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Objectives
• Understand the benefits of working in a clean
and neat environment
• Define the 5S principles, and identify visual tools
• Explain how to apply the 5S principles and
visual tools to enhance workplace organization
• Learn how to kick start and launch a 5S initiative
• Define the critical success factors for 5S
implementation
NOTE: This is a PARTIAL PREVIEW. To
download the complete presentation, please
visit: http://www.oeconsulting.com.sg
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Outline
• Introduction to 5S
• 5S Provides a Solid
Foundation to Lean
Implementation
• Types of Waste in the
Workplace
• What is 5S?
• Benefits of 5S
• 5S Principles - Step By Step
• How to Conduct a Red
Tagging Exercise
• Creating a Visual Workplace
• Applying 5S to:
Safety
Quality
Equipment Reliability
Productivity
• 5S in the Office
• How to Implement 5S
• How to Sustain 5S
• 5S Audit System
• Supporting Lean Tools for 5S
• Critical Success Factors
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Introduction to 5S
• 5S is a structured program
to implement workplace
organization and
standardization
• 5S represents five
disciplines for maintaining
a visual workplace
• 5S is a foundation to
Kaizen and Lean
implementation, e.g. TPM
Sort
Set In OrderShine
Standardize
Sustain
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5S Lays the Foundation for a Lean
Enterprise
Productivity
5S
Heijunka Standardized Work Kaizen
Just-In-Time
• Continuous flow
• Takt time
• Pull system
• Flexible workforce
Jidoka
• Separate man &
machine work
• Abnormality
Identification
• Poka yoke
•Visual Control
Goals:
highest quality,
lowest cost, shortest lead times
Involvement
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5S Establishes a Baseline for Kaizen
Activities
Standardize
Standardize
StandardizeKaizen
Kaizen
Kaizen
P
DC
A
Kaizen (改 善) =
Continuous Improvement
Plan
DoCheck
Act
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5S
Suggestion
System
Continuous
Improvement
Teams
5S is a Cornerstone of Employee
Engagement
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5S Helps to Eliminate Waste
Over-production
Producing more than what
the customer needs
Inventory
Building and storing extra
services/products the
customer has not ordered
Transportation
Moving product from
one place to another
Rework
Reprocessing, or
correcting work
Over-processing
Adding excess value
when the customer
does not require it
Motion
Extra physical/mental
motion that doesn’t add
value
Intellect
Not using employees full
intellectual contribution
Waiting
Employees waiting for
another process or a
machine/tool
Waste
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What is 5S?
Principles General Description
1S Sort
Remove what is not needed and keep
what is needed
2S Set in Order
Arrange essential items in order for
easy access
3S Shine
Keep things clean and tidy; no trash or
dirt in the workplace
4S Standardize
Establish standards and guidelines to
maintain a clean workplace
5S Sustain
Make 5S a habit and teach others to
adhere to established standards
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What is the purpose of 5S?
Immediately make problems visible
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Benefits of 5S
• 5S makes our workplace more
pleasant
• 5S improves work efficiency
• 5S and safety go hand-in-hand
• 5S leads to better customer
satisfaction and higher
productivity
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1S : Sort
• Principle
Stratification management
Dealing with the causes
• Meaning
Distinguish between the
necessary and unnecessary
Get rid of what you do not
need
“When in doubt, move it out”
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1S : Sort
Degree of
Need
Frequency of Use Storage Method
Low
• Things you have not used in
the past year
• Things you have used once in
the last 6-12 months
• Throw them out
• Store at a distance
Medium
• Things you have only used
between 1-6 months
• Store in a central
place in the workplace
High
• Things used once a week
• Things used daily
• Things used hourly
• Store near the work
site or carry on the
person
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2S : Set In Order
• Principle
Functional storage
Search elimination
• Meaning
Arrange essential items in
order for easy access
A place for everything
Everything in its place after
use
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2S : Set in Order - Office Desk
An office desk before and after conducting 5S Sort, Set In
Order and Shine. Clutter and unused items have been
removed leaving only what is needed.
Before After
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3S : Shine
• Principle
Cleaning as inspection
Degrees of cleanliness
• Meaning
Eliminate the sources of dirt
and filth
Cleaning as a form of
inspection
Clean everything, inside out
Shine check sheet
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3-Step Approach to Cleaning
Common areas, walls, ceilings, lights,
storage areas, toilets, “junk yards”,
shelves, filing cabinets, etc.
Individual workstations, chairs, drawers,
computers, cabinets, shelves, etc. Clear
away things underneath your table!
Measuring instruments, e.g. micrometer,
gauges, vernier calipers, contact
surfaces, etc.
