6S Guide

This guide will help you create a more efficient and

productive business. The added safety component
enhances the original 5S methodology
Contents
1 Introduction

2 The Five Pillars

3 Sort

4 Set in Order

5 Shine

6 Standardize

7 Sustain

8 The 6th S: Safety

9 Summary

10 Additional Resources

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Introduction

If your company is like most organizations, you’re searching for a

competitive edge. Something that will reduce costs, increase sales,
emphasize safety, make you more agile in a changing business
environment.

You’ve found it.

6S builds upon the 5S systematic approach to workplace

organization with an added step focused solely on safety.

6S has the same principles as its traditional counterpart with

efficiency, competitiveness, and survival at the core. It is a
deceptively simple system that creates an organized and productive
workplace while acknowledging the importance of workplace safety.

It’s not just about cleaning up and eliminating toolboxes. 6S creates

a safer workplace environment that can adapt and succeed

Chaos and unproductivity are your enemies; organization and

efficiency are your allies. The sixth S, an extra step aimed at creating
or improving safety processes, strives to complete the same goals the
original 5S system: elimination of waste and improved productivity.

If implemented correctly and followed diligently, 6S will lead to the

benefits of a 5S program:

• Lower costs • Better quality

• Increased productivity • Higher employee satisfaction

Implementing the sixth S however, will ensure the first 5S steps are
followed through safely and efficiently. While it can be argued safety
is built into the foundation of the 5S system, the added step centered
around safety guarantees occupational safety will be addressed in
the process.

Chapter 1 [Link]/guides
The Five Pillars
Originally developed by Hiroyuki Hirano for manufacturing
companies in Japan, the principles of 5S translate well to the
laboratory, the repair facility, and even the corporate office. Almost
any work environment will benefit from the structure and efficiency
this model provides.

5S is sometimes called the five pillars because just like the physical
pillars that hold up a structure, 5S has five elements that support the
effectiveness of the system.

And just like the pillars of a building, if one was to weaken or fail, the
entire structure would fall.

The five steps/pillars of 5S are:

1 Sort 4 Standardize

2 Set in Order 5 Sustain

3 Shine

Chapter 2 [Link]/guides
Sort
Sort is the process of removing all Original Japanese word:
the items not needed for current
Seiri
production from the workspace.

5S begins with the Sort step. Sort is the cornerstone of 5S and will
help get rid of problems such as:

• Tools and materials impeding workflow

• Wasted time looking for parts, tools, and products
• Stockpiling unnecessary and expensive inventory
• Safety hazards resulting from clutter

The goal of Sort is to eliminate all the unneeded tools and materials
and create a space free of clutter. This allows for a workflow free
from distraction.

A good rule of thumb is: “If you do not use it on a daily basis, throw it
out.” Leave only the things you absolutely need to get your job done.
This includes tools, materials, and machinery.

When executing the Sort step, you must be vigilant and ruthless.
Doing this first step correctly will lay the groundwork for 5S and
ensure a successful implementation of the 5S model.

Identifying unneeded parts and tools is not always an easy task.

Employees and managers get so used to the chaos that they don’t
even see it anymore.

5S has an effective tool that will help you with your sort process: red
tags.

Chapter 3 [Link]/guides
 Red Tags

Red tags help you identify objects that need to be

removed from the workplace.

When you see something you think may need

to be removed, you put a red tag on it. This lets
everyone know this item needs to be evaluated.

On the red tag, indicate what action should be

taken:

1. Leave the item where it is

2. Relocate the item
3. Dispose of the item
4. Recycle the item
5. Place in “Red Tag Holding Area”

The Red Tag Holding Area is a location where

items are placed until you determine their value.

For example, say you have a tool you haven’t seen

anyone use in a long time, but you aren’t sure you
should get rid of it. Place it in the red tag holding
area with a date on it, perhaps for a month from
now. If that date passes and no one has used the
tool, you can safely assume it’s not needed and
remove it from the workplace.

On the other hand, if you determine an item

is still needed, remove the red tag and find an
appropriate location to store it.

Shop Red Tags:

 [Link]/Lean-Supplies

Chapter 3 [Link]/guides
Set in Order
Set in Order is the process of putting
everything in a place that is easy to Original Japanese word:
get to. All items should be clearly Seiton
marked so anyone can easily find its
proper home.

Begin the Set in Order phase of 5S only when the Sort phase is
complete. This phase will be useless if there is unnecessary clutter
in the workspace.

The goal of Set in Order is to create a standardized and consistent

way to store and retrieve tools and materials. The key here is
standardization. The user must develop this system based on how
often the tools and materials are accessed and the process that uses
them.

Some guidelines to consider:

 If items are used together, store them together.

