sS Education
What is 5S?
6S Safety
Floor Marking
Kaizen
Kanban
Labels &Signs
Lean Manufacturing
Pareto Chart
Pipe Marking
QA Quality Assurance
Root Cause
Six Sigma
Total Quality Management
Zero Defects
What is 5S?
5S is asystem for organizing spaces so work can be performed efficiently, effectively, and safely This systerm
focuses on putting everything where it belongs and keeping the workplace clean, which makes it easier ic
people to do their jobs without wasting time or risking injury.
5S Translation
The term 5S comes from five Japanese words:
" Seiri
Sort
set in o
" Seiton
" Seiso
5S
Seiketsu
Shitsuke
Sustain
In English, these words are often translated to:
Stanndardize
" Sort
" Set in Order
" Shine
Standardize,/ Leave a message
heOrigins of 58- 5S &tean Manufartharing
iswoet he u of ee s
AIstain
fach Srepresents one part of a five-step process that can improve the overall function of a business
The Origins of 5S - 5S &Lean Manufacturing
5S began as part of the Toyota Production System(TPS), the manufacturing method begun by leaders at the
Toyota Motor Company in the early and mid-20th century. This system, often referred to as Lean manufanturng
in the West, aims to increase the value of products or services for customers. This is often accomplished by
finding and eliminating waste from production processes.
Lean manufacturing involves the use of many tools such as 5S, kaizen, kanban, jidoka, heijunka, and poka-ycke
5S is considered a foundational part of theToyota Production System because until the workplace is in a clean
organized state, achieving consistently good results is difficult. Amessy, cluttered space can lead to mistakes,
slowdowns in production, and even accidents, allof which interrupt operations and negatively impact a
company.
By having a systematically organized facility, a company increases the likelihood that production will occur
exactly as it should.
Benefits of 5S
Over time, the 5S methodology leads to many benefits, including:
’ Reduced costs
’ Higher quality
’ Increased productivity
’ Greater employee satisfaction
’ Asafer work environment
at Are the 5 S's?
e 5S concept might sounda little abstract at this
point, but in
feality, it's a very practical, hands-on tool that everyone in the SORT
workplace can be a part of. 5S
5S involves assessingeverything present in aspace, rernoving
what's unnecessary, organizing things logically, performing
housekeeping tasks, and keeping this cycle going. Organize, clean,
repeat.
Let's take acloser look at each of the parts of 5S
Sort
The first step of 5S, Sort, involves going through all the tools, furniture,
materials, equiprnent, etc. in a work afea
to determine what needs to be present and what can be rernoved.
Sorme questions to ask during this ph.
include:
’ What is the purpose of this item?
’ When was this item last used?
’ How frequently is it used?
’ Who uses it?
’ Does it need to be here?
These questions help determine the value of each item. Aworkspace might be better off without unnecestatt
items or items used infrequently. These things can get inthe way or take up space.
Keep in mindthe best people to assess the items in space are the people who work in that space. They ar t
ones whocan answer the above questions.
When a group has determined that some items aren't necessary, consider the following options:
" Give the items to a different department
Recycle/throw away/sell the items
Put items into storage
AREDTAG
For case5 when an iterr's value is uncertain for ezarnple, a tool hasnt been used recently, but soneone
thinks it might be needed in the future use the red tag method Red tags are usually cardboard ta4s r
itern suct a
st1ckers that can be attached to the iterns in question Uters fill out the inforrnation about the
’ Location
’ Description
’ Narne of person applying the tag
’ Date of application
Then the itern is placed in a 'red tag area with other questionable items if after a designated armount of tre
(perhaps arnonth or two) the itern hasn't been used, it's tirne to rernove it frorn the workspace. It s not wortth.
hanging onto things that never get used since they just take up space
Tip: Set a reminder-onyour phone or computer, or posted somewhere in the workspace-t
check back in with the red tagarea so it doesn't get forgotten.
Set in Order
Once the extra clutter is gone, it's easier to see what's what. Now work groups can corme up with their
strateg1es for sorting through the remaining iterns. Things to consider
’ Which people (or workstations) use which iterns?
’ When are items used?
’ Which iterns are used most frequently?
-’ Should iterns be grouped by type?
items?
Where would it be most logical to place
ergonomic for workers than others?
’ Would some placements be more
down on unnecessary motion?
-’ Would some placements cut
necessary to keep things organized?
’ Are more storage containers
arrangements are most logical. That will require thinking
Duringthis phase, everyone should determine what
people take through the space, etc.
through tasks, the frequency of those tasks, the paths
relationship between the organization and larger Lean
Businesses may want to stop and think about the
the least amount of waste?
efforts. What arrangement willcause
take the form of:
In Lean manufacturing, waste can
" Defects
" Waiting time
" Extra motion
" Excess inventory
Overproduction
" Extra processing
" Unnecessary transportation
. Unutilized talents
Tip:For 5S, specifically consider how the layout and organization of an area could
increase/decrease waitingtime,motion, and unnecessary transportation.
