The 5S Numbers Game

5S Numbers Game

A fun and exciting way to present the 5S concepts to our team!

• This is a simple training game we will use to show how to perform 5S and to drive home important key points

• Hopefully you find it challenging (like the real-world) and have some fun along the way

CreditsThis exercise is based on an exercise from www.superteams.com which was adapted from one created byKirt Tassmer of Stanley Fastening Systems.The original game was developed by RWD Technologies, Ltd.

DisclaimerThis is for entertainment purposes only. 5S Supply is not liable for any unintended outcomes.

Introduction

• Before State – Round 1• Sort – Round 2• Simplify – Round 3• Systematic Cleaning• Standardize• Sustain – Round 4• Benefits – Round 5

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

Instructions – Round 1

• Please wait until you hear the entire instructions before starting – DO NOT turn over the page until asked to do so

• Individually, with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…)

• You will have 30 seconds to complete this task

29 3031

53535454

5656 5757

67676868

7676 7777 7878 7979

858686 8787

959696

97979898 9999

Report Out – Round 1

• Record your highest number found and a comment on your Overall Scorecard sheet

• The instructor will ask for your score – the lowest score is what’s recorded for the entire group

• What was it like trying to do this? How did it feel?

• How can we apply this to everyday life?

29 3031

53535454

5656 5757

67676868

7676 7777 7878 7979

858686 8787

959696

97979898 9999

Is this an 8, 88, 4, 84???

Were there any quality issues?

Is this 66 or 99? 89 or 68?

Why is 39 listed twice?Which one is

the 6 and which one is the 9?

• To sort through, to sort out• Guideline: If it is not needed in the next 30

days, Orange Tag it• “When in doubt, move it out!”• 5S Orange Tag Technique• Place a Orange Tag on the item and move it

to the 5S Orange Tag Holding Area• Items will be dispositioned: keep, throw out,

donate, scrap, shred, recycle, etc.

29 3031

53535454

5656 5757

67676868

7676 7777 7878 7979

858686 8787

959696

97979898 9999

Let’s orange tag the numbers we don’t need (51-100) and the duplicate 39.

29 3031

53535454

5656 5757

67676868

7676 7777 7878 7979

858686 8787

959696

97979898 9999

29 3031

53535454

5656 5757

67676868

7676 7777 7878 7979

858686 8787

959696

97979898 9999

Now let’s move them to the 5S Orange Tag Holding Area.

29 3031

53535454

5656 5757

67676868

7676 7777 7979

858686 8787

959696

97979898 9999

29 3031

• Let’s do the same exercise with the unneeded items removed from the work area - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…)

29 3031

• The lowest score is what’s recorded for the entire group

• What was the exercise like this time?

• What can we learn from this?

Simplify

• Now that the area has been cleared out of unnecessary items, it is time to find a “home” for items that will remain

• Guideline: Any item that you want to keep after the 5S Orange Tagging Event needs to have a specific home

• “A place for everything and everything in its place.”• Organize items to make them convenient to get and

put away• Use visual controls to help this process (signs, lines,

labels, color-coding)

29 3031

Let’s rearrange the numbers in order that we will use them.

29 3031

3 4 5 6 7 8 9 10

11 12 13 14 15

17 1819

21 2223

24 2526 27 28

293031 32 33 34 35 36 37 38

43 44 45

3 4 5 6 7 8 9 10

11 12 13 14 15

17 1819

21 2223

24 2526 27 28

293031 32 33 34 35 36 37 38

43 44 45

Did you notice that we had to work around a few things like the numbers that were already there? 20

• Let’s do the same exercise with the numbers better organized - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…)

3 4 5 6 7 8 9 10

11 12 13 14 15

17 1819

21 2223

24 2526 27 28

293031 32 33 34 35 36 37 38

43 44 45

• What was the exercise like this time?• What benefits can you see from “Sort” and

“Simplify”?• Record on Scorecard sheet

Systematic Cleaning

• Now that the area has been cleared out of unnecessary items, it is time to “shine” the items that remain

• Guideline: Get items to a “like-new” condition• “Clean and inspect or inspect through

cleaning”• Everyone participates, make it simple and

easy to get cleaning supplies and schedule it!• If you find something out that may become an

issue, fix it or have it fixed

3 4 5 6 7 8 9 10

11 12 13 14 15

17 1819

21 2223

24 2526 27 28

293031 32 33 34 35 36 37 38

43 44 45

For Shine we will make sure the numbers are in good working order. So let’s clean this mess up!

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

21 22 23 24 2526 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

Standardize

• We need to have standards for the first three S’s: Sort, Simplify and Systematic Cleaning

• Guideline: Make up the rules for the first three S’s and then follow and enforce them.

