5S Numbers Game
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The 5S Numbers Game A fun and exciting way to present the 5S concepts to your team!
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Transcript of 5S Numbers Game
The
5S Numbers Game
A fun and exciting way to present the 5S concepts to your team!
• This is a simple training game you can 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• Set-in-Order – Round 3• Shine• 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
1
23
4
56
7 8
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1112
1314
1516
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23
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53535454555656 5757
5858
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6465
66666767
6868
3939
7071
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757676 7777 7878 7979
8081
82
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858686 8787
8888
89
9091
92
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959696
97979898 9999 100
GO!
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?
1
23
4
56
7 8
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1516
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21 22
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24 25
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53535454555656 5757
5858
5959
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6465
66666767
6868
3939
7071
72
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757676 7777 7878 7979
8081
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83
84
858686 8787
8888
89
9091
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93
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959696
97979898 9999 100
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?
Sort
• To sort through, to sort out• Guideline: If it is not needed in the next 30
days, Red Tag it• “When in doubt, move it out!”• 5S Red Tag Technique• Place a Red Tag on the item and move it to
the 5S Red Tag Holding Area• Items will be dispositioned: keep, throw out,
donate, scrap, shred, recycle, etc.
1
23
4
56
7 8
9
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1314
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21 22
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24 25
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3940
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4950
5151
5252
53535454555656 5757
5858
5959
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61
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6465
66666767
6868
3939
7071
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73
74
757676 7777 7878 7979
8081
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858686 8787
8888
89
9091
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959696
97979898 9999 100
Let’s red tag the numbers we don’t need (51-100) and the duplicate 39.
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7 8
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4950
5151
5252
53535454555656 5757
5858
5959
60
61
62
63
6465
66666767
6868
3939
7071
72
73
74
757676 7777 7878 7979
8081
82
83
84
858686 8787
8888
89
9091
92
93
94
959696
97979898 9999 100
1
23
4
56
7 8
9
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1112
1314
1516
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21 22
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24 25
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29 3031
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36
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3940
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47
48
4950
5151
5252
53535454555656 5757
5858
5959
60
61
62
63
6465
66666767
6868
3939
7071
72
73
74
757676 7777 7878 7979
8081
82
83
84
858686 8787
8888
89
9091
92
93
94
959696
97979898 9999 100
Now let’s move them to the 5S Red Tag Holding Area.
78781
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4
56
7 8
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1112
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21 22
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24 25
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3940
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5151
5252
53535454555656 5757
5858
5959
60
61
62
63
6465
66666767
6868
3939
7071
72
73
74
757676 7777 7979
8081
82
83
84
858686 8787
8888
89
9091
92
93
94
959696
97979898 9999 100
1
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56
7 8
9
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Instructions – Round 2
• 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…)
• You will have 30 seconds to complete this task
1
23
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56
7 8
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1112
1314
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GO!
Report Out – Round 2
• Record your highest number found and a comment on your Overall Scorecard sheet
• The lowest score is what’s recorded for the entire group
• What was the exercise like this time?• What can we learn from this?
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
• Guideline: Any item that you want to keep after the 5S Red 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)
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Let’s rearrange the numbers in order that we will use them.
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11 12 13 14 15
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21 2223
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293031 32 33 34 35 36 37 38
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11 12 13 14 15
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21 2223
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293031 32 33 34 35 36 37 38
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41 4243 44 45
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4748 49
50
3939
Did you notice that we had to work around a few things like the numbers that were already there? 20
Instructions – Round 3
• 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…)
• You will have 30 seconds to complete this task
12 3 4 5 6 7 8 9 10
11 12 13 14 15
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17 1819
21 2223
24 2526 27 28
293031 32 33 34 35 36 37 38
40
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50
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20
GO!
