The 5-S System

Workplace Organization

Participant Handout Material

 Outline
– Introduction
– Objectives/Program Overview
– Creating a 5-S vision
– Workplace observation
– Sort
– Straighten
– Shine
– Standardize
– Sustain
– Workshop summary
Objectives
• Understand the steps to take in
developing an environment
that:
– is Organized
– is Safe
– is Productive
– is capable of smooth work flow
– puts the operator in control
 Program Overview
• Project based
– After learning each step, we will go practice them in sequence
• Workplace observation
– Document current conditions
• Sort
– Red tag process
• Straighten
– Physically rearrange
• Shine
– Clean and remove reasons for contaminants
• Standardize
– Implement visible signals to ensure team understanding
• Sustain
– Develop communication strategies
 Workplace Observation
• Clearly define target area

• Identify purpose and function of target area

• Develop area map

• Show material, people, equipment flow

• Perform scan diagnostic

• Photograph problem areas

• Develop a project display board (area)

 Target Area Vision
Safety
Current Condition Desired Conditions
 Target Area Vision
Product Quality
Current Condition Desired Conditions
 Target Area Vision
Equipment Maintenance
Current Condition Desired Conditions
 Target Area Vision
Work Efficiency
Current Condition Desired Conditions
 Target Area Vision
Inventory Levels
Current Condition Desired Conditions
 Target Area Vision
Information Flow
Current Condition Desired Conditions
Sketch of the Current Work Area
Show flow of people, equipment, and materials with arrows
 Date
Step Item
Determine what is and is not needed
Unneeded equipment, tools, etc. ...are present
Unneeded items are on walls (bulletin boards etc.)
Sort
Items are present in aisleways, stairways, corners, etc.
Unneeded inventory, supplies, parts, materials are present
Safety hazards (water, oil, chemicals) exist
A place for everything…
Correct places for items are not obvious
Items are not in their correct places
Straighten
Aisleways and equipment locations are not identified
Items are not put away immediately after use

Workplace
Height and quantity limits are not obvious
Cleaning and looking for ways to keep it clean
Floors, surfaces, and walls are not free from dirt
Equipment is not kept free from dirt, oil, and grease

Scan
Shine
Cleaning materials are not easily accessible
Lines, labels, and signs are not clean
Other cleaning problems are present
Maintain and monitor the first three categories

Checklist
Necessary information is not visible
All standards are not known and visible
Standardize
Checklists don't exist for all cleaning and maintenance jobs
All quantities and limits are not easily recognizable
How many items can't be located in 30 seconds or less
Stick to the rules
How many workers have not had 5-S training
How many times last week was daily 5-S not performed
Sustain
Number of times that personal belongings were not stored
Number of times job aids are not available or up to date
Number of times last week 5-S inspections were not done
Total

Number of problems found+D13 Rating

None 5
1 4
2 3
3-4 2
5 or more 1
Workplace Scan Score Card
Five "S" Steps

Sort
5

3
Sustain Straighten
2

Standardize Shine
 Sort “Red Tag” Process
• Key idea: “When in doubt, move it out”

• Prepare tags

• Attach red tags to unneeded items

• Remove red tagged items to “Dinosaur

Burial Ground”

• Evaluate (disposition) red-tagged items

 Red Tag Inspection Sheet
Search Look for unneeded furniture Look for unneeded materials
• Floors • Cabinets • Raw material
• Aisles • Benches, tables • Supplies
• Operation areas • Chairs • Parts
• Workstations • Carts • Work in process
• Corners, under equipment Search these storage places • Finished goods
• Small rooms • Shelves • Shipping materials
• Offices • Racks Look for other unneeded items
• Loading docks • Closets • Work clothes
• Inside cabinets • Sheds • Helmets
Look for unneeded equipment Search the walls • Work shoes
• Machines, small tools • Items hung up • Trash cans
• Dies, jigs, bits, • Old bulletin boards • Other
• Conveyance equipment • Signs
• Plumbing, electrical parts • Other _________
 Red Tagged Items Log
Needless Items # of Date Reason for Notes /
(describe) items Tagging Disposition
 Item Disposition List
Use this list to help determine the disposition of each red tagged item, then
transfer the information onto both the red tag and the Needless Item Log

