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Lean in Action

5S System: Techniques for Efficient Workplace


Organization

Management Meeting
Month X, 20XX
What is 5S?

• A visual method of workplace organization


• 5S helps to:
- Have needed material, tools, supplies, and documentation at
hand, organized, and identified
- Maintain a clean work area with tools and equipment in top
condition
- Standardize workplace organization
- Maintain a occupationally-safe, ESD-safe, FOD-free
workplace

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Why employ 5S?

• An organized, clean workplace:


- Shortens Span Times
- Reduces the non-value added work of searching for
materials, tools, equipment and paperwork
- Reduces Floor Space requirements
- Prevents and detects errors and defects
- Raises team pride and job satisfaction
- Makes work easier to accomplish
• In short, an organized workspace
- enhances safety
- improves quality
- and reduces cost and cycle time

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Elements of a 5S Program
1.Sort

2.Set in Order

3.Shine

4.Standardize

5.Sustain

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5S - Down to Basics

SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN


Remove all A place for Remove dust, Spread Everyone
non-essential everything dirt & debris. through the who uses the
items from and Cleaning will work place. work area is
around the everything also highlight Checklists are encouraged
work area. in its place. any previously made showing to adopt the
Any essential Arrange items unforeseen exactly where new system.
items that do so they can problems. and when Eventually
not fit or work, be found, Prioritize regular the new
or are broken, retrieved safety, quality maintenance arrangements
are tagged and returned and reliability should take will become
for action. easily. issues. place. the culture.

For 5S to be effective, everyone must take full


responsibility for their own area of work, while
supporting 5S throughout the shared workplace

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Elements of a 5S Program
1.Sort
- Eliminate the clutter
“When in Doubt, Throw It Out!”
- Create a place for everything and put everything in its place
- Arrange needed items so that they are easy to use and label
them so that “anyone” can find them and put them away
- Use Visual Aids to aid understanding and minimize
complexity
 Shadow Boards
 Labels (“Return addresses”)
 Clearly marked places for items that are movable
 Area Identification signs
 Lines on the floor
2.Set in Order

3.Shine

4.Standardize

5.Sustain
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Sort: Workstations

What work
is being
Performed?

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Sort: Workstations

Before

After

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Sort: 5S Holding Area

• If unsure whether or not to


discard an item, a 5S
Holding Area should be
established
• Items should remain in the
area for a short period of
time, reassessed, and either
discarded or (if needed)
placed back into the work
area
• All items should have a 5S
Holding Tag for
identification (next slide)
• Items will be logged in a
database and tracked

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Sort: 5S Holding Tag (example)

• Tag is used for


tracking and Date placed in
5S Holding Tag
Holding Area
maintaining items that Date:
are in the 5S Holding Individual that
Tagged By:
area that are to be tagged the item

reevaluated for either Area item came from (stock,


assembly, Test area etc.)
Location:

disposal or for Short description (include


Item Description:

placement back into P/Ns if necessary)

appropriate area Reason why in Holding Area


Why in Holding Area:

• 5S Holding Tag
(obsolete, not needed, broken, etc.)

should be filled out


completely and
ACTION
logged into database 1. Discard
Proposed next steps to take 2. Return to
3. Move to Common Holding Area
4. Other

CATEGORY
1. Equipment
2. Tools
3. Flight Hardware
Used to track all items
4. GSE
5. Supplies
6. Other

example

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Elements of a 5S Program

1.Sort
2.Set in Order
- Organize and label, set boundaries and limits
“A Place for Everything and Everything in its Place”
• Why: Makes things easy to locate, easy to put away, readily apparent if
missing
• Results: No wasted time looking for tools or documents; they are
identified and on hand when needed
- One-Step Rule: Nothing that is used daily is stored more than a step
away. Improve economy of motion, save valuable seconds, and make the job
less frustrating.
- 45 Degree Rule: Arrange the immediate work area layout to minimize
twisting, especially applicable for bench work. If something weighs more than
a few pounds, make sure it is beyond immediate reach so the lifter must
reposition the body properly for lifting.
- Strike Zone Rule: Store things above the knees and below the chest.
This will help to reduce the chance of back strain.
- Higher the Pounds - Closer to Knuckles: Locate heavy items to
eliminate bending, stooping or unnecessary arm movements during lifting.

