“5S” CAK SAFETY COUNCIL JANUARY 27, 2016

BACKGROUND

• 5S is part of the “Lean Management Philosophy”

• Lean Management Philosophy

Definition - To remove waste and streamline

LEAN

Quality Freedom from failures

Achieving zero defects and zero accidents

Higher quality Fewer defects, errors & accidents, reduced poor response times, breakthrough

Waste Overproduction

Waiting

Transport

Poor Process Design

Inventory

Motion

Defects & Accidents

Skills

Cost of Poor Quality (COPQ)

5S

Lean Management Philosophy

To remove waste and streamline

Can be dated back to Venetian’s 1574 ship

building

Most refer to 5S as having Japanese origin,

post WWII

5S - STEPS

Sort

Set in order

Shine

Standardize

Sustain

5S - SORT

Sort Items used Daily

Place close to area of use

Items used once a week Place close to process

Items used once every two months Place in storage

Items of infrequent use Place in temporary storage, if not used in one year - dispose

Items not used Throw away

5S – SET IN ORDER

Arrange needed items so they are easy to find

and use

Label items and storage sites to be visually

recognized

“A place for everything and everything in its

place”

Implement visual control

5S - SHINE

Remove dirt, grime and dust from the

workplace

Keep everything swept and clean

If a mess is made immediately clean it up

Learn to work clean

5S – STANDARDIZE

Like work stations should be the same

Like tools should be the same

Standardize as much as possible

5S - SUSTAINABILITY

Complete documented audits for measurement

Analyze results and identify areas of needed

improvement

Maintain program with a dynamic approach for

continuous improvement

Be careful what you measure it may drive the

wrong results

BEFORE & AFTER 5S

BEFORE & AFTER 5S

KISS

COST EFFECTIVE DECISIONS

VS.

5S ABSOLUTELY IMPROVES SAFETY

Reduced motion – less tired, more focused, not hurried, repeated motion, less frustrated, better attitude, more time for safety conciseness

Reduced ergonomic risk – less strains, odd body motions, greater balance

Removed hazards - tripping, slip, noise, electrical wiring, spills, heat exposure, protrusions, fumes, dust, chemical

Visual identification - more aware, less to compute

Behavior based safety – self discipline, empowerment, accountability

QUESTIONS?