An

An EASEworks®
EASEworks® Manufacturing
Manufacturing Tutorial
Tutorial

The
The “5S”
“5S” Philosophy
Philosophy

Ver 6
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Copyright EASE Inc Tutorials© 1986-2002
The
The “5S”
“5S” Philosophy
Philosophy

Based on Japanese words that begin with S, the 5S Philosophy

focuses on effective work place organization and standardized
work procedures. 5S simplifies your work environment, reduces
waste and non-value activity while improving quality efficiency
and safety.

IfIf you’re
you’re going
going to
to do
do it,
it, do
do itit RIGHT!
RIGHT!

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Sort
Sort –– (Seiri)
(Seiri)

The first S focuses on eliminating unnecessary items from the

workplace.

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Sort
Sort –– (Seiri)
(Seiri)
An effective visual method to identify these unneeded items is called
red tagging. A red tag is placed on all items not required to complete
your job. These items are then moved to a central holding area. This
process is for evaluation of the red tag items. Occasionally used items
are moved to a more organized storage location outside of the work
area while unneeded items are discarded.

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Sort
Sort –– (Seiri)
(Seiri)

If you don’t use it,

move it!

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Sort
Sort –– (Seiri)
(Seiri)
Sorting frees up valuable floor space and eliminates such
things as broken tools, obsolete jigs and fixtures, scrap and
excess raw material.
The Sort process also helps prevent the ‘hoarder’ job
mentality (“I might need it”).

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A
A place
place for
for everything
everything
&&
everything
everything in
in its
its place
place

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Set
Set in
in Order
Order –– (Seiton)
(Seiton)
The second S focuses on efficient and effective storage methods.
You must ask yourself these questions:

1. What do I need to do my job?

2. Where should I locate this item?
3. How many do I need?

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Set
Set in
in Order
Order –– (Seiton)
(Seiton)
Strategies for effective Set In Order are:

 Painting floors
 Outlining work areas and locations
 Shadow boards
 Modular shelving and cabinets

“A
“A PLACE
PLACE FOR
FOR EVERYTHING
EVERYTHING AND AND
EVERTHING
EVERTHING IN
IN ITS
ITS PLACE”
PLACE”

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Shine
Shine –– (Seiso)
(Seiso)
Once you have eliminated the clutter and junk that has been clogging your
work areas and identified and located the necessary items, the next step is
to thoroughly clean the work area. Daily follow-up cleaning is necessary in
order to sustain this improvement. Workers take pride in a clean and clutter-
free work area and the Shine step will help create ownership in the
equipment and facility.

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 Shine
Shine –– (Seiso)
(Seiso)
Workers will also begin to notice changes in equipment and facility
location such as air, oil and coolant leaks, repeat contamination and
vibration, broken, fatigue, breakage, and misalignment. These changes,
if left unattended, could lead to equipment failure and loss of production.
Both add up to impact your company’s bottom line.

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Standardize
Standardize –– (Seiketsu)
(Seiketsu)
Once the first three of the 5S’s have been implemented, you should
concentrate on standardizing best practice in your work area. Allow your
employees to participate in the development and documentation of such
standards. They are a valuable but often overlooked source of information
regarding their work.

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Standardize
Standardize –– (Seiketsu)
(Seiketsu)
Standardize means establishing “Best Manufacturing
Practices, including:

 Workplace Layout and Design

 Materials Handling Analysis
 Clear and Concise Work Instructions
 Well Defined Work Methods
 Safe (Ergonomic) Working Practices
 Cycle Time Reduction
 Training
 Documentation

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Sustain
Sustain –– (Seiketsu)
(Seiketsu)

This is by far the most difficult S to implement and achieve.

Human nature is to resist change and more than a few

organizations have found themselves with a dirty cluttered shop a
few months following their attempt to implement 5S. The tendency
is to return to the status quo and the comfort zone of the "old way"
of doing things.

Sustain focuses on defining a new status quo and standard of

work place organization.

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The
The “5S”
“5S” Philosophy
Philosophy
Once fully implemented, the 5S process can increase moral, create
positive impressions on customers, and increase efficiency and
organization.