Category Action
Obsolete  Sell
 Hold for depreciation
 Give away
 Throw away
Defective  Return to supplier
 Throw away
Used about once per week  Store in area
Used less than once per month  Store where accessible in plant
Seldom used  Store offsite (or in distant place)
 Sell
 Give or throw away
Use unknown Store until information is found
 Straighten
Make it obvious where things belong

– Lines
• Divider lines
• Outlines
• Limit lines (height, minimum/maximum)
• Arrows show direction
– Labels
• Color coding
• Item location
– Signs
• Equipment related information
• Show location, type, quantity, etc.
 Straighten Check Sheet
Equipment Materials
• Machines • Raw material
• Small tools • Supplies
• Dies • Parts
• Jigs • Work-in-process
• Bits • Finished goods
• Conveyance equipment • Shipping materials
• Cleaning equipment • Cleaning supplies

Furniture Other items

• Cabinets • Charts, graphs, bulletin boards
• Benches, tables • Pens, pencils
• Chairs • Work clothes
• Carts • Helmets
• Shelves • Work shoes
• Racks • Trash cans
Shine
• Clean everything, inside and out
• Inspect through cleaning
• Prevent dirt, and contamination
from reoccurring

– Results in
• Fewer breakdowns
• Greater safety
• Product quality
• More satisfying work environment
Shine Check Sheet
• Ceilings
• Aisles
• Workstations
• Corners, under equipment
• Loading docks
• Walls
• Doors
• Pillars, posts
• Floors
• Machines
• Conveyance equipment
• Plumbing, sinks
• Cabinets, shelves, racks
• Carts, Racks
• Drawers, storage bins
• Fixtures, power boxes
 Shine Cleaning Plan
Task Location Who When Materials/
tools needed
 Standardize
• Establish guidelines for
the team 5-S conditions

• Make the standards and

5-S guidelines visual

• Maintain and monitor

those conditions
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, equipment
• Shine
– Cleaning schedule
– Maintenance tasks
– Checklist of what to look for as
cleaning is performed
 Date
Step Item
Determine what is needed and what is not needed
Unneeded equipment, tools, etc. are present
Unneeded items are on walls (bulletin boards, etc.)
Sort
Items are present in aisleways, stairways, corners, etc.
Unneeded inventory, supplies, parts, materials are present
Safety hazards (water, oil, chemicals) exist
A place for everything…
Correct places for items are not obvious
Items are not in their correct places
Straighten
Aisleways and equipment locations are not identified
Items are not put away immediately after use

Workplace
Height and quantity limits are not obvious
Cleaning and looking for ways to keep it clean
Floors, surfaces, and walls are not free from dirt
Equipment is not kept free from dirt, oil, grease

Scan
Shine
Cleaning materials are not easily accessible
Lines, labels, and signs are not clean
Other cleaning problems are present
Maintain and monitor the first three categories

Checklist
Necessary information is not visible
All standards are not known and visible
Standardize
Checklists don't exist for all cleaning and maintenance jobs
All quantities and limits are not easily recognizable
How many items can't be located in 30 seconds or less
Stick to the rules
How many workers have not had 5-S training
How many times last week was daily 5-S not performed
Sustain
Number of times that personal belongings were not stored
Number of times job aids are not available or up to date
Number of times last week 5-S inspections were not done
Total

Number of problems found+D13 Rating

None 5
1 4
2 3
3-4 2
5 or more 1
 Sustain
Determine the methods your team will
use to maintain adherence to the
standards

• 5-S concept training

• 5-S communication board
• Before and after photos
• One point lesson
• Visual standards and procedures
• Daily 5-minute 5-S activities
• Weekly 5-S application
 Review and Summary
• List each of the 5-S steps
• Describe the “30-second test”
• Why is total employee involvement
so important?
• What is management’s role?
• Briefly describe each step in the 5-S
system
• How do you intend to use this
information?