An Introduction to 5S

Learning Objectives
The purpose of the this module is:

To introduce the 5S philosophy, actions and

measurements.

Understand and apply simple Visual Display

and Visual Control techniques.

Explore and examine the benefits of adopting

these disciplines.

The Benefits of Implementing 5S

5S provides a basis for being a world-class competitor and the

foundation for a disciplined approach to the workplace.

Safer working conditions

A cleaner and more organized work area

Reduction in non-value added time
Effective work practices
Efficient work processes
Facilitating a change: Safer, Better, Faster !

And The 5-Ss are

Seiri (Separate) or Sort

Seiton (Straighten) Store, or Put-in Place
Seiso (Clean) or Shine
Seiketsu (Standardize)
Shitsuke (Discipline) or Sustain
+ Safety !

Sometimes called 5S + 1 or 6S

Safety 1st ! (in everything we do!)

Seiri (Separate) or Sort
Seiton (Straighten) Store, or Put-in Place
Seiso (Clean) or Shine
Seiketsu (Standardize)
Shitsuke (Discipline) or Sustain

Sort and Separate

Separate the necessary from the unnecessary.

Identify what is required to work a process or perform

a particular operation or task.

Remove unnecessary tools, equipment, files, binders,

parts, procedures, furniture, and other stuff from the
area.

1 - Sorting Activity Steps

Establish criteria and explain the handling of items
Assign zones to people
Conduct an event
Identify not-needed items from what is needed
Move identified not-needed items to holding area
Conduct a white elephant sale or AUCTION
Conduct an initial cleaning

Focus on doing and attaining results

Red Tag (Example)

Red Tag
Item number_______________
Description________________
Date Tagged_______________
Tagged by_________________
Circle one:
Stored

Disposed

Reason
_____________________________

Red tags (somewhat of a standard) should be used

to identify items that need to be moved or disposed
of from the area performing the Sorting event.

2 - Straighten (or Put-in Place)

Organize materials according to frequency of use

Implement visual aids to improve communication

Lay it out - for when YOU are not there

Steps to Straightening process

Identify key equipment and supplies
Determine location for every item
Develop shadow boards
Label needed items
Determine required quantities
Outline locations of equipment,
supplies, common areas, and safety zones
Document workplace layout, equipment, safety
zones, and supplies
Work team involvement is crucial to
success

3 - Shine (Clean)

Perform initial clean and sweep of the area

Perform daily cleaning and inspection of area and

equipment to determine status and need for
corrective and preventive action

A daily discipline to an agreed upon plan that is

executed by the work area team members

A performance improvement discipline

Shining Steps
Identify key points to check
to ensure proper performance
Determine acceptable performance
Determine corresponding
visual indicators and controls
Mark equipment and controls
Establish who and when cleaning plan
Conduct daily cleaning and inspections
Progress Towards Prevention over
Detection

4 - Standardize

Determining, sharing, and using the best processes

and methods

Standardization serves to minimize variation and the

effect of variation on quality and speed

We want to look towards standardization with

process tooling, methods, parts, sub-assemblies,
design, etc
The Standard Becomes the Baseline for
Further Improvement

Steps to Standardization

Document present work area agreements

and routine checks
Establish and document standardized
methods across similar work areas
Document new standard methods

Attacking Process and Methods Variation

5 - Sustain

Keeping the gains and building further

progress

A Continuous Improvement thought process

becomes the culture

Pride in Improvement, Accomplishments, and

the Desire to do More

Steps to Sustaining

Determine 5S level of achievement

Perform routine checks, including point
photography
Analyze results of routine checks
Measure progress and plan for continuous
improvement

Sustain Success (6S) through Habit

Document The Current Situation

Purpose:
Record the current situation as a baseline for progress
Preparation:
Obtain a camera or photographic assistance
Obtain a layout and mark the before-picture place and angle
Explain the steps of current situation documentation
Publish the picture taking date
Do it:
Take work area photos
Evaluate current 5S level of achievement

Without a Baseline Measurement,

Progress Cannot Be Determined

A 5S Case Study (example)

Purpose:
To Document Before and After
ACTIONS !

Without a Baseline Measurement,

Progress Cannot Be Determined

After

Before

Excess inventory in area

Lack of space for work & storage

- Clutter removed
- Consolidation of workspace
& storage

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After

Before

Scattered work in process

No protocol for Engs seals in
area for failure analysis

- Racks organized with work in

process & out of work area

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After

Before

Work area was not defined

Storage in several areas
Old furniture

- Machines lined up to optimize

flow
- Relocated & upgraded hoist
- Standardized benches
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After

Before

Product with no part code

Non-conforming to paint booth
regulation

- Safer condition
- Decreased excess inventory

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After

Before

Work areas were not conducive to

communication or flow

- Work space standardized

- Flow optimized assemble,
test & package

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After

Before

Cluttered work areas

Old benches

- Standardized work areas

- Each employee is responsible
for cleaning bench at days
end
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After

Before

Testing equipment scattered &

unorganized

- Testing equipment along one

wall and upgraded

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After

Before

Instruction manuals in 2 cabinets with

boxes on top

- Instruction manuals in 1
cabinet organized and
labeled

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Levels of Achievement (Strive for Five !)

LEVEL

5
Continuous
Improvement

LEVEL

4
Focus On
Reliability

LEVEL

3
Focus On
Reliability

Cleanliness
problem areas
are identified and
mess prevention
actions are in
place.

Needed items
can be retrieved
in 30 seconds
with minimum
steps.

Potential
problems are
identified and
countermeasures
documented.

Proven methods
for area
arrangement and
practices are
shared and used

Root causes are

eliminated and
improvement
actions include
prevention.

Cleaning
schedules and
responsibilities
are documented
and followed.

Minimal needed
items arranged in
manner based on
retrieval
frequency

Work area
cleaning,
inspection, and
supply restocking
done daily.

Proven methods
for area
arrangement and
practices are
used in the area.

Sources,
frequency of
problems are
noted w/root
cause &
corrective action

Initial cleaning is
done and mess
sources are
known and
corrected.

Needed items
are outlined,
dedicated
locations are
labeled in
planned
quantities

Visual controls
and indicators
are set and
marked for work
area.

Agreements on
labeling,quantitie
s, and controls
are documented.

Work group is
routinely
checking area to
maintain 6S
agreements.

Sort

Straighten

Shine

Standardize

Sustain

A Simple 5S Progress Check

There are 5 ways to appraise the level of 5S at each

stage.
1. Evaluation of self/ team.
2. Evaluation by expert/ consultant.
3. Evaluation by supervisor/ manager.
4. Combination of the above.
5. Friendly competition among groups.

Key to Sustaining a Visual Business

Make it FUN !

5S Implementation
Keys to Success

Lessons Learned
Start with cross functional

team
Discuss benefits (METRICS)
Train, then immediately do
Agree on a vision
Agree on standards
Define the area to do
Define roles
Dont let participants walk
away

Get everyone involved

Get commitment and

authorization for facility wide

improvement
Have leaders set expectations
& do follow-up
Establish standards
Establish routines
Keep it simple
Link to other Improvement
activities

Summary

5S is more than cleaning up, it is a discipline that is

used to support all Lean Enterprise activities.

Visual Controls, like Visual Displays, can resolve

many information and communication problems in the
workplace.

Another important result is fewer work frustrations

and a SAFER and more satisfying work experience.

Again, the result is improved work efficiency and

effectiveness.

Thank You