 Put frequently used items closest to the user.

 If possible, devise a let-go system in which tools are attached to a

retractable cord and automatically go back to the stored position.

 Place items so the user doesn't need to bend or twist much to access
them.

 Arrange tools and materials in order of use.

The Set in Order step utilizes several strategies to accomplish its

goals.

Chapter 4 [Link]/guides
 Labels and Signs

A key component of any organizational program,

labeling is the easiest way to quickly and visually
identify proper placement of tools, materials, and
equipment.

For example, drawers of tool chests can be

labeled with their contents so employees can
easily find what they need. The floor can even be
labeled indicating where trash cans, machinery,
and other equipment should be placed so these
things always find their way back to where they
belong.

This type of labeling makes it easy for even

people unfamiliar with your system to locate
items and return them to the right places. It also
helps with sustaining organizational processes
because once everything is properly labeled,
it’s easier for employees to keep 5S in focus on
a daily basis. If they ever forget the location of
something, the answer is right in front of them.

In addition, larger signs, banners, and posters

can be used to convey messages of organization
or safety, including reminders of the 5S process.
Large signs can be posted above storage areas,
for example, to facilitate clean-up at the end of
shifts.

Together, these tools create a great backbone for

any visual organization program.

Shop Labels, Signs, and Label Printers:

 [Link]

Chapter 4 [Link]/guides
 Labels for everything.™
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Chapter x [Link]/labeltac
[Link]/guides
 Line Marking

Painted or taped lines are often associated with

safety (pedestrian paths, forklift and equipment
paths, etc.), but they are also very useful for
marking work areas, as well as locations for
pallets, raw materials, finished goods, shipping,
and other static locations.

By marking the boundaries of these areas, you’ll

make it easier for employees and visitors to make
sense of space.

Industrial floor tapes are preferred to painted

lines as they are more resistant to foot and
forklift traffic and don’t require long dry times.
They are also easy to clean and require little
upkeep. These tapes come in many colors and
sizes so you can create a marking system that
makes sense for your facility.

Often, companies also use thinner vinyl tapes

(0.25” to 2” width) of different colors to mark
workbenches and work cells. These tapes can
create visual cues or indicate the locations of
tools/equipment that shouldn’t move. This helps
keep work areas clear of clutter and keeps these
static items in their optimal positions.

These techniques can be used for work cells of

any kind. They will improve workflow and result
in improved productivity. Additionally, misplaced
items and equipment are easy to spot.

Shop Floor Marking:

 [Link]/floor-marking-tapes

Chapter 4 [Link]/guides
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 Tool Foam
For tool drawers, you can use customizable foam
to create a tool organization system to prevent
tools from going missing. This foam can also
help protect your toolbox and tools from damage.

This customizable foam is usually available as

part of a kit, which means you will receive two
pieces of foam in contrasting colors. The brighter
color foam is placed in the bottom of the drawer.
You trace the outlines of your tools on the second
piece of foam and cut them out using a foam-
cutting knife. Then when you place that layer of
foam into your drawer, the brighter color beneath
will show through, highlighting any missing tools.

Shop Foam Products:

 [Link]/foam-organizers

Chapter 4 [Link]/guides
 Shadow Board / Tool Outlining

Tool outlining means creating a visual outline of

your tool so you can quickly return it to its proper
home.

For pegboards and other hanging tool systems,

this is done by placing painted or vinyl cutouts of
your tools behind those tools. Vinyl tool outlines
work well since they are easy to apply and require
no maintenance. This method is called shadow
boarding.

These methods of organizing tools are simple

but effective. They make organization more
visual, which makes it easier for people to follow
your organizational protocols without too much
thought.

Shop Tool Outline Vinyl:

 [Link]/tool-organization

Chapter 4 [Link]/guides
Shine
Shine means removing all the dirt Original Japanese word:
and grime and keeping the workplace
Seiso
clean on daily basis. You want to get it
clean and keep it clean.

You eliminated clutter with Sort and you organized with Set in Order.
Now it’s time to sanitize with Shine.

When you implement this step, two things will happen. First, your
employees will like coming to work in a clean environment. Second,
because you are keeping the equipment and your surroundings
in great shape, you will have fewer injuries and fewer equipment
breakdowns. That means greater productivity and fewer costs.

In the 5S system, cleaning is everyone’s responsibility. Although

you may still use a janitorial staff to tackle large jobs, the detailed
cleaning will be done by your employees. You must train your staff to
view dirt and chaos as an intolerable situation.

This must be a culture that is followed from the CEO down to the
apprentice.

Standardize your cleaning program for best results. Train your

employees to do it correctly. Make sure they know what they
are responsible for and give them the tools to do the job. Utilize
checklists and diagrams for consistency.

