Lean Training


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What is it? What’s it for? How does it work? When do you use it? What’s an example?

What is it?    5S is a workplace organization technique It is a way to involve associates in the ownership of their workspace It helps create and maintain the efficiency and effectiveness of a work area 5S is a common starting point for Lean activities in a company .

What’s it for?  It is a way to create:       Cleaner work areas More organization Safer working conditions Less wasted time Efficient work processes and practices More available space .

How does it work?   5S is most effective when applied in a systematic way The following video illustrates the 5S methodology 5S Video .

clean and ready to use Systematic Cleaning or Sweeping – cleaning for inspection Standardizing – developing common methods for consistency Sustaining – holding the gains and improving .The Five S’s      Sorting – separating the needed from the not-needed Simplifying – a place for everything and everything in its place.

Sorting Separating the Needed from the NotNeeded  Eliminate not-needed items and perform an initial cleaning      Establish criteria/handling of items Identify not-needed items Move not-needed items to holding area Conduct a white-elephant sale Conduct an initial cleaning .The First S .

equipment.The Second S .Simplifying A place for everything and everything in its place. label items Document layout. clean and ready to use  Arrange workplace for safety and efficiency      Identify key equipment and supplies Determine location for each item Outline locations and zones Develop shadow boards. supplies .

The Third S – Systematic Cleaning Cleaning for Inspection Perform daily cleaning and inspection to understand work conditions       Identify points to check for performance Determine acceptable performance Determine visual indicators/controls Mark equipment/controls Conduct daily cleaning/inspections .

Standardizing Developing Common Methods for Consistency Make abnormal conditions noticeable and document agreements     Document agreements and checks Establish/document standard methods across similar work areas Document new standard methods .The Fourth S .

Sustaining Holding the Gains and Improving  Maintain the gains from other 5S activities and improve     Determine 5S Level of Achievement Perform routine checks Analyze results of routine checks Measure progress and plan for continuous improvement .The Fifth S .

Getting Started    Planning – launches your 5S activity Evaluating – tells you what you need to do Preparing – gets you ready for implementation .

activities.Planning       Assemble a 5S Lead team Define the work area 5S boundaries Assign work group members to their 5S areas Install a 5S communication board Determine 5S targets. and schedule Review/finalize plans with work group and site leadership .

5S Boundaries Area 1 Monica & Chandler Joey & Phoebe Area 2 Area 3 Rachel & Ross Area 4 Jerry & Kramer .

Five S Communication Board Five S Team Members Levels of Achievement Five S Implementation Plan Five S Implementation Plan Five S Boundaries Photos Photos Five S Routine Checklist Current Situation Five S Routine Checklist After Five S .

Evaluating Your Initial Situation    Prepare to take work area photos Take work area photos Evaluate current 5S Level of Achievement .

root causes are identified. labeling. assessed against business minimized in number/ size and assess area readiness.5S Workplace Organization Levels of Achievement Level 5: Continuously Improve Level 4: Focus on Reliability Level 3: Make it Visual Level 2: Focus on Basics Level 1: Just Beginning Needed items are routinely reworked/ replaced as needed to improve work area performance M ethods for housekeeping. inspections. housekeeping. files and supplies needed item labeling and documented labeled with required have been established for the visual controls are posted quantities work area and followed by work team Needed items can be retrieved within 30 seconds and require a minimum number of steps Problem sources are documented with solutions defined and implemented Root causes have been eliminated and improvement actions focus on developing preventive methods Sources and frequency of problems are documented as part of routine work. 04-06-01 . and corrective action plans are developed Work team is routinely checking area to maintain 5S agreements and posting results Needed and not needed items have been sorted and not needed have been removed from work area Needed items have been safely stored and organized according to frequency of use Key work area items to be checked are indentified and documented Work area agreements are 5S level has been determined identified and documented and posted on the for needed item organization communication board and work area controls Needed and not needed items are mixed throughout the work area Items are placed randomly throughout the work place Key work area items to be checked during a sweep are not identified No work area agreements exist There is no measurement of 5S performance Sorting Simplifying Sweeping Standardizing Sustaining rev. needs to assure functionality are properly arranged for potential problems are and work place design are and fit retrieval and use identified and fixed consistently followed and demonstrate area performance improvement A list of needed items for the Needed items have dedicated Visual controls for Work area agreements for work area has been locations and are properly equipment. inspections. and work place design are continually improved and shared externally as applicable Needed items are routinely Needed items have been Daily inspection occurs to Agreements for labeling.

Preparing for Implementation        Obtain existing standards for color-coding and signage Decide on 5S color-coding and signage standards Prepare for Sorting Prepare for Simplifying Prepare for Systematic Cleaning Prepare for Standardizing Prepare for Sustaining .

and schedules Document current situation Apply 5S’s Document improvements Determine new improvement goals and action steps . activities.Summary: Implementing Five S’s        Share 5S Overview Choose work area implementation group Determine implementation targets.

personal items Making time available Following agreements consistently Maintaining the gains Giving rewards and recognition Integrating 5S with other improvement activities . or moving.Issues and Concerns        Communicating across shifts Disposing of.

What’s an example? .

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What’s an example? Before After .

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Questions? .

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