5S and Visual Factory

Lean Manufacturing Series

© 2009 Factory Strategies Group LLC. All rights reserved.

Contents
1. 2. 3. 4. Introduction Background and History Components and Implementation Knowledge Check

© 2009 Factory Strategies Group LLC. All rights reserved.

2

Introduction
‡ 5S is a method to improve and sustain workplace organization ‡ 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). ‡ These are foundational to continual improvement and a manufacturing strategy based on "Lean Manufacturing" (waste removing) concepts. ‡ Reduces clutter ‡ Reduces the time it takes to look for tools and equipment ‡ ´A place for everything and everything in its placeµ ‡ Improves how the operation appears to customers ² always be ´tour readyµ ‡ Creates pride in the workplace ‡ Many companies have a standard that any tool must be able to be found within 60 seconds.
© 2009 Factory Strategies Group LLC. All rights reserved. 3

All rights reserved.S. © 2009 Factory Strategies Group LLC.Background and History ‡ Taiichi Ohno created the original ´4Sµ concept of workplace organization and visual control at Toyota during the early 1950·s. 4 . manufacturers added a sixth ´Sµ for ´safetyµ during the 1990·s. ‡ The concept was further refined into ´5Sµ during the 1960·s and 1970·s. ‡ U.

Components and Implementation ‡ 5S and Lean Manufacturing ‡ Elements of 5S Sort Straighten Shine Standardize Sustain Safety ‡ Visual Factory ‡ Implementation plan © 2009 Factory Strategies Group LLC. 5 . All rights reserved.

6 . inside and out ‡ Standardize Establish policies and procedures to ensure 5S ‡ Sustain Training. All rights reserved. daily activities ‡ Safety (often called ´6Sµ or ´5S + 1µ) A safety commitment in all activities © 2009 Factory Strategies Group LLC.Elements of 5S ‡ Sort Remove all unnecessary materials and equipment ‡ Straighten Make it obvious where things belong ‡ Shine Clean everything.

All rights reserved. 7 .Types of Waste ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ Overproduction Excess inventory Defects Non-value added processing Waiting Excess motion Transportation Other Wastes: Untapped Human Potential Inappropriate Systems Wasted Utility Resources Wasted Materials © 2009 Factory Strategies Group LLC.

Life Without 5S ‡ The Good. All rights reserved.First the Bad and the Ugly . 8 . Bad and the Ugly © 2009 Factory Strategies Group LLC.

The Good ² After 5S © 2009 Factory Strategies Group LLC. All rights reserved. 9 .

After 5S ‡ Clear. metrics and other current information ‡ Always ´customer tour readyµ © 2009 Factory Strategies Group LLC. 10 . shiny aisles ‡ Color-coded areas ‡ Posted processes. All rights reserved.

5S Examples Before 5S © 2009 Factory Strategies Group LLC.Cleaned. organized and drawers labeled (less time and frustration hunting) 11 . After 5S . All rights reserved.

move it out ‡ Red tag exercise (more later) © 2009 Factory Strategies Group LLC. 12 . All rights reserved.Sort ‡ Identify clutter and disposition ‡ When in doubt.

Straighten ‡ Make it obvious where things belong Lines x x x x Divider lines Outlines Limit lines (height. minimum/maximum) Arrows show direction Labels x Color coding x Item location Signs x Equipment related information x Show location. type. All rights reserved. 13 . etc. © 2009 Factory Strategies Group LLC. quantity.

14 .All unneeded tools. All rights reserved.5S Examples ² Sort and Straighten See the difference? ‡ Sort .A place for everything and everything is in its place © 2009 Factory Strategies Group LLC. parts and supplies are removed from the area Straighten .

tables ‡ Chairs ‡ Carts ‡ Shelves ‡ Racks © 2009 Factory Strategies Group LLC. graphs. pencils ‡ Work clothes ‡ Helmets ‡ Work shoes ‡ Trash cans 15 . bulletin boards ‡ Pens.Straighten Check Sheet Equipment ‡ Machines ‡ Small tools ‡ Dies ‡ Jigs ‡ Bits ‡ Conveyance equipment ‡ Cleaning equipment Furniture ‡ Cabinets ‡ Benches. All rights reserved. Materials ‡ Raw material ‡ Supplies ‡ Parts ‡ Work-in-process ‡ Finished goods ‡ Shipping materials ‡ Cleaning supplies Other items ‡ Charts.

and metrics!) ‡ Results in Fewer breakdowns Greater safety Product quality More satisfying work environment © 2009 Factory Strategies Group LLC. news. inside and out ‡ Prevent dirt and contamination from reoccurring ‡ Remove outdated material (like old posted charts. 16 . All rights reserved.Shine ‡ Clean everything.

Shine ‡ The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean. All rights reserved.5S Examples . 17 . © 2009 Factory Strategies Group LLC.

shelves. racks Carts. 18 . posts ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ Floors Machines Conveyance equipment Plumbing. Racks Drawers. storage bins Fixtures. All rights reserved. sinks Cabinets. under equipment Loading docks Walls Doors Pillars. power boxes © 2009 Factory Strategies Group LLC.Shine Check Sheet ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ Ceilings Aisles Workstations Corners.

Standardize ‡ Establish guidelines for the team 5-S conditions ‡ Make the standards and 5-S guidelines visual ‡ Maintain and monitor those conditions © 2009 Factory Strategies Group LLC. All rights reserved. 19 .

