This presentation is designed as a gentle intro to the concept of 5s and shows the benefits clearly.
It is designed to be followed by practical exercises on the shop floor / office
Please feel free to comment, all feedback is appreciated
2. Objectives
To understand the importance of 5s to
our Lean initiatives.
To know what the 5S’s are and know the
key benefits of each.
To be able to participate in group and
individual 5s activities.
5. Sort
• Everything at the workplace should be
related to the work being done there.
• Leave only what is needed, in the
amounts needed.
• Remove all items that are not needed
for current / regular production.
6. Benefits of sort
• Keeps the work area clean and clutter free.
• Reduces the risk of accidents and near
misses.
• Creates extra work space where necessary
items can be placed.
• Reduces the time spent searching for tools
and equipment.
• Less clutter results in a more pleasant
working environment.
7. • A method of identifying potentially
unneeded items in the work area.
• Ensures that no needed items are
accidentally disposed of.
• Allows us to evaluate the usefulness of
an item by segregating it when we are
unsure of it’s use.
Red Tagging
8. • The three questions to ask
- Is this item needed?
- If it is needed, is it needed in this quantity?
- If it is needed, is this the best location for it?
• Holding areas
- A safety net between questioning whether
something is needed and getting rid of it.
- Items are held for a set time (30 days?).
- Notices are put out for unknown items so that they
may be claimed by anybody who has a genuine need
for them.
After the allocated time, unwanted items are disposed of.
Red Tagging
9. • Define the necessity of the item in order to
perform the work required on a day to day
basis.
- If it isn’t needed it should be disposed of.
• Determine the frequency with which the item is
needed.
- If it’s needed infrequently it can be stored away from the
work area.
• Decide the quantity of the item required to
perform the regular work.
- Excess items can be disposed or stored away.
Red Tagging Aims
10. • Establish red tag holding area.
- An area is set aside to store tagged items which need
further evaluation
• Red tag items.
- the 5s team goes through the 5s area and red tags all
items they believe can be removed from the area or
disposed of.
- Any items that we are unsure of are also red tagged.
- All tagged items are listed on a log sheet with a location
and description.
- this log is circulated throughout the company so that
anybody may claim an item if it is required.
Red Tagging Steps
11. • Evaluate the red tagged items.
- Decide if items should be disposed of, or kept for a
period to determine their necessity.
• Remove questionable items to the red tag
holding area.
- Assign responsibility of the area to the team.
- Circulate item log.
- After 30 days the items should be reviewed a final
time. Log any items which have been removed
back to the work area due to being required.
- Dispose of, store away from the area, or sell any
items left after the time period has passed.
Red Tagging Steps
12. • Defective tools or inventory.
• Obsolete tooling, jigs, inventory.
• Worn out tools.
• Broken equipment.
• Outdated posters, signs & notices.
• Excessive quantities of
materials, tools, supplies.
• Excessive personal items.
Examples of Unneeded Items
14. • Everything that remains after Sort
should have a place.
• Arrange things so that they are easy to
use, and label them so that anyone can
find them and put them away.
• Place frequently used items closer to
you than those used less often.
Set
15. • For every item in the workplace we will
need to:
- Identify it.
- allocate a place to store it.
- Determine how much / how many to store at the
workplace.
- Create a visual marker for it.
Set
16. • Decide where to keep needed items.
- Keep frequently used items at point of use.
- Screwdrivers next to screws, order of use.
• Organise items in a way that makes sense.
- Make it easy for anyone to find them, use them and
put them back after use.
- Make it obvious when items are not in their correct
place.
- Use visual indicators such as area photos to show
the area in it’s correct state.
Set
17. • Safety is improved.
- Ergonomic storage of tools and materials.
- Clean, clutter free floors and walkways.
• Tools and parts are stored properly so
there’s less damage.
• Less waste of motion – reduced searching
for materials, tools & supplies.
• Reduced inventory of
materials, supplies, leaving more free
space.
• A more pleasant working environment.
Benefits of Set
18. • Standardisation
- Creating a consistent method of carrying out
tasks and procedures.
• Visual controls
- Used to identify standards.
- Examples;
• Where items belong and how many belong there.
• Standard procedures.
• Area photographs.
