5S Basics

5S

5S 1
 8 WASTES
• Defect / Correction
• Overproduction
• Waiting
• Not utilizing employee talents
• Transportation / material movement
• Inventory
• Motion
• Excessive processing
5S 2
 Visual Factory-Information Gathering/Organization
PAB = Process Analysis Board
COB = Certified Operation Board
PPB = Process Performance Board
PAB
(Hourly)
COB
(Daily) From
Each
PPB Department
(Monthly)

Department Reporting Information Center

(Plant-wide Reporting)

5S 3
Sort
Straighten
Shine
Standardize
Sustain

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5S 9
 There are basically three
different types of workplaces...

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1S Sort

2S Straighten

3S Shine

4S Standardize

5S Sustain

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 1S
Sort
• Segregate What Is Needed, Needed
Later, and Not Needed
• Discard What Is Not Needed
•Segregate Needed Items By Frequency
of Use

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Where to Perform

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 Item Name
&/or Description:

Department: Value per Item:

Classification:
5S --- RED TAG . Raw Material . Machine / Equipment

. Work-in-Process . Mold / Jig

er #

box
Ent

in
. Component . Tool / Fitting

Reason: . Finished Product . Other______________

. Unnecessary . Unknown
er #
Ent

box
in . Defective . Other______________
Action: Completed:
. Leftover Material
. Eliminate

. Return
er #

box
Ent

in

. Move to Red Tag Storage

Tag Attached: . Action Taken:

Other_______________
G-

(--
E-
C

X
X
X
E

Year_____ Month_____ Day____ Year_____ Month_____ Day_____ File completed Tag at ____________

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Sort

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 2S
Straighten

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5S 30
 Large
Large Claw Small Crescent
Small Claw Hammer Crescent Wrench
Hammer Wrench

Flat Tip
Screwdriver

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Stage 1 Stage 2 Stage 3 Stage 4

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Before

After

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Before

After

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Before

After

5S 39
Before

After

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 3S
Shine

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Why Shine?

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Shine Targets

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 Location Being Audited:
5S Assessment
(place cursor in red corner for INSTRUCTIONS)
5S To-Do Items
· Remove unneeded equipment, tools,
furniture, etc.
· Provide information on
department PPB
Sort
· Review excess inventory, supplies,
Score Sheet
parts, or materials
· Identify existence of safety hazards
(water, oil, chemical, machines,
extension cords, etc.)
· Correct location for items are
identified
Straighten
· Items are placed in their correct
locations
· Aisle ways, workstations, equipment
locations are indicated
· Items are put away immediately
after use
· Inventory or WIP height and quantity
limits are obvious
· Floors, walls, stairs, and surfaces are
free of dirt, oil and grease
· Equipment is kept clean and free of
dirt, oil, and grease
Shine
· Cleaning materials are easily
accessible
· Lines, labels, signs, etc. are clean
and not damaged
· No other cleaning problems
(of any kind) are present
· Necessary information is visible
Standardize
· All standards are known and visible
· Checklists exist for all cleaning and
TPM maintenance jobs
· All quantities and limits are easily
recognizable
· All necessary items can be located
in 30 seconds
· All team members have had
5S training
· Daily 5S actions performed
Sustain
· Place all personal belongings
stored in a neatly maintained
location
· Job aids are current and readily
accessible
· Routine 5S Implementation Audit
is performed until sustained
Legend: <2 (RED)
{Enter Location here}
Observed Condition Improvement Action
Remove unnecessary items. All items not required for
performing operations are removed from the work area. 0
Only tools and products are present at workstation
Storage of cleaning equipment: All cleaning equipment
stored in a neat manner; handy and readily available when 0
needed
Items on floor: Work-in-process, tools and any other
material are not left to sit directly on the floor. Large items
such as tote boxes are positioned on the floor in clearly 0
marked area, identified by painted or taped lines.
Storage and arrangement:: Boxes, containers, and
materials are always stored neat and at correct work angles
convenient to the operators where appropriate. When
items are stacked evenly or in a manner that would not
cause them to toppling over. Storage areas are provided 0
for all necessary items at POUS (Point-Of-Use Storage).
No items are placed on top of machines, cabinets, and
equipment. Unidentified items can not lean against walls
or columns.
Operating equipment/machinery: Each piece of
equipment/machinery has guards and deflectors that 0
prevent debris from falling uncontained to the floor.
Document storage: Only documents necessary to the
operation are stored at the workstations and are stored in a 0
neat and orderly manner.
Tool and gauges arrangement: Tools, gages and fixtures
are arranged neatly and stored, kept clean and free of any 0
risk of damage.
Aisle ways maintenance: Aisles are always free of
materials and obstructions; nothing is placed on the lines
and objects are always placed at right angles to the aisles 0
where appropriate.
Equipment painting: All machines and equipment are
neatly painted; equipment cleaning schedule developed 0
and posted for each major piece of equipment.
Workbench and desk control: Kept free of objects
including records and documents (unless in use). Tools and 0
fixtures are clean and placed in their proper location.
Information boards: PPB, COBs, and PABs are arranged
in a neat and orderly manner. No outdated, torn, or soiled 0
documents are displayed
Emergency access: Fire hoses and emergency
equipment are unobstructed and stored in a prominent easy-
to-locate area with proper identification. E-Stop switches 0
and breakers are marked or color-coded for immediate
visibility.
Aisle ways marking: Aisles and walkways are clearly
marked and can be identified at a glance; lines are straight
and at right angles where appropriate with no chipped, worn 0
floor marking.
Equipment maintenance: Controls of machines are
properly labeled. Critical points for daily maintenance
checks are clearly marked. Equipment check sheets are 0
clean, neatly displayed and completed daily.
Tool and gauges convenience: Tools, gages and fixtures
are arranged so they can be easily accessed when needed. 0
Shelves and benches arrangement: Arranged, divided and
clearly labeled it is obvious where things are stored; status 0
and condition is recorded
Document control: All documents are labeled clearly as to
content and responsibility for control and revision. Obsolete
0
Equipment cleanliness: All machines and equipment are
kept clean by routine daily care. 0
Floor cleaning: All floors are clean and free of debris, oil
and dirt. Cleaning of floors is done routinely -- daily at a 0
minimum—posted schedule.
5S control and maintenance: There is a disciplined
system of control and it is maintained at the highest
possible level. It is the responsibility of every one to
maintain this system and environment. Documentation exist 0
indicating cleaning responsibility for each team member in
the work area.
2 to 4.75 >4.75 (GREEN) 5S Implementation Audit Score = 0.00
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It is important that we
establish the first 3S
before we progress to
the next 2S.

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 4S
Standardize

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 5S
Sustain

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January 2007 June 2007

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 ?
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Now, what would you do?

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Remember
5S
1S Sort
2S Straighten
3S Shine
4S Standardize

5S Sustain

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