5S BASIC TRAINING

What is 5S and why do we want to do it?

 5S is a set of techniques providing a standard approach

to housekeeping within Manufacturing.

It is often promoted as being far more than simply housekeeping

and some of the elements described below certainly have broader implications. It originated, as did most of the elements of JIT, within Toyota. A cornerstone of 5S is that untidy, cluttered work areas are not productive. As well as the physical implications of junk getting in everybody's way and dirt compromising quality, we are all are happier in a clean and tidy environment and hence more inclined to work hard and with due care and attention.

What is 5S & Why we need 5S? 5S is short for:

1. 1. 5s Seiri (Sort) 2. Seiton (Set) 3. Seiso (Shine)

4. Seiketsu (Standardisation) 5. Shitsuke (Sustain) 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts. 5S is one of the activities that will help ensure our companys survival.

5S
1. Sort - All unneeded tools, parts and supplies are removed from the area
Going through all the tools, materials, etc., in the plant and work area and keeping only essential items. Everything else is stored or discarded

2. Set in Order - A place for everything and everything is in its place

Arrangement of the tools, equipment and parts in a manner that promotes work flow. For example, tools and equipment should be kept where they will be used, and the process should be set in an order that maximizes efficiency. For every thing there should be place and every thing should be in its place.

 3. Shine - The area is cleaned as the work is

performed
Systematic Cleaning or the need to keep the workplace clean as well as

neat. At the end of each shift, the work area is cleaned up and everything is restored to its place. This makes it easy to know what goes where and have confidence that everything is where it should be. The key point is that maintaining cleanliness should be part of the daily work - not an occasional activity initiated when things get too messy.

 4. Standardize - Cleaning and identification methods are consistently

applied
Standardized work practices or operating in a consistent and standardized fashion. Everyone knows exactly what his or her responsibilities are to keep above 3S's.

5. Sustain - 5S is a habit and is continually improved

Refers to maintaining and reviewing standards. Once the previous 4S's have been established, they become the new way to operate. Maintain the focus on this new way of operating, and do not allow a gradual decline back to the old ways of operating. However, when an issue arises such as a suggested improvement, a new way of working, a new tool or a new output requirement, then a review of the first 4S's is appropriate.

th 6

S
dangerous conditions

Also - Work areas are safe and free of hazardous or

6S - Safety is sometimes added. There will have to be continuous

education about maintaining standards. When there are changes that will affect the 5S program such as new equipment, new products or new work rules-it is essential to make changes in the standards and provide training. Companies embracing 5S often use posters and signs as a way of educating employees and maintaining standards.

Some 5S Examples

Before 5S

After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)

Before 5S

After 5S

Before 5S

After 5S

Before 5S

After 5S

5S Examples - Sort, Set in Order

See the difference? 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order - A place for everything and everything is in its place

5S Examples - Shine

3. Shine - The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.

5S Examples - Standardize
4. Standardize - Cleaning and identification methods are consistently applied

Departments have weekly 5S tours

Every job has duties that use Sort, Set in Order and Shine

We all have common duties to do our part to keep all areas of the plant in shape - breakroom, restrooms, locker area, parking lot, etc

5S Examples - Sustain
5. Sustain - 5S is a habit and is continually improved
5S is a simple concept with powerful results. You will get additional information on 5S so that you will be well equipped. Our experience is that the more we do 5S the better the work environment becomes: cleaner, safer, more organized, the work is easier, less confusion and less stress. Use the 5S (work\home\play) - The more you use it the easier it becomes and life just gets better and better.

The Good, Bad and the Ugly

First the Bad and the Ugly - Life Without 5S

The Good

Summary
5-S is for you.
Clean-up and organize your work area every day so that each new day is easier and safer than the day before

Share your input with your leaders so that the tools you need will be available to you, increasing your efficiency.
Volunteer to help with the 5S tours and 5S events. Take a good look around...Imagine zero waste/zero confusion!