5S Techniques by Operational Excellence Consulting

© Operational Excellence Consulting. All rights reserved.
Sort
Set In OrderShine
Standardize
Sustain

© Operational Excellence Consulting. All rights reserved. 2
Objectives
• Understand the benefits of working in a clean
and neat environment
• Define the 5S principles, and identify visual tools
• Explain how to apply the 5S principles and
visual tools to enhance workplace organization
• Learn how to kick start and launch a 5S initiative
• Define the critical success factors for 5S
implementation
NOTE: This is a PARTIAL PREVIEW. To
download the complete presentation, please
visit: http://www.oeconsulting.com.sg

Outline
• Introduction to 5S
• 5S Provides a Solid
Foundation to Lean
Implementation
• Types of Waste in the
Workplace
• What is 5S?
• Benefits of 5S
• 5S Principles - Step By Step
• How to Conduct a Red
Tagging Exercise
• Creating a Visual Workplace
• Applying 5S to:
 Safety
 Quality
 Equipment Reliability
 Productivity
• 5S in the Office
• How to Implement 5S
• How to Sustain 5S
• 5S Audit System
• Supporting Lean Tools for 5S
• Critical Success Factors

Introduction to 5S
• 5S is a structured program
to implement workplace
organization and
standardization
• 5S represents five
disciplines for maintaining
a visual workplace
• 5S is a foundation to
Kaizen and Lean
implementation, e.g. TPM
Sort
Set In OrderShine
Standardize
Sustain

5S Lays the Foundation for a Lean
Enterprise
Productivity
5S
Heijunka Standardized Work Kaizen
Just-In-Time
• Continuous flow
• Takt time
• Pull system
• Flexible workforce
Jidoka
• Separate man &
machine work
• Abnormality
Identification
• Poka yoke
•Visual Control
Goals:
highest quality,
lowest cost, shortest lead times
Involvement

5S Establishes a Baseline for Kaizen
Activities
Standardize
Standardize
StandardizeKaizen
Kaizen
Kaizen
P
DC
A
Kaizen (改善) =
Continuous Improvement
Plan
DoCheck
Act

5S
Suggestion
System
Continuous
Improvement
Teams
5S is a Cornerstone of Employee
Engagement

5S Helps to Eliminate Waste
Over-production
Producing more than what
the customer needs
Inventory
Building and storing extra
services/products the
customer has not ordered
Transportation
Moving product from
one place to another
Rework
Reprocessing, or
correcting work
Over-processing
Adding excess value
when the customer
does not require it
Motion
Extra physical/mental
motion that doesn’t add
value
Intellect
Not using employees full
intellectual contribution
Waiting
Employees waiting for
another process or a
machine/tool
Waste

What is 5S?
Principles General Description
1S Sort
Remove what is not needed and keep
what is needed
2S Set in Order
Arrange essential items in order for
easy access
3S Shine
Keep things clean and tidy; no trash or
dirt in the workplace
4S Standardize
Establish standards and guidelines to
maintain a clean workplace
5S Sustain
Make 5S a habit and teach others to
adhere to established standards

What is the purpose of 5S?
Immediately make problems visible

Benefits of 5S
• 5S makes our workplace more
pleasant
• 5S improves work efficiency
• 5S and safety go hand-in-hand
• 5S leads to better customer
satisfaction and higher
productivity

1S : Sort
• Principle
 Stratification management
 Dealing with the causes
• Meaning
 Distinguish between the
necessary and unnecessary
 Get rid of what you do not
need
 “When in doubt, move it out”

1S : Sort
Degree of
Need
Frequency of Use Storage Method
Low
• Things you have not used in
the past year
• Things you have used once in
the last 6-12 months
• Throw them out
• Store at a distance
Medium
• Things you have only used
between 1-6 months
• Store in a central
place in the workplace
High
• Things used once a week
• Things used daily
• Things used hourly
• Store near the work
site or carry on the
person

2S : Set In Order
• Principle
 Functional storage
 Search elimination
• Meaning
 Arrange essential items in
order for easy access
 A place for everything
 Everything in its place after
use

2S : Set In Order - Examples

2S : Set in Order - Office Desk
An office desk before and after conducting 5S Sort, Set In
Order and Shine. Clutter and unused items have been
removed leaving only what is needed.
Before After

3S : Shine
• Principle
 Cleaning as inspection
 Degrees of cleanliness
• Meaning
 Eliminate the sources of dirt
and filth
 Cleaning as a form of
inspection
 Clean everything, inside out
 Shine check sheet

3-Step Approach to Cleaning
Common areas, walls, ceilings, lights,
storage areas, toilets, “junk yards”,
shelves, filing cabinets, etc.
Individual workstations, chairs, drawers,
computers, cabinets, shelves, etc. Clear
away things underneath your table!
Measuring instruments, e.g. micrometer,
gauges, vernier calipers, contact
surfaces, etc.

4S : Standardize
• Principle
 5S standardization
 Visual management
• Meaning
 Establish guidelines
 Make standards and guidelines
visual
 Make standards so that any
abnormality becomes visible
 Use visibility tools

Standardization is the Way to
Sustain the Gains
Present
state
Future
state
Without
standardization, all
my improvements will
roll back with time…
STANDARDIZATION
Standardization is a tool that will ensure
your improvements will be sustained.

