Improving workplace #lean #CI

1. Continuous Improvement
5S Training

2. 5S Training Objectives
By the end of this module, the participants should be able to:
• Define and understand the importance of 5S methods.
• Put 5S into practice in your work area.
• Identify and overcome the barriers of productivity.
• Improve QUALITY of work.
• Practice efficiency at all times.
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3. 5S Fundamentals
“Misconception about 5S is that it is just housekeeping,
however it is more than just housekeeping”.
What is 5S?
• It is the name of the workplace organization method that uses a list of five Japanese
words: Sort, Shine, Signpost, Standardize and Sustain
• It is a structured program that systematically achieve total organization, cleanliness
and standardization in the workplace.
• It maintains visual workplace (visual controls and information Systems).

4. 5S Methodology
S1 Sort and Discard eliminates
non-essential items from the
workplace. A pleasant and
efficient workplace is created.
S1 ort and Discard
S2 Shine and Inspect removes dirt,
grime and dust from the workplace by
thoroughly cleaning equipment, floors
and walls.
S2 hine and Inspect
S3 Signpost and Order ensures that there is a place for everything
and that everything is in its place. Everything must be sign posted so
that it is visually clear where things belong.
S3 ignpost and Order
S5 Sustain refers to the discipline required to ensure that S1, S2,
S3 and S4 are properly maintained and improved.
S4 Simplify and Standardise by applying ergonomic
principles to the workplace to eliminate wasteful
activities and make work safer and easier.
S5 ustain
S4
implify
and
Standardise

5. 5S Example - Workplace
Before
After

6. 5S Example - Office
Before
After

7. 5S Example - At home
Before
After

8. S1 – Sort & Discard

9. S1: Sort and Discard
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Sort and Discard distinguish between necessary
and unnecessary items and discard items that are
not needed & unnecessary from the workplace.
“Keep only what is needed, only in the amounts needed and
only when needed”.
Why Sort and Discard?
• Removes waste from the workplace
• A clutter-free and efficient workplace is created.
• Makes the work place safer
• Creates more space by getting rid of unneeded
items in the work place.
• Makes it easier to visualise the process

10. S1: Sort and Discard Red Tag Technique
Red Tagging is a visible way to identify what is not needed in the workplace. Red Tags ask “Why
am I here?” and supports the first - “Sort and Discard”.
The Red Tag Technique involves the following steps:
4. Sort through the Red Tag items; dispose of those which are truly superfluous. Other items
can be eliminated at an agreed interval when it is clear that they have no use. Ensure that all
stakeholders agree.
5. Determine ways to improve the workplace so that unnecessary items do not accumulate.
6. Continue to Red Tag regularly.
1. Establish the rules for distinguishing between
what is needed and what is not.
2. Identify needed and unneeded items and attach
Red Tags to all potentially unneeded items.
Write the specific reason for Red Tagging and sign and date each tag.
3. Remove Red Tagged items and temporarily store them in an identified holding area.

11. S1: Sort and Discard – Red tagging Example
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12. S2 – Shine & Inspect

13. S2: Shine and Inspect
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Shine and Inspect means thoroughly cleaning
grime,the workplace, removing stains, spots,
debris and eradicating sources of dirt.
Why Shine and Inspect?
• A clean workplace is indicative of a quality
product and process.
• Dust and dirt cause product contamination
and potential health hazards.
• A clean workplace helps to identify
abnormal activities.
“Systemic cleaning and keeping the workplace neat should be
the order of the day, not an occasional activity initiated when
things go messy”.

14. S2: Shine & Inspect
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15. S3 Signpost & Order

16. S3: Signpost and Order
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Signpost and Order ensures that there is a
designated and demarcated place for each
and every item.
“A place for everything and everything in its place”.
Why Signpost and Order?
• Keep things used together, kept together
• Apply principles of Visual Management.
• Eliminates time spent looking for items
• Eliminate the need for excess items.
• To arrange the workplace in a manner than promotes workflow

17. S3: Signpost and Order Example
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18. S4 Standardise & Simplify

19. S4: Standardise and Simplify
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S4 Standardise and Simplify focuses on creating a simplified consistent
approach with which tasks and procedures are performed in the
workplace, as well as maintaining a clean and healthy work environment.
Why Standardise and Simplify?
• Keep the workplace neat enough for
visual identifiers to be effective in
uncovering hidden problems.
• Develop a system that will enable
everyone in the workplace to see
problems when they occur
• To define the standards by which
employees must measure and maintain
cleanliness
“To maintain a high standard of workplace
organisation by keeping everything clean and orderly

20. S4: Standardise and Simplify
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21. S5 Sustain

22. Do – S5 Sustain
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Sustain making a habit of properly maintaining the
correct procedures from the previous four steps and
strive for further improvement
Why Sustain?
• To sustain Sort, Shine Signpost activities
everyday.
• To maintain what has been accomplished.
• Develop a system that will enable everyone in
the workplace to see problems when they occur
• Team spirit and discipline are developed.
• Enhance operation effectiveness in a better
working environment
“Part of daily work and make a habit of maintaining
established procedures”.

23. 5S Benefits

24. Advantages of 5S
5S Implementation has the following benefits
• Increase space
• Improved productivity
• Elimination of time spent looking for things
• Accidents and mistakes minimised
• Work area easier to manage
• A clean and tidy workplace leads to improved employee well being and
Increased motivation
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25. 5S Implementation
Process

26. 5S Implementation Process
Identify
team
members
Select Area
Identify
Champion
Take Before
Pictures
Conduct 5S
Exercise
Conduct
Regular
Audits
Take After
Pictures
Conduct
Compliance
Reviews
Recognise
& Reward

27. Way Forward
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Actions to be taken immediately after 5S training
o Identify 5S Champions
o Establish Red-tagging holding areas
o Conduct red-tagging
o Identify the Abnormalities

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29. Thank you