5S Supply Webinar Series
© 5S Supply 2010 1www.5Ssupply.com
© 5S Supply 2010
Our formal presentation will run from 12:00 pm - 12:45 pm CDT. The final
15 minutes will be dedicated to your Questions & Answers.
Please feel free to submit your questions at any time during our session.
Submit them in writing (as the phone lines are muted) in the Questions
section of your webinar control panel.
If you have any technical issues during our event please call GoToWebinar
at 800-263-6317 and be sure to give our Webinar ID 387-068-018
Be sure you have dialed in to the audio portion. Dial 866-941-8436
(International: 001-347-573-9605) and enter Pass Code 635785. Your
telephone line will be muted to diminish any background noise.
Welcome to
Introduction to 5SWe will be starting shortly
Please read
© 5S Supply 2010
Introduction to 5S
Wednesday, February 24th, 2010
12:00 pm – 1:00 pm (CST)
brought to you by 5S Supply
www.5Ssupply.com5S simplified. Everything you need… all in one place.
5S Supply Webinar Series
© 5S Supply 2010 2www.5Ssupply.com
© 5S Supply 2010
Today’s Agenda“Behind all
workplace
successes
and failures
are the
5S’s.”
From “5 Pillars of the
Visual Workplace: The
Sourcebook for 5S
Implementation” by
Hiroyuki Hirano
• What is 5S
• Philosophy of 5S
• Benefits of 5S
• Explanation of each of the
S’s—Sort, Set-in-order,
Shine, Standardize, Sustain
• Q&A
© 5S Supply 2010
What is 5S?
5S Supply Webinar Series
© 5S Supply 2010 3www.5Ssupply.com
© 5S Supply 2010
What is 5S?
• Five words that begin with the letter “S”
• Meaning workplace organization and
standardization
• Foundational building block of Lean
• Builds teamwork and discipline
• It’s NOT JUST CLEANING!
© 5S Supply 2010
Where did 5S Come From?
• A fundamental part of the Toyota
Production System (TPS)
• Need for a safe working environment,
respect for people
• Quality, cost and delivery
5S Supply Webinar Series
© 5S Supply 2010 4www.5Ssupply.com
© 5S Supply 2010
Leadership
5SVisual
Standard Work
Batch Size Reduction Quick Changeover
Pull System & KanbanCellular & FlowTPM
V
S
M
Error-proofing
Teams
Problem Solving
Planning
Kaizen
POUS
Lean Enterprise
Layout
Building Blocks of a
Lean Enterprise
© 5S Supply 2010
Translation
Self-disciplineSustainDisciplineShitsuke
StandardizeStandardizeStandardizationSeiketsu
SweepingShineCleaningSeiso
Simplifying
accessSet in orderNeatnessSeiton
SortingSortOrganizationSeiri
*OtherConversionTranslationJapanese
* there are several other conversions
5S Supply Webinar Series
© 5S Supply 2010 5www.5Ssupply.com
© 5S Supply 2010
Other Names
• 6S = 5S + safety
• 7S = 5S + safety +
security
• 5Cs
1. Clear Out
2. Configure
3. Clean & Check
4. Conform
5. Custom & Practice
• Others
• 5S is the most common
term
• Using other terms may
confuse people if they
see or read other
information about 5S
• If done correctly, safety
is automatically part of
5S
© 5S Supply 2010
Garage Story
• 5S is like cleaning out your garage
• Clear everything out, make piles
• Organize the things that you are going to keep
• Clean top to bottom, fix or repair as needed
• What happens 6 months later?
5S Supply Webinar Series
© 5S Supply 2010 6www.5Ssupply.com
© 5S Supply 2010
Philosophy of 5S
Be a 5S learner, achiever and
thinker
© 5S Supply 2010
Why is 5S Necessary?
• Companies are like living
organisms, they must learn to
adapt and be flexible to survive
and thrive
• Customers, suppliers, people,
processes, materials,
technologies are continually
changing
• Deeply engrained processes,
culture, and customs are not
easily changed
“5S is easy,
getting
people to
change is
hard”
5S Supply Webinar Series
© 5S Supply 2010 7www.5Ssupply.com
© 5S Supply 2010
5S Philosophy
• 5S is not about the cleaning
• 5S is not just the steps, it is how you go
about your job – are you a Lean
Thinker?
• Think about the 5Ss as being attributes
of the type of person you would want to
hire
© 5S Supply 2010
What do you think of this
maintenance area?
5S Supply Webinar Series
© 5S Supply 2010 8www.5Ssupply.com
© 5S Supply 2010
Do you think that 5S applies to office,
common or support function areas?
© 5S Supply 2010
5S Dreamland
Fairies and robots
do not come out
in the middle of
the night and do
5S for you.
Who has to do it?