Foundations of Standardized Work
Simplify the Work Site

5S : Sustain
• Principle
 Habit formation
 Disciplined workplace
• Meaning
 Training
 ‘Before’ and ‘after’ photos
 Daily 5S five-minute activities
 Self-discipline

How to Sustain 5S?
• Get management commitment
• Get everyone involved
• Get authorization from management for 5S activities
• Promote 5S in the organization
• Do it all the way
• Gemba walk by CEO
• Conduct monthly review by 5S committee
• Use 5S as a platform to launch other continuous
improvement programs/initiatives

5S Audit Checklist & Results

Creating a Visual Workplace
• 5S can be enhanced by the
use of visibility tools
• Use 5S visibility tools to
help you monitor results
and look for things easily
and quickly
Note: Visual management IS
NOT decoration

Everyday Visual Management

3 Types of Visual Management
• Label to make it perfectly clear
where things belong and what the
procedures are
Visual
Display
• Quantify the path to targets for
success
• Graphs and Pareto charts
Visual
Metrics
• Create an error-proofed
environment to promote easy
adherence to standards
Visual
Controls

Example of Visual Metrics
Process Costs
Product Profitability
100%
Revenue
Rework
On TimeCycle Time Reduction WIP Backlog
Internal Quality
Customer Complaints

5S and Safety, Quality, Productivity &
Equipment Maintenance
5S
Safety
Quality
Productivity
Equipment
Maintenance

5S and Safety 1
• Wear protective clothes,
goggles and shoes in the lab
• Install protective covers on
equipment and machines
• Label warning signs
prominently
 High voltage, Radiation,
Slippery/Wet floor, etc.
 ‘Under Test – Do Not Switch
Off’

5S and Quality 1
• Train staff on 5S
• Provide on-the-job training
for new staff
 Use ‘Training Within Industry’
(TWI) methods for coaching
• Educate/Train staff to
recognize and prevent
mistakes

The One-Is-Best Campaign
• One-page memos
• One-hour meetings
• One-location files
• One-day processing

5S Implementation Process
Step 5: Implement 5S
Step 1: Establish a 5S Committee
Step 2: Define a 5S Implementation Pan
Step 3: Develop 5S Publicity Materials
Step 4: Provide 5S Education
Step 6: Audit, Evaluate & Follow-Up
Sort
Set In OrderShine
Standardize
Sustain

5S : Getting Started 1
• 5S publicity materials
 Booklets, badges, brochures, cups,
pens, etc.
• 5S training and education
 Provide 5S training to managers
and staff
 5S pamphlets
• 5S notice boards/intranet
 5S news
 ‘Before’ and ‘After’ photos

Launching a 5S Day 1
• Set aside half a day for this
event
 Best on Fridays or before a
festive season or public holiday
 Everyone in casual attire, e.g.
T-shirts
• Prepare sufficient cleaning
equipment, detergents,
paints, etc.
• Speech by CEO on
importance of 5S to all staff

Supporting Lean Tools for 5S
Zone 1
Zone 3 Zone 4
Zone 2 Chores
John Mark Sue Jim
Pack Table Restocking X X X
Supply Shelf Restocking X X X
Handling Incompletes X
Equipment Maintenance X
File Organizing X X X X
Visual Charts X X X
Cleaning X X X X
1. Zone Chart
3. Cross-training Matrix
Before
After
2. ‘Before’ & ‘After’ Photos

Critical Success Factors
• Top management commitment
• Involvement of all staff
• Sufficient resources, manpower,
admin, training, publicity, etc.
• Link with productivity and quality
initiatives
• Regular 5S Audit and management
review
• Recognition and reward for good 5S
practices

About
Operational Excellence
Consulting

About Operational Excellence
Consulting
• Operational Excellence Consulting is a management training and
consulting firm that assists organizations in improving business
performance and effectiveness.
• One of our unique strengths is going beyond a tools-focused
approach to seamlessly integrate people, processes, technology
and continuous improvement initiatives to suit the specific needs
and situations of our clients.
• We provide corporate learning programs and management advisory
services to assist our clients to achieve breakthrough in business
performance and effectiveness. Our aim is to support our clients in
designing, managing and executing lasting beneficial change.

To download this presentation,
please visit us at:
www.oeconsulting.com.sg
END OF PARTIAL PREVIEW

5S Techniques by Operational Excellence Consulting

Empfohlen

Empfohlen

Weitere ähnliche Inhalte

Was ist angesagt?

Was ist angesagt? (20)

Andere mochten auch

Andere mochten auch (19)

Ähnlich wie 5S Techniques by Operational Excellence Consulting

Ähnlich wie 5S Techniques by Operational Excellence Consulting (20)

Mehr von Operational Excellence Consulting

Mehr von Operational Excellence Consulting (20)

Kürzlich hochgeladen

Kürzlich hochgeladen (20)

5S Techniques by Operational Excellence Consulting