From 5S to 7S:

Towards
Organizational
Efficiency and
Effectiveness
2
 What is 5S?


The 5S system is a lean manufacturing tool that improves
workplace efficiency and eliminates waste. The 5S Methodology
has exploded in other areas of quality improvement including
total productive maintenance, the visual workplace, the Just-In-
Time (JIT) process, and Lean manufacturing.

The core principles of 5S involve creating and maintaining

 Visual order

 Organization

 Cleanliness

 Standardization

3
The Origins of 5S
THE TOYOTA PRODUCTION SYSTEM

It was Sakichi Toyoda and son Kiichiro as well as Toyota

engineer Taiichi Ohno who developed the 5S methodology or what they called the Total Production

System of TPS after World War II.

The three Toyota representatives looked at both Ford Motor Company’s assembly lines and the
inventory process at the supermarket chain Piggly Wiggly. Through analysis at Ford, they did
notice waste along with workers who had to wait for one step to be completed which resulted in
layoffs and rehiring. At Piggly Wiggly supermarkets, their inventory system of ordering only what
was needed based on demand helped them understand and implement the Just-In-Time or JIT
process into the 5S methodology.

4
5S BECOMES A POPULAR LEAN TOOL

 Companies around the world wanted to know exactly

what Toyota was doing that gave it a leg up on its
competitors.

 The 5S’s: Five Keys to a Total Quality Environment,

published by Takashi Osada in 1991 and Hiroyuki

Hirano’s 5S method titled 5 Pillars of the Visual

Workplace: The Sourcebook for 5S Implementation.

5
6
7
 There are basically three
different types of workplaces...

8
9
10
11
Therefore, 5S

12
13
14
 7S

Sort - All unneeded tools, parts and supplies are removed from the
area

Set in Order - A place for everything and everything is in its place

Shine - The area is cleaned as the work is performed

Standardize - Cleaning and identification methods are consistently
applied

Sustain - 7S is a habit and is continually improved

Safety - Improved safety

Spirit - Reliance on the people factor

15
 TOOLS FOR 7S

Shadow Boards Floor Markings Signs

Labeling Industrial printers 5S Tags

16
 7S
Examples

BEFORE AFTER
17
7S Examples

18