5S & Workplace Organisation

Program Outcomes

On completion of this program you will be able to:● Clearly understand the 5-S principles

● Identify opportunities around you

● Implement and sustain changes

● 5S is a reference to five Japanese words which when translated into English, all start with the letter S

● 5S is a philosophy and a way of organising and managing workspaces. Work flows with the intent to improve efficiency by eliminating waste, improving flow and reducing process unreasonableness

● 5S is a mnemonic for a methodology that is often incorrectly characterized as "standardised cleanup", however it is much more than cleanup

Introduction

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●Sorting [Seiri (整理 )]●Remove all unnecessary materials and equipment

●Straighten or Set in Order [Seiton (整頓 )]●Make it obvious where things belong

●Shining, Sweeping, or Systematic Cleaning [Seisō (清掃 )]

●Clean everything, inside and out

●Standardising [Seiketsu (清潔 )]●Establish policies and procedures to ensure 5S

●Sustain [Shitsuke (躾 )]●Training, daily activities

5S Elements

Why is 5-S Practiced?

A neat and clean workplace…

• Is a safer place to work in

• Has higher productivity

• Produces fewer defects

• Meets deadlines better

• Frees up valuable floor space

• Reduces the time it takes to look for tools and equipment

• Improves how the operation appears to customers – always be “tour ready”

• Creates pride in the workplace

• Is a starting point for improvement

“Visual order is the foundation of excellence in manufacturing. When it is in its place on the production floor, work gets done efficiently and effectively. When it is not in place, work still gets done – but at a level of cost that is hard to justify”

Gwendolyn D. Galsworth

Visual Systems

Why is 5-S Practiced?

© 2007 Superfactory™. All Rights Reserved.

First the Bad and the Ugly - Life Without 5S

The Good, Bad and the Ugly

The 5S numbers game

•This sheet represents our current work place•Our job during a 20 second shift, is to strike out the numbers 1 to 49 in correct sequence. Example: 1 2 3

•The team score will be represented by the lowest individual score achieved

Round No.1 – Normal Work Place

Round No.1 – Normal Work Place

•For action, we are going to implement 5S in this area

•Step 1 is “Sort” so we have removed from the area all the numbers from 50 to 90 which are not needed

•Same rule applies. Strike out numbers 1 to 49 in sequence during a 20 second shift

Round No.2 – Sort

Round No.2 – Sort

•Having achieved some improvement, we now need to move to Step 2 ”Set In Order”

•We have installed some racking, and we have organized the items so that with Number 1 in the bottom left hand corner, the numbers are located from left to right and bottom to top - examples 1 in the bottom left, 2 in the middle, and 3 in the top left

•Same rules apply 20 second shift, lowest individual score equals team score etc…

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Round No.3 – Straighten or Set in Order

Round No.3 – Straighten or Set in Order

•Having now made a significant step forward, and having ignored “Shine” for this exercise, we must “Standardise”

•Since we are dealing with numbers 1 to 49 in sequence, it seems logical to re-organize them in a standard way that makes the completion of the work task as easy as possible

•This should ensure that everyone is able to complete the task (and therefore produce a team score of 49)

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Round No.4 – Standardize

Round No.4 – Standardize

•To show respect for Standards it is necessary to make the “management” of the area visual

•Returning to our original work area, we have for this assignment two numbers missing. We cannot complete the task without these numbers - so first we have to find them

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Round No.5 – Sustain

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Round No.5 – Sustain

Round No.5 – Sustain

◗ Is the practice of laying out the work area to ensure that all tools, equipment, parts, materials etc are in an orderly manner which promotes effective work flow. The work area should be layed out in manner that eliminates extra movement.

◗ Store things you need close at hand

◗ Follow the “One is best” principle

● One set of tools/stationary

◗ Segregate● Things you don’t need

● Things you’re not sure about

Sort

BEFORE AFTER

Example - Sort

◗ Is the practice of sorting out items in the work area and only keeping to ones that are essential to the job being performed in the area

◗ Everything has a clear designated place

◗ Everything is in its designated place

◗ How quickly can you get things when you need them and how quickly can you put them away?

Straighten or Set in Order

Straighten or Set in Order …recommendations

◗ First in, first out arrangement◗ The more frequently it is used, the closer it is kept◗ Locate tools in all the places that they are used◗ Visibility in cupboards (clear doors if possible)◗ Responsible person indicated on cabinets, boards etc◗ Use shadow boards for tools◗ Address on board, return address on tool◗ Use labels, signs and outlining extensively◗ Identify what, where and how many (bin locations, pallet

stack heights)◗ Keep it off the floor◗ Put things at correct and safe heights

Location

Location

Press Tool

Coil Storage

Assembly & final check station

Tools &

Check jigs

Example - Straighten or Set in Order

BEFORE AFTER

Example - Straighten or Set in Order

BEFORE AFTER

Example - Straighten or Set in Order

◗ Is the practice of keeping the work area clean and neat. In Japanese companies cleaning is a daily activity at the end of each shift, thus ensuring that all items are returned to their correct location. The key point is cleanliness should become part of the team culture

◗ Everyone is a “janitor”

◗ Individual cleaning responsibility is assigned

◗ Provide cleaning tools & equipment

◗ Clean even the places most people do not notice

Keep your machines clean Keep your machines clean and you’ll always know and you’ll always know

what condition they’re in!what condition they’re in!

Shine

BEFORE AFTER

Example - Shine

BEFORE AFTER

Example - Shine

Standardise◗ Is the practice of standardising all work practices into

standards that everyone has to adhere to ensure all work is performed exactly the same way each time by all team members. This is achieved through visual management to facilitate easy understanding of the standards

● Standard daily cleaning procedure

● Standard work procedures

● Colour coding - labels, boxes, customers, zones, tools

Example Standardize

Avalon parts Camry partsInspection

station

Example Standardize

Sustain

◗ Is the practice of maintaining and reviewing the previous 4S’s. Maintain the focus on this new operating way to ensue that a decline back to the old ways does not occur

◗ This does not limit suggestions for a new way of working / a new tool / etc, but when a suggestion is to be implemented a full review of the first 4S's is required

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