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Set In Order: Tool Crib Before Organization

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Set In Order: Tool Crib After Organization

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Set In Order: Unorganized Toolbox

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Set In Order: Organized Toolbox

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Elements of a 5S Program

1.Sort

2.Set in Order

3.Shine
Clean everything, inside and out
“Inspection Through Cleaning”
• Why: Nobody works well around a mess; FOD can ruin or
delay a mission; a clean workplace promotes pride and
demonstrates an interest in quality; cleaning allows us to find
problems with equipment and tools in time to prevent delays
• Results: A bright, clean, organized, work area that promotes
confidence, quality, and on time delivery
4.Standardize

5.Sustain

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Shine: Before Cleaning

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Shine: After Cleaning

Recognize and Reward the Team !!

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Elements of a 5S Program

1.Sort

2.Set in Order

3.Shine

4.Standardize
Document the standard method for workplace organization
so we always do things in the same way
“Everything in a State of Readiness”
• Why: Standardizing the way we maintain a work area and perform our
work promotes consistency in how work is approached and accomplished,
and allows easier cross training and movement of personnel
• Results: Standardized presentation of work areas, material and tools for
work
5.Sustain

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Standardize: Best Practices for Organization

Old way

New Standard

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Standardize: Best Practices for Organization

Old way

New Standard

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Standardize: Shadow Part Kits

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Elements of a 5S Program

1.Sort

2.Set in Order

3.Shine

4.Standardize

5.Sustain
- Maintain discipline through systems and a supportive
culture
“Launching quality with persistence.”
• Why: Without sustaining the first 4 Ss, they will die; promotes a
continuous improvement environment
• Results: Ever improving quality, cycle times, on time commitments;
high motivation, recognition for excellence

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Sustain: Teams set Standards to meet
Customer Demand

• Communications Board in the area shows the Continuous


Improvement List, Current Schedules and Metrics
• White board is for anyone to post any issue to be put on the
Continuous Improvement List

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Sustain: Teams set Standards to meet
Customer Demand – Show progress

Publicity !

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Sustain: Standard Assessment Score
(spider web chart)
(Assessed Work Area)
1S (Sort)
20

Current Assessment
15 Previous Score

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5S (Sustain) 2S (Set in Order)


5
8

11
0

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4S (Standardize) 3S (Sweep)

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Getting Started

• Form 5S Teams:
- All players who regularly work in the work are/ center
- If you use tools, hook up & use test equipment, handle parts, or
regularly handle travelers, drawings or Work Procedures in the area,
we want you on the team

• Conduct 5S Kaizen event:


- Learn what a 5S workplace looks like
- Only needed things present
- Clean; dustless
- All things organized, arranged and identified
- Visuals help tell at-a-glance the state of the workplace (signs, posters,
arrows, charts, schedules, etc.)

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Getting Started

• Plan for Success:


- Set team 5S goals
- Appoint 5S champion(s)

• First Steps:
- Post 5S team roster with leader, champions, and backups for
calibration, shelf life, job supplies
- Create a 5S holding area
 Sort unneeded items and move them to the 5S holding area
- Conduct monthly 5S Assessments
 Using Standard 5S Assessment

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Monthly 5S Scoring
Area
Ma Jun Aug Septe Octob Nove
y e July ust mber er mber
-- example only -- 100k Ante Room 72 68 50 54 60 64 64
100k Clean
SSG 5S Score Room 66 50 42 48 54 60 60

May -November 2007 Component Test


Lab #1 60 60 76 78 78 90 90
Component Test
100k Ante Room Lab #2 60 60 60 60 64 64 64
100
Propulsion Test 100k Clean Room
Electronic Work
80 Center 72 78 78 84 80 90 90
TVAC Component Test Lab #1
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Expansion Bay 60 50 50 56 60 88 88

