5S

1. 5S
How to implement

2. Objective
The objective of this presentation is to introduce the
5S and what it can contribute to an organization and
how to implement it

3. Table of contents
Part 1
Introduction
Part 2
How to implement
Part 3
How to motivate people to practice 5S

4. INTRODUCTION
Part 1

5. What is 5S ?
5S is a visual method of workplace organization
It is a systemized approach to organized areas

6. Importance of 5S
5S helps to improve
Quality - Prevent errors
Productivity - Eliminates waste
Safety - Prevent accidents
Equipment reliability - Eliminate maintenance breakdowns

7. Importance of 5S contd….
 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

8. Why Implement 5S ?
 Shortens the span times
 Reduces the 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

9. Why Implement 5S ? Contd……
 Makes work easier to accomplish
 In short, an organized work space
 Enhances safety
 Improves quality
 And reduces cost and cycle time

10. THE ‘5S’ 1S - Sort
2S – Set in
Order
3S - Shine
4S -
Standardize
5S - Sustain

11. 1S – Sort
Sort is an action to identify and eliminate all
unnecessary items from your workplace
“when in doubt, through it out”

12. Sorting Policies
 Eliminating obstacles to make work easy
 Eliminate the need to take care of unnecessary items
 Provide no chance of being disturbed with unnecessary items
 Prevent accumulation of unnecessary items

13. Sorting and evaluation criteria
Sorting criteria
Low use
Things not used in the past year Dispose properly
Things used only once in past 6-
12 months
Store at a distance
Average use
Things used only in the past 2-6
months
Store in a central place
Things used more than once a
month
Store in a central place
High use
Things used once a week
Store near work site or carried
by the person
Things used everyday Store near work site or carried
by the person
Things used every hour Store near work site or carried
by the person

14. 2S Set in Order
Set in Order Is an action to put all the necessary items in
good order
“A place for everything and everything in its place”

15. Set in Order policies
 Make things easy to locate, easy to put away, readily apparent if
missing
 No wasted time looking for tools or documents, they are identified
and on hand when needed
 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
 Arrange the immediate work area layout to minimize twisting,
especially applicable for bench work.

16. 3S Shine
Shine is also an action to clean your
workplace thoroughly, clean everything
inside and out
“inspection through cleaning”

17. Shine policies
• Don’t wait until things get dirty. Clean your workplace including
machines and equipment, tools and furniture regularly so that they
do not have a chance to get dirty
• 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
• A bright, clean, organized work area that promotes confidence,
quality and on time delivery

18. 4S Standardize
Standardize is a condition where high standard of good
house keeping is maintained, so there is no dust and
rust anywhere
“everything in a state of readiness”

19. Standardize Policies
• Document the standard method for workplace organization so we
always do things in the same way
• 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

20. 5S Sustain
Sustain is a systemized approach to maintain discipline
through systems and supportive culture
“Launching quality with persistence”

21. Sustain Policies
• Without sustaining the first 4S will die
• It promotes a continuous improvement environment
• Ever improving quality, cycle times, on time commitments; high
motivation and recognition for excellence
• Visuals help tell at-a-glance the state of the workplace (signs, posters,
arrows, charts, schedules etc.)
• Plan for success

22. IMPLEMENTATION
Part 2

23. Getting started….
• Set 5S goals
• Appoint 5S champion(s)
• Post 5S team roaster with leader, champions, and backups for
calibration, shelf life, job supplies
• Create a 5S holding area

24. SORT
eliminate nonessential items from the workplace
Target outcome
An uncluttered workplace

25. Action steps
1. Identify a 5S project area and take “before” pictures
2. Review sorting criteria
3. Create a local red tag area
4. Tag, record, and remove red tagged items
5. Identify items can/cannot be red tagged
6. Make team and give 5S responsibilities
7. Establish sorting criteria
8. Allocate time for sorting
9. Take “after” pictures

26. Progress check
1. “Before” pictures taken
2. Anything from the work area that’s not in use has removed
3. “After” pictures taken

27. Set in Order (planning phase)
Evaluate the workplace and add smart workplace features
Target Outcome
A workplace that is visually instructive and is the source of minimal
waste and human errors

28. Action steps
1. Create a current state workplace diagram
2. Evaluate current workplace
3. Create a future state workplace diagram
4. Get approval for change
5. Target benefits of proposed changes clearly defined

29. Progress check
1. Improvement opportunities listed, discussed, and prioritized
• waste reduction ideas(e.g., excess motion, material handling etc.)
• error reduction ideas (e.g., checklists, visual instructions, or color coding)
• Ideas for making the workplace more visually instructive
• Ideas to overcome challenges and problems identified

30. Set in Order (implementation phase)
Create a well ordered, visually instructive work place
Target Outcome
A workplace that is visually instructive and is the source of minimal
waste and human errors

31. Action steps
1. Take “before” pictures
2. Implement workplace changes
3. Mark locations by creating addresses and applying labeling, marking
and color coding
4. Take “after” pictures

32. Progress check
1. “Before” pictures taken
2. Plant marking standards determined
3. 5S team clear on plan (e.g., goals/tasks/assignments)
4. Reorganization tasks completed (e.g., equipment moved, inventory
relocated)
5. Marking and identification tasks completed
6. “After” pictures taken

33. Shine
Define clean
Target Outcome
A clean workplace

34. Action steps
1. Define clean
2. Identify target area for cleaning
3. Take “before” pictures
4. Clean the work area
5. Take “after” pictures
6. Record key cleaning points
7. Inspection

35. Progress check
1. Team has established their definition for ‘clean’ in the target
workplace
2. Housekeeping staff consulted about cleaning
3. Cleaning tasks completed
4. Observation shared among team members about inspection activity

36. Standardize
Establish standards to maintain 5S improvments
Target Outcome
Develop procedures, checklists, and other mechanisms established to
maintain a work environment that is visually instructive, has minimal
waste and human error, and is clean, uncluttered and organized

37. Action steps
1. Update documentation to update changes
2. Make sure all stakeholders are aware of the new standards-inform
and educate

38. Progress check
1. Documents created or updated, for example
• Workplace diagrams
• Flow charts
• Procedures
• Work instructions
Job aids
2. Information and/or training provided to stake holders to assure
understading

39. Sustain
Monitor, expand and refine 5S results
Target Outcome
A workplace that automatically restores orders, regulates activity, and
continuously improves

40. Action steps
1. Monitor processes established during S4 standardize
2. Expand 5S efforts to other work areas
3. Evaluate 5S efforts and continuously improve
4. Recognize and reward strong efforts

41. Progress check
1. Sustain methods clearly defined, with responsibilities and target
dates identified
2. Sustain actions implemented, for example
• 5S teams present projected results
• Company leaders conduct 5S audits to see accomplishments and
opportunities

43. How to motivate people to
practice 5S
Part 3