Shine
Everyone thinks they know what housekeeping is. but it's one of the easiest things to overlook, especial
work gets busy. The Shine stage of 5S focuses on cleaning up the work area, which means sweeping.
dusting, wiping down surfaces, putting tools and materials away etc
tion to basic cleaning, Shine also involves performing reqular maintenanceon equipment and
inery Planning for maintenance ahead of time means businesses can catch problems and preven'
akdowns. That means less wasted time and no loss of profits related to work stoppages.
Chiningthe workplace might not sound exciting, but it's important. And it shouldn't just be left up to the
ianitorial staff. In 5S, everyone takes responsibility for cleaning up their workspace, ideally daily. Doing so
makes people take ownership of the space, which in the long run means people will be more invested in their
work and the company.
Tip: How to clean may seem obvious, but make sure people knowhow to properly Shine
their spaces. Show employees - especially new employees - which cleaners to use, where
cleaning materials are stored, and how toclean equipment, particularly if it's equipment that
could be easily damaged.
Standardize
Once the first three steps of 5S are completed, things should look
pretty good. All the extra stuff is gone, everything is organized,
spaces are cleaned, and equipment is in good working order.
PRoDUCION
The problem is, when 5S is new at a company, it's easy to clean
and get organized..and then slowly let things slide back to the way COSTS
they were. Standardize makes 5S different from the typical spring 92016 Creative Satety Supply
cleaning project. Standardize systematizes everything that just
happened and turns one-time efforts into habits. Standardize
assigns regular tasks, creates schedules, and posts instructions
so these activities become routines. It makes standard operating
procedures for 5S so that orderliness doesn't fall by the wayside.
Depending on the workspace,a daily 5S checklist or a chart might
be useful. Aposted schedule indicating how frequently certain
cleaning tasks must occur andwho is responsible for them isanother helpful tool.
Initially, people will probably need reminders about 55. Small amounts of time may need to be set aside daily
for 5S tasks. But over time, tasks will become routine and 5S organizing and cleaning will become a part o
regular work.
Tip: Visual cues such as signs, labels, posters, floor marking tape, and tool organizers also
play an important role in 5S. They can provide directions and keep items in place, in many
cases without words.
tain
nce standard procedures for 5S are in
procedures and place, businesses must
updating them as necessary. Sustain perform the ongoing work of maintaning thoe
also of keeping everyone in
the
refers to the process of keeping 5S running
smoothiy, ot
.he manufacturing tloor, in the organization involved. Managers need to
warehouse, or in the office, Sustain is participate,
about
as do employees out on
just an event or short-term
project. Ideally, 5S becomes a part of an making 5S a long tem progil, iot
euctained over time, that's when organization's culture. And when 55
businesses will start to notice continuous positive results
Tip #1:To help sustain 5S
practices, make sure all
switch departments) receive training about their new employees (or employees who
area's 5S procedures.
Tip #2: Keep things interesting. Look at what other companies are doing with
for organization can keep things 5S New ideas
improving and keep employees engaged.
Safety - The 6th S
Some companies like to include a sixth Sin their 5S program:
Safety. When safety is included, the system is often called 6S. The
Safety step involves focusing on what can be done to eliminate
risks in work processes by arranging things in certain ways. Safety
Meetlnd
Today!
This might involve setting up workstations so theyre more
ergonomic, marking intersections-such as the places where
forklifts and pedestrians cross paths-with signs, and labeling the
storage cabinet for cleaning chemicals so people are aware of
potential hazards If the layout of the workplace or the tasks
people perform are dangerous, those dangers should be reduced
as much as possible. That's what the sixthS focuses on.
Some people consider safety an outcome of performingthe other
five S'sappropriately, and as aresult say asixth S isn'tnecessar.
They think if the workspaceis properly organized and cleaned and
uses helpfulvisual safety cues, aseparate safety step is
unnecessary
shouldI'
to satety is right or wrong. But however abusiness wants to approach satety, t
Tee approach
aware that paying attentionto safety is inportant.
whethera 5S nprovement coud
Tip: If mishaps and accidents do happen, stop to consider or better siqns and labels
faces,
e made a difference?
Getting Started with 5S
ET IN
ORO
Fven though 5S is atairly simple concept, beginning a new 5S program can feel daunting. It's like undertakng
hin cleaning project in the garage or the basement at home, there's alot of stuff to deal with, and getting
started probably doesn't sound fun.
