Implementing 5S • S1 – Sort

“When in doubt, move it out”

• S2 – Set in Order “A place for everything and everything in its place.”

• S3 – Shine “Clean and Inspect”

• S4 – Standardize “Create the rules and follow them”

• S5 – Sustain “Make 5S a habit”

Roll Stock & F/G Before Kaizen

Not to scale

Roll Stock & F/G After Kaizen

Not to scale

Before Kaizen (F/G, Roll Stock, Box Mtl randomly located) Loc 201 Loc 202

Loc 203 Loc 204

F/G with roll stock

Corrugated pkg

mtl w/ roll stock

Before Kaizen (Roll & F/G material randomly located)

Sort – Red Tag Exercise

Sort – Red Tag Exercise

Sort – move it out (completed 3/28/07)

Sort – move it out

Sort – categorize

Define the

locations for

high volume

material

Shine “New Warehouse”

Define the locations for

low volume material

Set In Order (Bleached/Sleeve Material)

Before

Set In Order – Plastic Pkg

Before

Set In Order – F/G

Before

Set In Order – Roll Stock

Before

Set In Order – MRB (RM)

Before

FOIL PRINT

Set In Order – Print/Foil

Set In Order – “New Warehouse” Natural Kraft Roll Stock

Set In Order – dedicated location (6 locations, 3 SPK, 3 Natural Kraft)

Natural Kraft high volume

dedicated location

SPK high volume dedicated location

Open area for expanding volumes of roll stock (clamp

trucks unload train cars directly to high volume turn-over locations)

Standardize

Sustain (Warehouse Kiosk board)

Daily Check

Sheets

Daily Review

Status

Lessons Learned • Review & remove obsolete material

annually.

• When material is visible it is obvious if you are over-stocked.

• Having things “Set in order” makes easy access to retrieve.

• Organizes environment is a happy environment!