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TOYOTA 5S SYSTEM
SCM 462
Dr. Ron Lembke
The 5S
 Seiri – sort (housekeeping)
 Seiton – set in order (workplace organization)
 Seiso – shine (Cleanup)
 Seiketsu – standardize (Cleanliness)
 Shitsuke – sustain (Discipline)
 Visual workplace
Benefits of 5S
 Reduce waste hidden in the plant
 Improve quality and safety
 Reduce lead time and cost
 Increase profit
HGTV, anyone?
Toyota 5 s system
Seiri – sort
 Ensuring each item in a workplace is in its
proper place or identified as unnecessary and
removed.
 Sort items by frequency of use
 Get rid of unnecessary stuff
 Bare essentials for the job
 Red Tag system
 Can tasks be simplified?
 Do we label items, and dispose of waste frequently?
Red Tags
Seiton – set in order
 Time spent looking for things, putting away
 Arrange materials and equipment so that they
are easy to find and use
 Prepare and label storage areas
 Use paint, outlines, color-coded
 Consider ergonomics of reaching items
 Frequent, infrequent users
 “a place for everything and everything in its place”
Julia’s Kitchen
Lean Workspace
My Favorite Guru
 When you think of
something, put it on
a list.
 Check your lists
regularly.
 Don’t get sucked
into email
distractions.
 Get rid of the clutter
you don’t need.
Seiso – shine
 Repair, clean & shine work area (“Everyone is
a janitor”)
 Important for safety
 Maintenance problems such as oil leaks can
identified before they cause problems.
 Schedule for cleaning, sweeping, wiping off
 Cleaning inspection checklists
 Workspace always ready to work
 See workspace through customers’ eyes
Starbucks’ Simple Furnishings
Starbucks clutter
Image: Graham Garfield, Chicago-L.org
Seiketsu – standardize
 Formalize procedures and practices to create
consistency and ensure all steps are
performed correctly.
 Prevention steps for clutter
 Otherwise improvements from first 3 lost
 Everyone knows what they are responsible for
doing, when and how
 Visual 5S – see status at a glance
 Safe apparel, no wasted resources
Shitsuke – sustain
 Keep the processes going through training,
communication, and organization structures
 Allocate time for maintaining
 Create awareness of improvements
 Management support for maintaining
 Training, rewards
Visual Controls - Andon
 Inidcators for tools, parts, and production
activities
 Placed in plain sight of all workers so
everyone can understand status of system at a
glance
 If a machine goes down, or a part is defective
or delayed, immediate action can be taken
Texas Die Casting
 Set-up Cage
www.tocforme.com
Texas Die Casting
 Set-up Cage
Texas Die Casting
Office Entryway
Texas Die Casting
Misc. Table
Texas Die Casting
 Supply Cabinet
Implementation
 Gradually – too fast unsustainable
 During slow time
 Importance of training, Management
commitment
 Before & After photos
 Change of mentality, not campaigns and
slogans. Old way no longer OK
 MBWA, Patrols

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Toyota 5 s system

  • 1. TOYOTA 5S SYSTEM SCM 462 Dr. Ron Lembke
  • 2. The 5S  Seiri – sort (housekeeping)  Seiton – set in order (workplace organization)  Seiso – shine (Cleanup)  Seiketsu – standardize (Cleanliness)  Shitsuke – sustain (Discipline)  Visual workplace
  • 3. Benefits of 5S  Reduce waste hidden in the plant  Improve quality and safety  Reduce lead time and cost  Increase profit
  • 6. Seiri – sort  Ensuring each item in a workplace is in its proper place or identified as unnecessary and removed.  Sort items by frequency of use  Get rid of unnecessary stuff  Bare essentials for the job  Red Tag system  Can tasks be simplified?  Do we label items, and dispose of waste frequently?
  • 8. Seiton – set in order  Time spent looking for things, putting away  Arrange materials and equipment so that they are easy to find and use  Prepare and label storage areas  Use paint, outlines, color-coded  Consider ergonomics of reaching items  Frequent, infrequent users  “a place for everything and everything in its place”
  • 11. My Favorite Guru  When you think of something, put it on a list.  Check your lists regularly.  Don’t get sucked into email distractions.  Get rid of the clutter you don’t need.
  • 12. Seiso – shine  Repair, clean & shine work area (“Everyone is a janitor”)  Important for safety  Maintenance problems such as oil leaks can identified before they cause problems.  Schedule for cleaning, sweeping, wiping off  Cleaning inspection checklists  Workspace always ready to work  See workspace through customers’ eyes
  • 14. Starbucks clutter Image: Graham Garfield, Chicago-L.org
  • 15. Seiketsu – standardize  Formalize procedures and practices to create consistency and ensure all steps are performed correctly.  Prevention steps for clutter  Otherwise improvements from first 3 lost  Everyone knows what they are responsible for doing, when and how  Visual 5S – see status at a glance  Safe apparel, no wasted resources
  • 16. Shitsuke – sustain  Keep the processes going through training, communication, and organization structures  Allocate time for maintaining  Create awareness of improvements  Management support for maintaining  Training, rewards
  • 17. Visual Controls - Andon  Inidcators for tools, parts, and production activities  Placed in plain sight of all workers so everyone can understand status of system at a glance  If a machine goes down, or a part is defective or delayed, immediate action can be taken
  • 18. Texas Die Casting  Set-up Cage www.tocforme.com
  • 19. Texas Die Casting  Set-up Cage
  • 22. Texas Die Casting  Supply Cabinet
  • 23. Implementation  Gradually – too fast unsustainable  During slow time  Importance of training, Management commitment  Before & After photos  Change of mentality, not campaigns and slogans. Old way no longer OK  MBWA, Patrols