Typical Team Standards ‡ Sort Amount of inventory Tools that belong in the area How often to remove scrap ‡ Straighten Location of aisleways Location of tools. 20 . equipment ‡ Shine Cleaning schedule Maintenance tasks Checklist of what to look for as cleaning is performed © 2009 Factory Strategies Group LLC. All rights reserved.

standards and procedures ‡ Daily 5-minute 5-S activities ‡ Monthly 5S Audit © 2009 Factory Strategies Group LLC.Sustain ‡ Determine the methods your team will use to maintain adherence to the standards ‡ 5-S concept training ‡ Before and after photos ‡ Checklists. All rights reserved. 21 .

Safety ‡ Does not replace the existing site safety plan ‡ During 5S audits also review all areas for safety © 2009 Factory Strategies Group LLC. 22 . All rights reserved.

Begin reviewing your areas for 5S 2. Brief. All rights reserved. . b. Red tag sorting process (one time) 4.5S Implementation 1. Discuss 5S with each of your groups (brief group meeting) 3. Monthly 5S audit beginning __________ a. Brief 5S checklist or procedure for each area 6. d. Area Lead plus at least one person from outside that area Post results (I will look for them!) Review results with your group Take corrective action 23 © 2009 Factory Strategies Group LLC. simple daily 5S individual activity (´just look aroundµ) 5. c.

Red tags must be dispositioned within 30 days © 2009 Factory Strategies Group LLC. etc 2. Note in red tag log 4. Fill out and attach red tag 3. unused equipment. All rights reserved. Identify clutter. 24 .Red Tag Process ‡ One-time activity to remove or disposition clutter ‡ To be started within two weeks of this training 1.

Red Tag Inspection Sheet ‡ Search Floors Aisles Operation areas Workstations Corners. under equipment Small rooms Offices Loading docks Inside cabinets © 2009 Factory Strategies Group LLC. 25 . All rights reserved.

small tools Dies. All rights reserved. 26 . bits. tables Chairs Carts © 2009 Factory Strategies Group LLC. electrical parts ‡ Look for unneeded furniture Cabinets Benches. Conveyance equipment Plumbing. jigs.Red Tag Inspection Sheet ‡ Look for unneeded equipment Machines.

Red Tag Inspection Sheet ‡ Search these storage places Shelves Racks Closets Sheds Search the walls Items hung up Old bulletin boards Signs © 2009 Factory Strategies Group LLC. 27 . All rights reserved.

All rights reserved.Red Tag Inspection Sheet ‡ Look for other unneeded items Work clothes Helmets Work shoes Trash cans Other ‡ Look for unneeded materials Raw material Supplies Parts Work in process Finished goods Shipping materials © 2009 Factory Strategies Group LLC. 28 .

shelves. tables) Visually indicate amount of allowed inventory Keep metrics. wall charts.Visual Factory Mark-off the inventory locations Mark-off equipment/machine locations Mark-off storage locations (cabinets. and other information current ‡ Label all cabinets. etc with their contents ‡ Posted production status. shelves. 29 . upcoming jobs ‡ ‡ ‡ ‡ ‡ © 2009 Factory Strategies Group LLC. All rights reserved.

All rights reserved. .Knowledge Check © 2009 Factory Strategies Group LLC.

31 .Name the five ´Sµ components. All rights reserved. a) Sort b) Straighten c) Shine d) Standardize e) Sustain (Mark all that apply) © 2009 Factory Strategies Group LLC.

A safety commitment in all activities D. daily activities B. Clean everything. 32 . Training. Name F E B D A C Sort Straighten Shine Standardize Sustain Safety Description A.Match the 5S component name with it's description by dragging the description to the name. Remove all unnecessary materials and equipment © 2009 Factory Strategies Group LLC. inside and out C. Make it obvious where things belong F. Establish policies and procedures to ensure 5S E. All rights reserved.

33 .What are some ways in Straighten that you can make it obvious where things belong? (Mark all that apply) 1. Labels 3. Signs © 2009 Factory Strategies Group LLC. All rights reserved. Lines 2.

Fewer breakdowns 2. More satisfying work environment © 2009 Factory Strategies Group LLC. 34 . All rights reserved. Greater safety 4. Product quality 5. Slower processing 3.Performing Shine results in which of the following? (Mark all that apply) 1.

Before and after photos 3. All rights reserved. 35 . Daily 5-minute 5-S activities © 2009 Factory Strategies Group LLC. Checklists. standards and procedures 4.What are some ways your team can Sustain 5S? (Mark all that apply) 1. 5-S concept training 2.

All rights reserved. oA) True oB) False © 2009 Factory Strategies Group LLC.Strategy is sometimes called the sixth "S". 36 .

Fill out and attach red tag 4. Note in red tag log © 2009 Factory Strategies Group LLC. All rights reserved. 37 . etc 3. One-time activity to remove or disposition clutter 2. unused equipment.Which of the following are a part of the ´red tagµ activity? (Mark all that apply) 1. Identify clutter.

All rights reserved. etc with their contents © 2009 Factory Strategies Group LLC. Visually indicate amount of allowed inventory 4. 38 . Mark-off equipment/machine locations 3. Mark-off the inventory locations 2. Label all cabinets.What are some ways that you can maintain a Visual Factory? (Mark all that apply) 1. shelves.

All rights reserved. 39 .How can you implement 5S in your organization? © 2009 Factory Strategies Group LLC.

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