• “Make up the rules and then follow them”• Don’t forget to consider companywide

policies like color-coding, signage, replenishment, etc

• Make the rules easy to follow

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

21 22 23 24 2526 27 28 29 30

31 32 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

After looking at all the styles of font and sizes the team determined that some of these items can be standardized.

1 2 3 4 5 6 7 8 9 10

111213 141516 1718 192122 23 24 25 26 27 28 29 30

3132 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 503939

1 2 3 4 5 6 7 8 9 10

111213 141516 1718 192122 23 24 25 26 27 28 29 30

3132 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 503939

20Let’s add some more visuals like color-coding and lines.

1 2 3 4 5 6 7 8 9 10

111213 141516 1718 192122 23 24 25 26 27 28 29 30

3132 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 503939

Sustain

• Now that you have a well organized, clean and safe work environment, we must keep it that way

• Guideline: It’s not something extra, it’s part of everyday work

• “Make 5S part of everyday life.”• Sustain helps build the discipline we

need to have a great Lean organization

• In order to Sustain our gains we must be able to recognize abnormal conditions

• Let’s do a quick 5S Audit of the area

• Circle any “defects” that you find

1 3 4 5 6 7 8

121113 141516 1718 192122 23

25 26 27 28 29 30

3132 33

35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

How many did you find?• The “2” is missing• “9” is upside down• 11 and 12 are mixed up• “16” is not completely in it’s home• 24 and 34 are in the wrong location• “39” is missing• 46 is askewHow did you know?

1 3 4 5 6 7 8

12 1113 141516 1718 192122 23

25 26 27 28 29 30

3132 33

35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

• Let’s do the same exercise after applying our 5S principles - with a pen or pencil strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5…)

1 2 3 4 5 6 7 8 9 10

111213 141516 1718 192122 23 24 25 26 27 28 29 30

3132 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 503939

• What was the exercise like this time?• What benefits can you see from “Sort” and

“Simplify”?• How can we apply this to everyday life?

Before & After State

Before• Excess materials• Excessive search time• Large area• Cluttered• Difficult

• After• The correct materials• Minimal search time• Smaller area• Clean, neat &

organized• Easy

29 3031

53535454

5656 5757

67676868

7676 7777 7878 7979

858686 8787

959696

97979898 9999

Before

1 2 3 4 5 6 7 8 9 10

1112 13141516 1718 192122 23 24 25 26 27 28 29 30

3132 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 503939

20After

Benefits of 5S

• What benefits did we realize by applying 5S to our simulated workplace?

• Quality• Cost• Delivery/Service• Quantitative• Qualitative

• _________________• _________________• _________________• _________________• _________________• _________________• _________________• _________________

Wrap-up

• Can we apply this to the real world?

• Share an “Ah-ha” – something you learned, something that’s new, something that’s different or something that made an impression on you

• ________________________________________________________________

Thank Youfor participating

www.5Ssupply.com888 4 LEAN 5S

5S Simplified. Everything you need… all in one place!

Follow us @• www.blog.5Ssupply.com• Twitter.com/5Ssupply• LinkedIn Group 5S Supply• YouTube.com/5Ssupply

Forms and Facilitator Notes

Participant Forms &

Tips and Tricks

Instructor Notes

• This section has the forms and instructor notes to use during this training exercise

• Items needed:PowerPoint presentation (if desired)Pens or pencils, enough for each participantStopwatch, timer or watch with seconds hand to

time each round (30 seconds)One copy each of the forms for each participant

(see next slide)

• Print the Overall Scorecard form single sided

• Print the Rounds 1, 2, 3, 4 and 5 forms double sided with the words “Please do not turn over until told to do so.” on the front and the exercise on the back

Overall Scorecard

• Handout the Overall Scorecard at the beginning when you are explaining the exercise

• Ask the participants to record their individual scores on this sheet and any comments or “take-aways” from the round

Overall ScorecardComments• _________________• _________________• _________________• _________________• _________________• _________________• _________________• _________________

Exercise Number

Round 1

Round 2

Round 3

Round 4

Round 5

Round 1

Please do not turn over until told to do so.

29 3031

53535454

5656 5757

67676868

7676 7777 7878 7979

858686 8787

959696

97979898 9999

Round 2

29 3031

Round 3

3 4 5 6 7 8 9 10

11 12 13 14 15

17 1819

21 2223

24 2526 27 28

293031 32 33 34 35 36 37 38

43 44 45

Round 4

1 3 4 5 6 7 8

121113141516 1718 192122 23

25 26 27 28 29 30

3132 33

35 36 37 38 40

41 42 43 44 45 46 47 48 49 50

Circle the “defects”.How many did you find?

Round 5

1 2 3 4 5 6 7 8 9 10

1112131415 16 1718 192122 23 24 25 26 27 28 29 30

3132 33 34 35 36 37 38 40

41 42 43 44 45 46 47 48 49 503939

The 5S Numbers Game

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