Not only will employees feel

better about where they work, the
effect on continuous
improvement can lead to less
waste, better quality and shorter
lead times. Any of which will
make your organization more
profitable and competitive in the
market place

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 EASE Inc.
EASE Inc.
Thank you for viewing this tutorial.
CLIENTS
CLIENTS
For further information about EASE
CONSULTING
CONSULTING Inc, our clients, consulting services,
SOFTWARE
SOFTWARE
software products and software
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Who
Who is
is EASE
EASE Inc?
Inc?

EASE Incorporated is an international corporation,

founded in 1986.

EASE is headquartered in Southern California

with satellite offices in Europe and the United
States.

EASE Incorporated provides productivity improvement services through the

application of the EASEworks® Software, training, consulting services and
implementation support.

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EASE
EASE Customers
Customers

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The
The Service
Service
Our major focus is to offer sustainable productivity improvements and cost
reductions for our clients. We can provide you with consulting assistance for. .

 Equipment Evaluation  Training and Training Support &

 Facility Layout
 Establishing “Best Practices”
 Competitive Benchmarking
 Design Engineering
 Process Engineering
 Production Engineering
 Implementing Ergonomic
Improvements
Certification
 Improving Labor Efficiency
 Productivity Analysis
 Implementing Lean Manufacturing
 Manufacturing Engineering
 ISO 9000 Implementation
 Developing Work Standards
 Process Mapping

EASE will provide engineers with extensive experience in YOUR industry. Your
engineers will have the ability to take over, with confidence,
confidence where we leave off.

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Software
Software
EASEworks® Software modules cover:

 Work Standards  Work Instructions

 Product Cost Estimating  Ergonomics
 Line Balancing  Design For Assembly

EASE Inc. provides full training, start up assistance and consulting services for
all modules.

Software customization services are also available.

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 Contact
Contact Information
Information

Phone: (949) 348-7511

EASE
EASE Inc
Inc..
Fax: (973) 201-1600
27405
27405Puerta
PuertaReal,
Real,#380
#380
E-Mail: sales@easeinc.com
Mission
MissionViejo,
Viejo,CA
CA92691
92691
Web: www.easeinc.com

Ver 6
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 SAMPLE ONLINE
SAMPLE ONLINE
WORK
WORK
INSTRUCTION
INSTRUCTION

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 Full
Fullmotion
motion
video
videocancanbebe
displayed
displayed asas
part
partofofaawork
work
instruction
instruction

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Copyright EASE Inc Tutorials© 1986-2002
Work
Worktasks
taskscan
canbebe
analyzed in great
analyzed in great
detail
detailtotoevaluate
evaluate
alternative
alternativemethods.
methods.

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 Determining
Determining Value/Non-Value
Value/Non-Value
Added
Added Activities
Activities Value Added: Activities that
must be performed to meet
customer requirements

ASSEMBLY
PROCESS CONTRIBUTES
METALWORK
STEPS TO CUSTOMER
PACKAGING
DEMANDS? YES VALUE
YES
ADDED

YES
YES NO
NO
FINANCIALS
SCHEDULING
MINIMAL
MATERIAL
ESSENTIAL HANDLING
NECESSARY CONTRIBUTES
TO PRODUCE NO
NO TO BUSINESSR YES
YES
NON-VALUE
OUTPUT DEMANDS? ADDED

MOVEMENT
REWORK
NO NON-VALUE STORAGE
NO
ADDED
Non-Value Added: Activities that do not
contribute to meeting customer
requirements. These activities can
possibly be eliminated.
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This
Thischart
chartillustrates
illustrates
Value Added/Non-Value
Value Added/Non-Value
Added,
Added,Walking
Walkingand and
Internal Time.
Internal Time.

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This
Thisshows
showsmethods
methods
comparison
comparison andcost
and cost
benefits.
benefits.

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Here
Hereisisaacomparison
comparisonofof
the
thevalue
valueadded.
added.

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Not
Notonly
onlycan
canexisting
existingworking
workingpractices
practices
be
be evaluated, but alternatives canbe
evaluated, but alternatives can be
considered and cost justified.
considered and cost justified.

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AAleading
leadingbeef
beefprocessing
processingplant
plant
uses
uses EASE to compare thesame
EASE to compare the same
task for training and work content
task for training and work content
across
acrossall
allofoftheir
theirplants.
plants.

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