5S Supply Webinar Series
© 5S Supply 2010 9www.5Ssupply.com
© 5S Supply 2010
Benefits of 5S
© 5S Supply 2010
Myths about 5S
• 5S takes too much time.
• There aren’t any benefits for doing 5S in the office.
• 5S means to clean and I wasn’t hired to clean!
• It doesn’t really matter how we store things.
• I like the way my desk is. I can find everything Ineed so why does it matter how I have my things?
• Doing 5S will take away from me doing my realwork.
5S Supply Webinar Series
© 5S Supply 2010 10www.5Ssupply.com
© 5S Supply 2010
More Myths
• We’re clean and neat already.
• We have a cleaning crew so we don’t need to do 5S.
• We’re not idiots, we know what we are doing. 5S will just get in the way of us doing our jobs.
• We have so many problems here, why would you have us do 5S?
• There is no benefit for us to spend time to this 5S stuff.
© 5S Supply 2010
Benefits of 5S
• Teamwork
• Discipline
• More organized workplace
• Safer work environment
• Reduces stress
• Saves time
• Saves money
“Time is
money”
5S Supply Webinar Series
© 5S Supply 2010 11www.5Ssupply.com
© 5S Supply 2010
Benefits of 5S
• Impresses customers or auditors
• Reduces waste
• Better handle on true costs
• More pleasant place to work and increase moral
• Supports the other Building Blocks of Lean
© 5S Supply 2010
Sort
“When in doubt, move it out!”
5S Supply Webinar Series
© 5S Supply 2010 12www.5Ssupply.com
© 5S Supply 2010
Sort
• The first thing to do is to clear the clutter
out of the area
• Perform as a team
• Use the “30 day” rule
• Use the Red Tag technique
• Break the “just in case” mentality
• “When in doubt, move it out!”
© 5S Supply 2010
Sort
• Clearly distinguish
between:
– What is needed
currently and should
be kept
– What is not needed
and can be removed
Will be used
Will not be used
May be used
Keep
Red Tag
Discard
5S Supply Webinar Series
© 5S Supply 2010 13www.5Ssupply.com
© 5S Supply 2010
Sort
• Red Tags are visual signal that something may not
belong in your target area
• Attach Red Tags to items that don’t belong in the
immediate area
• Move the items to the Red Tag Holding Area
• Use simple Red Tags
• Have Red Tags easily available
© 5S Supply 2010
5S Red Tags
Name _______________ Date________
Item ____________________________
Reason for Tagging ________________
________________________________
Your
Name
Today’s
date
What the
item is
Why did you
tag it?
Use unknown,
Obsolete,
Not used here,
etc.
5S Supply Webinar Series
© 5S Supply 2010 14www.5Ssupply.com
© 5S Supply 2010
Other Tag Issues
• Some companies
use additional color
tags for
maintenance or
safety issues
• Companies that use
Red Tags for quality
issues have to
determine which
color tag to use
• Make sure you have
wire, string or tape
to attach tags to the
item
• Make sure everyone
on the team has
tags and a pen
© 5S Supply 2010
Red Tag Area
• The Red Tag Holding Area is a temporary holding
area – meaning things can’t stay in there forever
• If other people or groups need items, they are
allowed to take things from the Red Tag Holding
Area
• Dispose of items periodically (rules will be setup
during “Standardize”)
5S Supply Webinar Series
© 5S Supply 2010 15www.5Ssupply.com
© 5S Supply 2010
Notes on Red Tagging
• Avoid the “Pack rat” mentality
• Don’t worry about the “One thing”.
Focus on the benefits of clearing things
out of the immediate area.
• Just because an item is tagged, it
doesn’t necessarily mean that it is going
to be thrown away. We will make the
decision later if we need it or not.
© 5S Supply 2010
5S and Dilbert
5S Supply Webinar Series
© 5S Supply 2010 16www.5Ssupply.com
© 5S Supply 2010
Benefits of Sort
• Clears out the things that you didn’t need in your work area
• Reclaim room and space
• Reduces search time
• Allows for other changes like moving items or changing the layout
• Safer place to work
• Let’s employees feel that they have control over their area, instead of the areas controlling them
© 5S Supply 2010
Set-in-Order
“A place for everything and
everything in its place!”
