Benefits of 5S

5S

Safer Work Area

More organised

Best place to make good

quality parts

Less Wastes

Better working

environment

What are the 5S’s?

3

Set In Order

2

Sort & Shine

1

Shift Out

4

Standardise

5

Sustain

5S – Shift Out

• Why?

– Only have the equipment you need in the work area – NOTHING

MORE!!

– To remove all inherent problems and start from fresh

• How?

– Take everything out of area

– Decide what is needed and what is not

– Use red tags on problem items

1. Take out everything

Use a “Shift

Out” area

2. Decide what is needed

These are the tools

required for this area

3. Use Red Tags

Used For

Homeless Items

Broken Items

Safety Problems

Quality Problems

RED TAG LOGTag

#

Problem Solution

Use this to track your red tags

Obsolete Parts

Use Red Tags

5S – Shift Out

Remember:

1) Shift Out once / month

2) Create a “Central Red Tag Area”

3) Ensure each cell has its own supply of red tags

4) Train the operators and supervisors from the area before you do 5S

What to do with shifted out items

What How

Throw it away Dispose of useless items

Modify It Change it to another useful item

Sell It Sell to other companies

Return It Return items to your suppliers

Other Departments Lend to other departments

Give to other departments

5S - Shine & Sort

• Why?– We will be able to see the actual condition of the machines and work

area

– We will be able to find problems we would not normally be able to see

• How?– We clean everything from top to bottom and use red tags

• Homeless

• Broken

• Safety Problems

• Quality Concerns

• Wastes

• What do we need?– Rags, brushes, brooms, red tags, degreaser, gloves, safety glasses,

photographs

5S - Shine & Sort

5S - Shine & Sort

5S – Set in Order

• Why?– Everything must have a home

• How?– A place for everything

– Everything in its place

– Remember safety

– Remember how often you use it

– Constant quantity

• What do we need?– Tape, pens, labels

5S – Set in Order

5S – Set in Order

5S – Set in order

Before After

Before After

5S – Set in order

5S – Set in Order

5S – Set in order

Before After

5S – Standardize

• Why?– We need to keep 5S going – don’t loose it!

• How?– We must make it easy to maintain

– We must have a daily check sheet

– We must use visual management

– Everyone must understand their responsibilities

– We show other shifts / operators

• What do we need?– Photographs, Cell standard

5S – Standardize

Purpose : To list the standard layout, tools and equipment for the cell or area

Responsible: Area Leader

Work instructions, Job cards, Process Sheets need to be visable and displayed the

right locations

Green area charts and measures need to be updated

No extra tools, machines, material, scrap, should be in the area

Area must be clean and tidy

All containers with stock/parts must be labled, including raw material

All tools and machines must be clean and tidy

Scrap need to be contained and clearly marked

5 S Work Area Standard

PhotoDescriptions

Notes : The objective of this document is to standardise the work environment to ensure that it

is kept in a optimal working condition.

5S - Sustain

• Why?

– It is easier if everyone follows the rules, understands the benefits

and help us to improve

• How do we achieve this culture?

– It becomes a habit to keep 5S

– We share our knowledge with everyone

– We lead by example

– Our management supports us it

– We involve everyone

And then…everyone wins!

Before you start

• Plan for model area downtime

– Build up stock

– Have a before photo, then After Photo (from the same angle)

– SAFETY SHUTDOWN

– Remind zone staff of training date

• Plan for use machines e.g. forklift

• Arrange cleaning materials

• Arrange for red tags

• Arrange for yellow tape

• Demarcate Red tag area

5S- Implementation

AREA LAYOUT

5S LOG SHEET

CELL LAYOUT

5S

IMPLIMENTATION

PLAN

5S STANDARD

CELL AUDIT SHEET

RED TAG GRAPH

5S

AUDIT GRAPH

THANK YOU