5-S Implementation

Why Lean?

• The need for fast, flexible processes that give customers what they want, when they want it, at the highest quality and affordable cost.

• Eliminates waste that contributes to errors, defects and injuries in the workplace!

What are the 5-S’s???

• 1) Sort * clear out rarely used items, by red tagging

• 2) Sweep * clean it • 3) Straighten * organize and label ( a place for everything)

• 4) Schedule * Create rules to sustain the first 3S

• 5) Sustain *Use regular management audits to stay disciplined

1) SORT

• Definition-– To Sort out necessary and unnecessary items.

– To store often used items at the work area, infrequently used items away from the work area and dispose of items that are not needed.

• Why-– Removes waste

– Safer work area

– Gains space

– Easier to visualize the process

• Things to remember-

– Start in one area, then sort through everything

– Discuss removal of items with all persons involved

– Items that cannot be removed immediately should be tagged

SORT

• CATEGORIZE NECESSARY ITEMS:

• RARELY USED• OCCASIONALLY USED• FREQUENTLY USED

DIVIDE ITEMS INTO TWO CATEGORIES:

BAD

UNNECESSARY NECESSARY

2)SWEEP

• Definition-– To keep your area clean on a continuing basis.

• Why-– To prevent the area from getting dirty in the first place, so we don’t have to clean it up

afterward.

– A clean workplace is indicative of a quality product and process.

– Dust and dirt cause potential health hazards.

• Things to remember-– Sweep / Vacuum– Dust / Mop– Polish / Paint

SWEEPBUILD PRIDE IN WORK

AREAS

BUILD VALUE IN EQUIPMENT

ELIMINATE DIRT

SWEEP

CLEAN

3)STRAIGHTEN

• Definition-• Arrange all necessary items.

• A place for everything and everything in its place.

• Why-• Visually shows what is required or is out of place.

• More efficient to find items/documents (silhouettes/labels).

• Saves time,not having to search for items.

• Shorter travel distances.

• Things to remember-• Keep things used together-kept together.

• Use labels, tape, floor markings, signs, shadow outlines.

• Sharable items keep at central location (eliminated excess)

STRAIGHTEN

IDENTIFICATION LINES

4)Schedule

• Definition-• To maintain guidelines-Sort, Straighten and Sweep

• Why-• Prevents regression back to an unclean/disorganized environment (return items where

they belong)

• Things to remember-• Develop schedules, checklists

• Periodically evaluate area using 5”S” spreadsheet.

• Continually improve neatness

SCHEDULE

PREVENTIVE:

SORTING

STRAIGHTENINGCLEANLINESS

ASSIGN “3S” RESPONSIBILITIES

nnnnnam

Items neat?

Pallets stacked?

3.0

3.2

3.3

Aisles clean?

Schedule filled out?

3.4

4.1

Check on “3S” Maintenance Level

5 Point Checklist 5 Minute 5S 9:00-9:05am

1S-sort

2S-straighten

Yes

no

3S-sweep

4S-schedule

Yes

Yes

5S-sustain Yes

Integrate duties into regular work duties

Who is scheduled to Sort, Straighten and Shine?

X

X x X X ?

Joe Sally Bob

X X X

Y Y Y

5) SUSTAIN

• Definition-To maintain discipline, we need to practice and repeat until it becomes a way of life.

• Why- To build “housekeeping” into every day process.

• Things to remember - Training everyone is vital.

Involvement from all is necessary.

Commitment and discipline toward housekeeping is essential in taking the first step

in being World Class.

SUSTAIN

5 “S” RATING

0= Poor (Unacceptable)

1= Marginal

2= Satisfactory

3= Good

4= Excellent

5= Operating Room Conditions

(World Class Environment)

Benefits of 5-S Implementation:

• A cleaner workplace is a safer workplace

•Contributes to how we feel about our product, process, our company and ourselves

•Provides a Customer Showcase to promote our business

•Quality will improve

•Productivity, Efficiency and Effectiveness will increase

Are you on the bus?