5S Supply Webinar Series
© 5S Supply 2010 17www.5Ssupply.com
© 5S Supply 2010
Power of Set-in-order
• Now that the area has been cleared out
of unnecessary items, it is time to find a
“home” for items that will remain
• This is where fantastic results occur
• Reduces:
– Search time
– Stress
– Inventory and supplies
© 5S Supply 2010
Everyday Examples
• Kitchen
• Parking lots
• Highways
• Broom racks & Shine Carts
5S Supply Webinar Series
© 5S Supply 2010 18www.5Ssupply.com
© 5S Supply 2010
Set-in-order
• Now that you have used Sort, decide where
the items that you will keep belong
• Decide how many and how to replenish
• Make it visual and obvious if something is
out of place
© 5S Supply 2010
Decide Where Things Belong
Guidelines
• If it is used often, keep close at hand
• Designated location & label
• Use systems like the “2-label” system
• Shadows, lines, color-coding
• Easy to get & put away (ergonomic and
safe)
• Get items off the floor & top shelves
5S Supply Webinar Series
© 5S Supply 2010 19www.5Ssupply.com
© 5S Supply 2010
Other Set-in-order Issues
• Make it easy for
everyone to find and
use them – “30
second” rule
• Use “recoil”, getting
items back to where
they belong
• Make it obvious
when they are not in
there correct place
• Make items easy to
get and easy to put
away
© 5S Supply 2010
Benefits of Set-in-Order
• No guessing at where items belong and
how many
• No excess items
• Items are easy to find and put away
• Everyone passes the 30-second test
“A place for everything and
everything in its place!”
5S Supply Webinar Series
© 5S Supply 2010 20www.5Ssupply.com
© 5S Supply 2010
Shine
”To clean and inspect.”
© 5S Supply 2010
Shine
• Shine = clean + inspect
• Perform as a team
• Must plan Shine
• Have the necessary items easily
available
• 5S is not just cleaning!
5S Supply Webinar Series
© 5S Supply 2010 21www.5Ssupply.com
© 5S Supply 2010
Why Shine?
• Can prevent accidents or safety incidents
• People feel better when they work in a clean environment, this actually helps morale
• Working together helps build team work
• Impresses customers on tours
• Can spot potential problems with equipment before they occur
© 5S Supply 2010
Make it Fit Your Organization
• Even if you have a cleaning crew or service,
do they know exactly what you want and what
is expected of them? Is it followed?
• Wiping and cleaning common areas helps
reduce the spread of germs thus improving
sick-time related absenteeism
• Make it quick and simple - or better yet, think
of ways to prevent dirt from accumulating in
the first place!
5S Supply Webinar Series
© 5S Supply 2010 22www.5Ssupply.com
© 5S Supply 2010
Initial Cleaning and Inspection
• Have to have a plan
• Start at the top and work down
• Clean and inspect major items first
• Be thorough, restore to “like new” condition
• Clean floors and aisle ways last
• Everyone has to participate
• Schedule it
• Take it Serious
© 5S Supply 2010
Planning Shine
Determine
• Task
• Location
• Who
• When
• Cleaning materials
needed
Supplies
NeededTeamArea
Desks
Equipment
Files/Storage
Common
Areas
Supplies
5S Supply Webinar Series
© 5S Supply 2010 23www.5Ssupply.com
© 5S Supply 2010
Additional Ideas for Shine
• Prevent dirt in the first place or at least contain it
• Low cost solution versus breakdowns
• Plan ahead
• Everyone participates as a team
• Make it quick (and fun!)
• Have the right tools & supplies ready
© 5S Supply 2010
Benefits of Shine
• A more pleasant place to work
• Promotes a professional atmosphere
• People actually have the tactile sensation by touching their equipment, machines and work areas
• You are able to find small problems
before they become BIG problems
• Safer and cleaner workplace
5S Supply Webinar Series
© 5S Supply 2010 24www.5Ssupply.com
© 5S Supply 2010
Standardize
“Make up the rules and follow and
enforce them!”
© 5S Supply 2010
Standardize
• Standardize means to set up the rules for
Sort, Set-in-order and Shine
• Have the 5S teams and 5S Design Teams set
the standards
• Standards must be simple and easy to follow
• Use audits to help maintain the standards
5S Supply Webinar Series
© 5S Supply 2010 25www.5Ssupply.com
© 5S Supply 2010
Standards for Sort
Red Tag Rules
• When to Red Tag
• How to Red Tag
• What’s go on the Red Tag
• more…
Rules for the Red Tag Holding Area
• When to clear out
• How to dispose of items
• more…
Description: How to fill-out a Red Tag
One-point Lesson
5S Red Tag
Name ______________ Date __________
Item ______________________________
__________________________________
Reason for Tagging __________________
__________________________________
Write in your name
1
Fill-in date tagged
2
Write in the
name or
description
of the item
3
Write in the reason for tagging
(obsolete, needs repair, not
needed, scrap, use unkown, etc.)