Start with practical steps such as deciding which departments and individuals will be involved, what tratnu
needed, and what tools to use to facilitate the process. Determining these concrete things will help beqin thc
process of 5S implementation.
Who Should Participate in 5S?
Here's the short answer to this question: everyone. If a department is starting 5S, managers and all other
employees should be included. If anyone is left out, this could lead to confusion or to messes that peopl dont
want to take ownership of.
It is possible that some people will play a bigger role in 5S than others, which is fine. There might be 5S
cOordinators who are in charge of installing and maintaining 5S labeling, keeping tracking of assigned tasks, or
introducing new department members to the 5S system. These people will obviously spend a lot of time
thinking about 5S compared to others. Everyone should think about 5S regularly, though. 5S might initially iitke
place as an event, but ideally it becomes a part of daily work for everyone.
It'salso important to remember that company leaders should participate in 5S, especially if 5S is acompany
wide effort. When people see their superiors taking 5S seriously by participating in it, they'll be nore likely to
take it seriously, to0.
5S Training
Anyone who willparticipate in 5S activities needs to receive [Link] could be done in aclassrooni t .
with atraining DVD, and/orthrough hands-on activities. Ademonstration of how 5S could occur at a
workstation might also be useful.
oyees understand why the companyis goingto start using 55 and why it'simportant, theyshould be
briethistory of 5S, its parts, and its benefits.
possiblethat the way 5S is carried out at one organization or even one department will be different
ite
performing 5S for the first time may need to work out the best way to perform the steps
others, So groups
their spaces.
onbod
5S is new, and then any new employees who come
any case,everyone should receive trainingwhen
5S as well.
later should receive training about
5S &Visual Communication
spaces cleaner and therefore
Akey part of 5S is that it makes
people can more easily get their
easier tO navigate. That means
tools such as labels, floor
work done. Visual communication
shadow boards can
markings, cabinet and shelf markings, and
simpler. Plus, these tools can help
make navigating spaces even TRASH
workplace that uses visual
keep the workspace organized. A
referred to as a visual workplace.
management in this way is often
used in 5S are:
Some common visual tools
Floor Marking Tape
locations where equipment or
outline work cells, mark the
These tapes can be used to patterns,
hazards. They come in a variety of colors and
materials are placed, or highlight surfaces.
used on shelves, workbenches, cabinets, and other
and can also be
Labels and Signs
indicate the
colors, and symbols to convey information. They can
These visuals use text,
to store parts. Many styles and
tell people where
contents of drawers, call out hazards, or with a labei and
businesses even choose tomake these in-house
s0zes exist, and some
sign printer.
Shadow boards &Toolbox Foam
boards use cutouts '
visuals are helpful in workspaces with a lot of tools. Shadow
These pegboard. Toolbox foam
that are placed behind the spot where a tool hangs on a
tools out of a top layer
similarly, except it fits into atoolbox drawer. The tool's shape is cut
works highlight
bright bottom layer of foam shows through. Both of these methods
of foam, so a finished
tools and tellpeople exactly where tools should be placed when they re
missing
using them.
noOseto Use some or all of
everything, and these visual tools. All of
everything in its
place." These tools them help
make it clearachieve the often-cited sayino
become,a problem
So easily.
where things belong, so
plyouUse color
nderstandsthem.
r-coded floor markings, tapes, or
Post a color
chart if other visual cues, nake
sure everyone
necessary.
5S Outside
Government Manufacturing - In Healthcare, the Office, or
5S originated in the
manufacturing industry at Toyota and it has proven useful for
industries, not just the automobile industry. In
recent decades,5S has moved beyond manufacturers in many
industries such as healthcare. Many offices also employ 5S, manufacturing to other
as do some schools and other
organizations. government
The basic steps of 5S can be applied to any
workplace. An office can use 5S to keep supplies
hospitals and medical clinics. 5S can even be used in a communal kitchen to keep the fridge organized, can
as
from filling up
with expired food. It's really just a matter of determining what workspacesand work processes will
benefit
most from improved workplace organization.
5S Example
Look at the example below to see 5S in action. Before 5S, spaces are clutteredand confusing. After 5S,
evervthing has an assigned place, which is often marked with floor marking tape, labels, and other visua cues.
Before 5S After 5S
c2015 ete Slety
Supply
02015Cteative Satety Sup ly
aDnormalties and spot potential problems before th ey
When sSisused in the workplace, it s easier to detect
significant issues.
grow into
Long-lerm Savings
55 VS.
leadersconsidering
using 5S may wonder if 5Sis expensive to implement. Generally, it's not There
ss investment
up-front in tools like floor marking tape and labels, and some time does need to be spent
Dean
trainingand on
5Sactivities, which takes up employees' time. In the long run, though, 5S makes processes
n
smoothly and prevents mishaps, and those things usually save businesses money.
run more