Chapter 5 [Link]/guides
Inspection and Maintenance
Cleaning is not the only facet of Shine. The daily Shine ritual should
also include inspection and routine maintenance.

As your employees are doing their daily cleaning routine, they should
be inspecting tools and machinery for damage as well. Include this in
the daily checklist to make sure it gets done.

Periodic routine maintenance should also be done at this time. Some

examples are checking the oil level in machinery, tightening up belts,
hoses, nuts, and bolts, or checking if tools need sharpening.

The goal for Shine is to keep everything in great working order

so it lasts as long as possible and doesn’t break down.

Clean and properly maintained tools and machines also increase

safety in the workplace. Fewer injuries and less downtime equate to
higher morale and higher productivity.

What if an employee sees a pool of oil that wasn’t there before or

notices a safety hazard?

If it’s a quick fix, put a maintenance tag on it and notify your

supervisor. If something needs further evaluation, there should be a
maintenance log you can fill out that will ensure further action.

And don’t forget your computers and other office equipment! They
need to be defragmented (PCs) and air-dusted periodically to keep
them in good condition.

Everything is coming together. The groundwork has been set for a

successful 5S implementation. Now we move on to the pillar that will
be the glue that keeps it all together: Standardize.

Chapter 5 [Link]/guides
Standardize
Standardize creates a system of tasks Original Japanese word:
and procedures that will ensure the
Seiketsu
principles of 5S are performed on a
daily basis.

We all have our own way of doing things. This kind of individuality is
great in our personal lives because it makes life more interesting.

But non-conformity can be unproductive in the workplace. If your

employees start doing things their own way, then things will start to
get missed and conditions will slowly begin to deteriorate.

The Standardize pillar utilizes a set of schedules and checklists that

can be easily followed so each step of 5S is performed exactly the
same way every day.

This way, each employee knows what he needs to do, when he needs
to do it, and exactly how to do it.

There is no room for uncertainty.

Standardize uses three steps to make sure that the 5S pillars are
getting done consistently and correctly:

Chapter 6 [Link]/guides
1) Make sure each employee knows his responsibilities.

If employees don’t know exactly what is expected of them, then how can
they do it?

They should have a clear understanding of their daily and weekly Sort, Set
to Order, and Shine tasks. Their responsibilities should be clearly written out
on a checklist or a chart so they can be easily accessed throughout the day.

2) Make it a part of their daily routine.

If you train your employees correctly, they will execute the steps of 5S
without even thinking about it.

"That wrench is out of place. Its home is here." -or- "I know the next tool I
need is the screwdriver because my tools are stored in the order that I use
them."

No extra thought is needed; employees flow through their daily routine

because they can see that it makes sense.

3) Periodic evaluation.

Once the steps are in place, you can evaluate performance at regular
intervals.

You can either form a committee made up of employees from different

departments or assign evaluation to department supervisors. Either way,
you will need a system to ensure tasks are consistently getting done.

Standardize is essential to the success of your 5S implementation. If your

staff has procedures to follow to complete the steps, you will ensure long-
term success and reap all of the rewards of 5S.

Chapter 6 [Link]/guides
Sustain
Sustain gives your staff the Original Japanese word:
commitment and motivation to follow
Shitsuke
each step, day in and day out.

Once you start the 5S method at your business, you will see
improvements very quickly. But the key to long-term success is
simple: diligence.

Have you ever gone on a diet to lose a few pounds? In the beginning,
you really keep at it. You stay away from those French fries, eat more
fruits and veggies, and may even go for a jog a couple days a week.
You lose six pounds in two weeks.

But inevitably, you start to slip. You’re out with friends and you
indulge in dessert. Or you hit your favorite fried chicken joint. It’s only
this one time, you say. Before you know it, you’re back to your old bad
habits and have gained all of your weight back.

That’s just human nature. If there is nothing to keep you motivated,

you will start to cut corners and slip. The fifth pillar, Sustain, is
designed to keep your staff motivated and on track.

Take concrete steps to make sure 5S doesn't fall by the wayside.

The five suggestions on the next page can help Sustain 5S and keep
your program functioning well.

Chapter 7 [Link]/guides
Assign the time to do it.

Give your staff the time to do the steps correctly. For example,
designate the fifteen minutes before lunch and shift end as Shine
time. During this time, their main focus is cleaning and organizing
according to their checklists.

Start from the top.

Your whole organization must be on board if 5S is going to work in

the long run. If your employees see that management is not following
the steps, do you think they will continue to do it?

Create a reward system.

Have friendly competitions between departments each month and

reward the winner. Buy them lunch, let them go early one day, or give
them priority parking. It doesn’t have to break the bank; you just want
to show them your appreciation for a job well done.

