Professional Documents
Culture Documents
5S
5S 1
8
• Defect / W ASTES
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
Depa
(Monthly)
rtme
nt
Department Reporting
Information Center
(Plant-wide Reporting)
5S 3
Sort
Straighten
Shine
Standardize
Sustain
5S 4
5S 5
5S 6
5S 7
5S 8
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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5S 18
5S 19
1S
Sor
t
• Segregate What Is Needed, Needed
Later, and Not Needed
• Discard What Is Not Needed
• Segregate Needed Items By Frequency
of Use
5S 20
Where to Perform
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5S 22
5S 23
Item Name
&/or Description:
Classification:
5S --- RED TAG . Raw Material . Machine / Equipment
Ent
box
er
in
#
. Component . Tool / Fitting
in
#
. Defective . Other
Action: Completed:
. Leftover Material
. Eliminate
. Return
box
Ent
er
in
#
(--
E-
X
X
L
C
X
E
Year Month Day Year Month Day File completed Tag at __ ____ __
5S 24
Sort
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5S 26
5S 27
5S 28
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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5S 34
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
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Before
After
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5S 41
3S
Shine
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Why Shine?
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5S 45
5S 46
Shine Targets
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5S Assessment
Location Being Audited: {Enter Location here}
(place cursor in red corner for INSTRUCTIONS)
Sort
· Review excess inventory, supplies,
performing operations are removed from the work area.
Score Sheet
parts, or materials
· Identify existence of safety hazards Only tools and products are present at workstation
(water, oil, chemical, machines,
extension cords, etc.)
Straighten
locations
· Aisle ways, workstations, equipment them to toppling over. Storage areas are provided for all
necessary items at POUS (Point-Of-Use Storage).
0
locations are indicated
· Items are put away immediately No items are placed on top of machines, cabinets, and
after use equipment. Unidentified items can not lean against walls
· Inventory or WIP height and quantity or columns.
limits are obvious
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.
· Floors, walls, stairs, and surfaces are Aisle ways maintenance: Aisles are always free of
materials and obstructions; nothing is placed on the lines
free of dirt, oil and grease
· Equipment is kept clean and free of and objects are always placed at right angles to the aisles 0
dirt, oil, and grease where appropriate.
Shine
· Cleaning materials are easily Equipment painting: All machines and equipment are
accessible
· Lines, labels, signs, etc. are clean
neatly painted; equipment cleaning schedule developed 0
and posted for each major piece of equipment.
and not damaged
· No other cleaning problems Workbench and desk control: Kept free of objects
(of any kind) are present 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
· Necessary information is visible visibility.
· All standards are known and visible
Standardize
stored in a neatly maintained and dirt. Cleaning of floors is done routinely -- daily at a 0
location minimum—posted schedule.
· Job aids are current and readily 5S control and maintenance: There is a disciplined
accessible system of control and it is maintained at the highest
· Routine 5S Implementation Audit possible level. It is the responsibility of every one to
is performed until sustained maintain this system and environment. Documentation exist 0
indicating cleaning responsibility for each team member in
the work area.
Legend: <2 (RED) 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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5S 59
January 2007 June 2007
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?
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Now, what would you do?
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Remember
5
1S
2S
Sort
Straighten
S
3S Shine
4S Standardize
5S Sustain
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