4
Attach tag using
wire, tape, string,
or other method
5
Move item to the Red Tag Holding Area6
© 5S Supply 2010
Standards for Set-in-Order
• Which items, where, how many
• Who replenishes
• Return all items… and What to do when items are
missing
• Visual standards – signs, lines, labels and color
coding
5S Supply Webinar Series
© 5S Supply 2010 26www.5Ssupply.com
© 5S Supply 2010
Standards for Shine
• Clean and Inspect (C&I) Schedule
• Show the task, person responsible,
items needed, frequency, the time
element and the desired state
• Where to keep cleaning supplies, how
to replenish
© 5S Supply 2010
5S Clean and Inspect ScheduleItem: ID:
Key: Clean & Inspect activity required ���� Cleaning activity completed ����
Frequency of C&I
No Team Member
Task Requirement MON TUE WED THUR FRI TimeMin
1 Technician Wipe down equipment Cleaner & Wipes � � � � � 1
2 Operator Clean or replace filter Cleaner, rags, filter (if required) � � � � � 3
3 Helper Sweep floor Broom � � � � � 2
4 Supervisor Inspect safety guards Visual � 1
5 Manager Complete Diagnostic
Checklist Post results on 5S Display Board � 5
6 All 5S Weekly Meeting Agenda, ½ hour max � 30
7
8
9
10
Total 42
5S Supply Webinar Series
© 5S Supply 2010 27www.5Ssupply.com
© 5S Supply 2010
Key for Standardize
• Make the rules, then follow and enforce them
• People usually think 5S fails at Sustain, but it
typically fails at enforcing the rules
• Policies drive behaviors
• Make the rules simple and easy to follow
• Use immediate correction
• Lead by example
• Do not allow 5S to take a backseat to other
things
© 5S Supply 2010
Benefits of Standardize
• Everyone knows the rules
• Easy to understand and to follow
• You have to have a standard in order to
know that you have improvement
• Sets the foundation for successful 5S
implementation and Sustain
• Allows you move on to “Sustain”
5S Supply Webinar Series
© 5S Supply 2010 28www.5Ssupply.com
© 5S Supply 2010
Sustain
“Make 5S part of everyday life.”
© 5S Supply 2010
5S Discipline
• Management’s support – without this 5S
will never work!
• 5S is not something extra, it’s part of
everyday work
• Get everyone involved – teamwork
• Helps set the base for other Lean efforts
• Creative ways to prevent Standardize
from deteriorating
5S Supply Webinar Series
© 5S Supply 2010 29www.5Ssupply.com
© 5S Supply 2010
Ways to Make 5S a Habit
• On-going
communication –
newsletters,
communication boards,
posters, short meetings
• Field trips,
benchmarking
• Reward and recognition
• Use immediate
correction
• Lead by example
• 5S promotions
© 5S Supply 2010
More Ways to Make 5S a Habit
• Training and additional
“Booster” training once
or twice per year
• Brainstorm problems
and solutions
• Study groups
• Capture Lessons
Learned, share Best
Practices
• Continued 5S Audits
• Contests
• 6-week photos
• “Extreme 5S Makeover”
video
• 5S Campaign boards
Sort
Set-in-Order
Shine
Standardize
Sustain
Check Red Tags
Check missing items
Check lights
Update audit schedule
New Contest
Jim, Bob
Jennifer, Ralph
Homer, Marge
Eileen, George
All
5S Item Team
5S Campaign Week of XX/XX
5S Supply Webinar Series
© 5S Supply 2010 30www.5Ssupply.com
© 5S Supply 2010
Additional Information for
Success
• Everyone has to participate
• Promote participation
• Keep at it, even when it isn’t easy
• Make sure everyone understands what
5S is and why it’s needed
• Remember, 5S is a low cost solution
• 5S is essential for Lean
© 5S Supply 2010
Q&A
Please submit your questions at
this time
5S Supply Webinar Series
© 5S Supply 2010 31www.5Ssupply.com
© 5S Supply 2010
Developer
Anthony Manos
• Tony Manos is a Professional Business Advisor with expertise in
Lean. Trained and certified by the Department of Commerce,
National Institute of Standards and Technology (NIST) in Lean
principles and as a trainer in Lean courses. He is an international
trainer and speaker on Lean topics.
• Mr. Manos is a Senior Member of ASQ, SME and AME and is a
Shingo Prize examiner
© 5S Supply 2010
Recommended
Resources5S Garage: An
Introduction to
5S and Lean
Principles “5S Pillars of the Visual Workplace: The
Sourcebook for 5S Implementation” by
Hiroyuki Hirano
“5S for Operators: 5 Pillars of the Visual
Workplace” by Productivity Press
5S Supply Webinar Series
© 5S Supply 2010 32www.5Ssupply.com
© 5S Supply 2010
Additional Resources
Group 5S Supply
© 5S Supply 2010
Q&A
If we don’t get a chance to answer your
question today, please send it to:
5S Supply Webinar Series
© 5S Supply 2010 33www.5Ssupply.com
© 5S Supply 2010
Upcoming Events
• March 2010 – 5S for the Office
Don’t forget to visit us at
www.5Ssupply.com888 4 LEAN 5S
© 5S Supply 2010
Thank you for attending
Your opinion is important to usA short survey will be sent to you
You may sign-off now