Thermal Component Test Lab #2 Harness Work


40 Center 44 42 58 64 64 64 64

20 Large Vibe 50 44 56 58 58 58 58
Stockroom Electronic Work Center Mechanical
0
Work Center 80 86 86 86 94 94 94
Receiving
Small Vibe Expansion Bay Inspection 76 72 74 78 82 78 78
RF Range 48 60 60 62 66 64 64
Shipping & Receiving Harness Work Center
May Shipping &
June Receiving 70 66 80 82 82 82 82
RF Range Large Vibe July Small Vibe 50 48 72 82 82 86 86
Receiving Inspection Mechanical Work Center August
Stockroom 82 90 96 100 96 92 92
September
October Thermal 66 74 70 70 66 72 72
November TVAC 60 52 52 58 64 64 64
Propulsion Test 56 71 71 74 82 78 78
Levels of Achievement
SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN

What Level
Work place checks are
Necessary and
Tools, supplies and Work/break areas and Work place methods are not randomly performed and
LEVEL 1 unnecessary items are
materials are randomly machinery are dirty and consistently followed and are there is no visual
Just Beginning mixed together in the
located. disorganized. not documented. measurement of 5S
work area.
performance.

Work/break areas and


A recognizable effort has
Necessary and Designated location machinery are cleaned on Methods are being improved,
LEVEL 2 been made to improve the
unnecessary items are established for all items a regularly scheduled but changes have not been

is Your Work
Focus on Basics condition of the
separated. as needed. basis. Key items documented.
workplace.
identified.

Working environment changes


Designated locations are
Visual Controls are in are documented and 5S schedules and safety
All unnecessary items marked to make
LEVEL 3 place for labeling and performed the same by all practices have been
have been removed organization more visible
Make It Visual quantity levels. Machines employees. Visual Controls are developed and are
from the work area. (color, outlines, labels,
are cleaned daily. in place for labeling and utilized.
numbers, etc).
quantity levels.

LEVEL 4
Focus On
Area?
Consistency
A dependable,
documented method
has been established to
keep the work area free
of unnecessary items.

Waste is immediately
Documented method of
visual sweep to identify
items out of place or
exceeding quantity
limits.
5S techniques are
understood and practiced
continually. 5S schedules
are posted and followed.
Substantial process
documentation is available and
followed.

Dependable, documented Everyone is continually seeking


Follow through with 5S
schedules and safety
practices is evident.

There is a general
LEVEL 5 visible and triggers a Defined process to appearance of a confident
method of preventative the elimination of waste with
Focus on planned response with evaluate and improve understanding of, and
cleaning and changes documented and
Prevention root cause analysis and movement and motion. adherence to, the 5S
maintenance. information shared.
corrective action. principles.

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Let’s Go !

• Designate and identify location(s) for cleaning gear


• Tape aisle ways and perimeter of work areas
• Shadow box all needed tools; hang large tools on outline boards
• Sweep/ shine floors; post a cleaning schedule w/ names &
assignments
• Clean in corners, around I-beams & columns; wipe off wire
molds, vents, equipment, cabinets so that there is no dirt, dust,
paper clips, loose pens, loose papers, sticky notes, throw away
or put away ANYTHING laying around
• Remove things from the top of cabinets, consoles, tables,
chairs, etc.

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Let’s Go !

• ANYTHING that HAS to be stacked is stacked neatly (90°) in a


designated location
• Implement visual helps to indicate where things go, including
cleaning and safety gear
• Conscientiously conduct FOD and ESD surveillance
• Perform TPM on equipment
• Keep aisles clear; limit extension cords; no tripping or tipping
hazards; call attention to safety equipment locations
• Visually highlight equipment safety features (emergency stops,
stay out areas, etc.)

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Let’s Go !

• Post evacuation routes near exits


• ID chemical storage cabinet locations and check frequently
• ID and Wear protective equipment
• Have MSDS sheets in a clearly marked area
• Find a place for EVERYTHING; mark its perimeter and identify it
• Maintain the 5S bulletin board
• Evidence “clean-as-you-go” throughout the day
• Assess the area monthly; discuss and act on results
• Post results in 5S display area
• Hang posters, signs, etc. to sustain 5S

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Lean in Action
5S System: Techniques for Efficient Workplace
Organization

Management Meeting
Month X, 20XX

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