• Colour coding
• Restock markers
Keys to Set
19. • Used for identifying locations on floors
and walkways.
• Segregate working areas from
walkways.
• May show:
- Flow direction.
- Storage location.
- Hazards or safety devices.
- Areas to be kept clear.
Painting / Marking
20. • Colour coding
- Shows which parts, tools etc are used for which
purpose, or which items are used together.
- Used for storage containers.
- Used to set items to a specific work area.
• Outlining
- Shows what parts and tools go where.
- Shadow boards.
• Cross hatching
- Areas to be kept clear.
Painting / Marking
23. • Clean the area
- Remove all dust, dirt
- Floors clean
- Work surfaces clean
- Inside all cupboards, drawers etc clean
- All tools clean
• A clean workplace suggests quality
work!
Shine
24. • Safety
- No debris, fluids or materials on floor to cause
slips, trips or falls
• Morale
- Dirty workplaces are unpleasant to work in.
- Clean workplaces foster pride in what we do.
• Customer service / satisfaction
- Customers touring a clean and organised
factory are more likely to see us as a quality
driven business and want to work with us.
Benefits of Shine
25. • Machine reliability
- Easier to identify issues on clean
machines, meaning they can be addressed
sooner.
- Cleaning is a form of inspection.
• Equipment / Tools
- Clean equipment functions more effectively.
- Easier to spot damage or wear on clean
equipment and tools than on dirty ones.
Benefits of Shine
27. • All procedures, practices and activities
established with the first 3s’s occur
consistently and at regular intervals.
- There is no point in going through Sort, Set or
Shine if we are going to let things go back to the
way they were.
• Makes implementing Sort, Set and
Shine a daily habit so that conditions are
maintained at the desired level.
Standardise
28. • Safety
- Walkways and floors are kept clear and hazard
free.
• Efficiency
- Storage areas remain organised.
- Materials, tools and equipment remain organised
and cared for.
• We maintain all the benefits gained from
Sort, Set and Shine.
• We have a template for expanding the 5s
area across the whole plant.
Benefits of Standardising
29. • Decide who is responsible for each
activity / area.
- Activity charts, Checklists, Schedules.
• Integrate 5s into daily work activities.
- 5 minute 5s, daily cleaning / inspection.
• Ensure 5s conditions are being
maintained.
- 5s audits, 5s walk rounds.
Establishing the Habits
31. • 5s Audits.
- Checking the level of effectiveness of the first 3s’s.
- Use traffic light system, green, amber, red, to display
current state of area.
- To be conducted routinely by operators, managers and
directors.
• 5s Walk rounds.
- Weekly tours by managers / directors to note
improvements made and to encourage any further
improvements that can be made.
Monitoring
32. • Having the discipline to maintain the
correct standards over time.
• Creating conditions, and an atmosphere
that encourages the constant practice of
good habits, and the elimination of bad
ones.
• Creating a culture which constantly
looks for improvement opportunities.
Sustain
33. • A workforce that is trained and aware of the
benefits of 5s.
• Time allowed to practice and maintain.
• Organised, focussed effort.
• Management support and drive.
• Efforts that are recognised, and
appreciated.
• All improvements need to be beneficial and
purposeful.
Keys to Success
36. • Sort – To put things in order.
- Remove what is not needed.
• Set – Arrange for ease of use.
- Place things in a way that they are easily accessible
whenever they are needed.
• Shine – Clean.
- Keep area clean and free from rubbish.
• Standardise.
- Best practices to be used throughout.
• Sustain – Commitment and self discipline.
- Develop a culture of 5s and improvement.
The 5S’s
37. • Reduced set-up times.
• Reduced searching
times.
• Increased floor space.
• More pleasant
working area.
• Employees enabled to
lead improvements.
• Less frustration.
• Less wasted labour.
• Better equipment
reliability.
• Higher quality.
• Lower cost.
• Safer working area.
• & many, many other
benefits.
Benefits
38. • Challenge traditional ideas.
• Find ways to make the impossible
possible.
• Don’t accept excuses.
• Go for the simple solution, don’t
overcomplicate things.
• Correct mistakes right away.
• Involve everybody.
• Improvement never ends!
Keys to Success