Report Out – Round 3
• Record your highest number found and a comment on your Overall Scorecard sheet
• The lowest score is what’s recorded for the entire group
• What was the exercise like this time?• What benefits can you see from “Sort” and
“Set-in-Order”?• Record on Scorecard sheet
Shine• 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
12 3 4 5 6 7 8 9 10
11 12 13 14 15
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17 1819
21 2223
24 2526 27 28
293031 32 33 34 35 36 37 38
40
41 4243 44 45
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4748 49
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20
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
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20
Standardize
• We need to have standards for the first three S’s: Sort, Set-in-Order and Shine
• 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
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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
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After looking at all the styles of font and sizes the team determined that some of these items can be standardized.
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111213 141516 1718 192122 23 24 25 26 27 28 29 303132 33 34 35 36 37 38 4041 42 43 44 45 46 47 48 49 50
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20
1 2 3 4 5 6 7 8 9 10
111213 141516 1718 192122 23 24 25 26 27 28 29 303132 33 34 35 36 37 38 4041 42 43 44 45 46 47 48 49 50
3939
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 303132 33 34 35 36 37 38 4041 42 43 44 45 46 47 48 49 50
3939
20
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
Instructions – Round 4
• 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• You will have 30 seconds to complete
this task
1 3 4 5 6 7 8 9 10
121113 141516 1718 192122 23
2425 26 27 28 29 30
3132 3334
35 36 37 38 4041 42 43 44 45 46 47 48 49 50
20
GO!
Report Out – Round 4How 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 9 10
121113 141516 1718 192122 23
2425 26 27 28 29 30
3132 3334
35 36 37 38 4041 42 43 44 45 46 47 48 49 50
20
Instructions – Round 5
• 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…)
• You will have 30 seconds to complete this task
1 2 3 4 5 6 7 8 9 10
111213 141516 1718 192122 23 24 25 26 27 28 29 303132 33 34 35 36 37 38 4041 42 43 44 45 46 47 48 49 50
3939
20
GO!
Report Out – Round 5
• Record your highest number found and a comment on your Overall Scorecard sheet
• The lowest score is what’s recorded for the entire group
• What was the exercise like this time?• What benefits can you see from “Sort” and
“Set-in-Order”?• 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
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7 8
9
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4950
5151
5252
53535454555656 5757
5858
5959
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61
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63
6465
66666767
6868
3939
7071
72
73
74
757676 7777 7878 7979
8081
82
83
84
858686 8787
8888
89
9091
92
93
94
959696
97979898 9999 100
Before
1 2 3 4 5 6 7 8 9 10
111213 141516 1718 192122 23 24 25 26 27 28 29 303132 33 34 35 36 37 38 4041 42 43 44 45 46 47 48 49 50
3939
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)
Forms
• 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.
1
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56
7 8
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1516
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21 22
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24 25
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29 3031
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33
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3940
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42
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45
46
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48
4950
5151
5252
53535454555656 5757
5858
5959
60
61
62
63
6465
66666767
6868
3939
7071
72
73
74
757676 7777 7878 7979
8081
82
83
84
858686 8787
8888
89
9091
92
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959696
97979898 9999 100
TOP
Round 2
Please do not turn over until told to do so.
1
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3939
TOP
Round 3
Please do not turn over until told to do so.
12 3 4 5 6 7 8 9 10
11 12 13 14 15
16
17 1819
21 2223
24 2526 27 28
293031 32 33 34 35 36 37 38
40
41 4243 44 45
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4748 49
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20
TOP
Round 4
Please do not turn over until told to do so.
1 3 4 5 6 7 8 9 10
121113 141516 1718 192122 23
2425 26 27 28 29 30
3132 3334
35 36 37 38 4041 42 43 44 45 46 47 48 49 50
20
TOP
Circle the “defects”.How many did you find?
Round 5
Please do not turn over until told to do so.
1 2 3 4 5 6 7 8 9 10
111213 141516 1718 192122 23 24 25 26 27 28 29 303132 33 34 35 36 37 38 4041 42 43 44 45 46 47 48 49 50
3939
20
TOP