Get everyone involved.

Form a committee made up of employees and supervisors

of different departments. Their job will be to oversee the
implementation of 5S for a fixed period, maybe six months. Then you
can rotate in new members.

Let them see it.

Posters, banners, and newsletters can be a constant reminder of the

importance of 5S.

Chapter 7 [Link]/guides
The 6th S: Safety
Safety is an ongoing process supported by nearly all pillars of the
5S system.

While the 6th S is not part of the original concept of 5S developed

at Toyota, Lean experts all over the world have discovered that
a facility’s safety program is just as integral to productivity and
efficiency as any of the other 5 Ss. Since one of the guiding
principles of all Lean methodologies is to eliminate waste, it makes
perfect sense that safety issues that cause delays, damage, or
worse, injuries to employees, would need to be eliminated. Safety
issues cause delays in production and cost companies a lot of
money; the 6th S helps businesses stay safe so that employees stay
protected and production continues uninterrupted.

If you think about it, safety just naturally fits for the other steps of 5S:
Arranging spaces in logical ways, organizing tools and materials, and
cleaning regularly make it easier for people to do their jobs without
tripping, slipping, experiencing an ergonomic injury, etc. Therefore,
Safety has established itself as the 6th S, and its benefits is worth
re-evaluating safety at your facility.

The 6th S also helps facilities stay in compliance with OSHA

regulations and other standards, so this is a step not to be skipped.
Companies that don’t follow safety standards, properly mark
hazards, or fail to submit accident reports in a timely manner can
receive costly penalties from OSHA. Strong safety programs can
prevent all of that from happening.

Chapter 8 [Link]/guides
Tips for getting Safe:
Use visual communication like floor and wall signs
to alert workers and visitors of hazards. These
communication signals will help keep your business
in compliance with safety regulations and help protect
workers from accidents. Signs are available in OSHA-
compliant headings, signals, and symbols, and are
designed with bright, easy-to-read font for better visibility.

Use floor marking material like SafetyTac® Hazard

Tape to communicate danger. Floor marking tape
is recommended in the Set in Order step to create
storage space and parking areas for large equipment,
but it can also be used to increase safety. Creating
pedestrian lanes in heavy-traffic situations decrease
the chance of accidents. Using floor marking tape to
create buffer zones around sensitive instruments like
pipes or storage racks reminds workers to maintain a
safe distance.

Displaying safety processes and posters in break

rooms helps remind workers of safety programs.
Workers have a lot to think about; it’s easy to let rules
fade from memory. Posting safety protocols in high-
visibility areas help ingrain these practices in workers’
brains. Repetition is a useful tool when it comes to safety.

Chapter 8 [Link]/guides
Include safety policies in training and orientation for
new employees. Doing so stitches the importance
of safety into your company’s culture, and instills the
need to follow safety protocols at all times.

Make sure first aid equipment is functional and

clearly marked. First aid is essential in responding
to workplace accidents and injuries; it’s crucial that
supplies are stocked, equipment like eyewash stations,
emergency showers, and AEDs are working correctly,
and that these things are clearly marked so that folks
can find them quickly.

Implementing strong safety processes helps protect workers

from injury, improve productivity, and eliminate waste.

Chapter 8 [Link]/guides
Summary

6S is a system, a philosophy, and a culture.

The true power of 6S reveals itself when your whole organization

embraces its ideals and your employees see that your business is
transforming itself.

The 5S model for workplace efficiency and organization is both

powerful and simple. It has the potential to transform your company
into a productive warehouse, manufacturing facility, or office.
Including Safety as the sixth S, creates recognition of its importance
in the workplace.

One of 6S’s most powerful attributes is that it’s a visual model. Each
tool has an outlined home and each pathway is marked with lines.
Vision is our dominant sense, and because 5S uses colors, lines, and
labels to organize, following the steps becomes second nature very
easily.

Remove the clutter with Sort, organize with Set to Order, clean with
Shine, set your routine with Standardize, motivate with Sustain, and
incorporate Safety into your procedures.

It’s that easy.

Questions about 6S or Lean?

Call us at 1-866-777-1360

Chapter 9 [Link]/guides
Additional Resources

Products featured in this guide:

Red Tags
[Link]/Lean-Supplies

Labels
[Link]/labels

Label and Sign Printers

[Link]/label-and-sign-printers

Floor Marking Products

[Link]/floor-marking-tapes

Foam Products
[Link]/foam-organizers

Tool Outline Vinyl

[Link]/tool-organization

5S Revealed - Training DVD

[Link]/5Srevealed

or shop our full selection of products online at [Link]

Chapter 10 [Link]/guides
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