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4S : Standardize
• Principle
5S standardization
Visual management
• Meaning
Establish guidelines
Make standards and guidelines
visual
Make standards so that any
abnormality becomes visible
Use visibility tools
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Standardization is the Way to
Sustain the Gains
Present
state
Future
state
Without
standardization, all
my improvements will
roll back with time…
STANDARDIZATION
Standardization is a tool that will ensure
your improvements will be sustained.
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Foundations of Standardized Work
Simplify the Work Site
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5S : Sustain
• Principle
Habit formation
Disciplined workplace
• Meaning
Training
‘Before’ and ‘after’ photos
Daily 5S five-minute activities
Self-discipline
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How to Sustain 5S?
• Get management commitment
• Get everyone involved
• Get authorization from management for 5S activities
• Promote 5S in the organization
• Do it all the way
• Gemba walk by CEO
• Conduct monthly review by 5S committee
• Use 5S as a platform to launch other continuous
improvement programs/initiatives
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Creating a Visual Workplace
• 5S can be enhanced by the
use of visibility tools
• Use 5S visibility tools to
help you monitor results
and look for things easily
and quickly
Note: Visual management IS
NOT decoration
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3 Types of Visual Management
• Label to make it perfectly clear
where things belong and what the
procedures are
Visual
Display
• Quantify the path to targets for
success
• Graphs and Pareto charts
Visual
Metrics
• Create an error-proofed
environment to promote easy
adherence to standards
Visual
Controls
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Example of Visual Metrics
Process Costs
Product Profitability
100%
Revenue
Rework
On TimeCycle Time Reduction WIP Backlog
Internal Quality
Customer Complaints
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5S and Safety, Quality, Productivity &
Equipment Maintenance
5S
Safety
Quality
Productivity
Equipment
Maintenance
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5S and Safety 1
• Wear protective clothes,
goggles and shoes in the lab
• Install protective covers on
equipment and machines
• Label warning signs
prominently
High voltage, Radiation,
Slippery/Wet floor, etc.
‘Under Test – Do Not Switch
Off’
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5S and Quality 1
• Train staff on 5S
• Provide on-the-job training
for new staff
Use ‘Training Within Industry’
(TWI) methods for coaching
• Educate/Train staff to
recognize and prevent
mistakes
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The One-Is-Best Campaign
• One-page memos
• One-hour meetings
• One-location files
• One-day processing
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5S Implementation Process
Step 5: Implement 5S
Step 1: Establish a 5S Committee
Step 2: Define a 5S Implementation Pan
Step 3: Develop 5S Publicity Materials
Step 4: Provide 5S Education
Step 6: Audit, Evaluate & Follow-Up
Sort
Set In OrderShine
Standardize
Sustain
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5S : Getting Started 1
• 5S publicity materials
Booklets, badges, brochures, cups,
pens, etc.
• 5S training and education
Provide 5S training to managers
and staff
5S pamphlets
• 5S notice boards/intranet
5S news
‘Before’ and ‘After’ photos
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Launching a 5S Day 1
• Set aside half a day for this
event
Best on Fridays or before a
festive season or public holiday
Everyone in casual attire, e.g.
T-shirts
• Prepare sufficient cleaning
equipment, detergents,
paints, etc.
• Speech by CEO on
importance of 5S to all staff
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Supporting Lean Tools for 5S
Zone 1
Zone 3 Zone 4
Zone 2 Chores
John Mark Sue Jim
Pack Table Restocking X X X
Supply Shelf Restocking X X X
Handling Incompletes X
Equipment Maintenance X
File Organizing X X X X
Visual Charts X X X
Cleaning X X X X
1. Zone Chart
3. Cross-training Matrix
Before
After
2. ‘Before’ & ‘After’ Photos
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Critical Success Factors
• Top management commitment
• Involvement of all staff
• Sufficient resources, manpower,
admin, training, publicity, etc.
• Link with productivity and quality
initiatives
• Regular 5S Audit and management
review
• Recognition and reward for good 5S
practices
39. © Operational Excellence Consulting. All rights reserved. 39
About Operational Excellence
Consulting
• Operational Excellence Consulting is a management training and
consulting firm that assists organizations in improving business
performance and effectiveness.
• One of our unique strengths is going beyond a tools-focused
approach to seamlessly integrate people, processes, technology
and continuous improvement initiatives to suit the specific needs
and situations of our clients.
• We provide corporate learning programs and management advisory
services to assist our clients to achieve breakthrough in business
performance and effectiveness. Our aim is to support our clients in
designing, managing and executing lasting beneficial change.
40. © Operational Excellence Consulting. All rights reserved.
To download this presentation,
please visit us at:
www.oeconsulting.com.sg
END OF PARTIAL PREVIEW