make people highly efficient and effective in their doing work.
1. Sort Keep near you only what you regularly use
2. Straighten Find exactly what you need to use in less than 30 seconds
3. Shine Have your workplace and equipment ready for immediate use
4. Standardize Everyone does each job in the same way and is challenged to improve it
5. Sustain Everyone does their part to foster a safe, efficient and effective workplace