Continuous Improvement5S Training

5S Training Objectives

By the end of this module, the participants should be able to:

• Define and understand the importance of 5S methods.

• Put 5S into practice in your work area.

• Identify and overcome the barriers of productivity.

• Improve QUALITY of work.

• Practice efficiency at all times.2

5S Fundamentals

“Misconception about 5S is that it is just housekeeping, however it is more than just housekeeping”.

What is 5S?

• It is the name of the workplace organization method that uses a list of five Japanese words: Sort, Shine, Signpost, Standardize and Sustain

• It is a structured program that systematically achieve total organization, cleanliness and standardization in the workplace.

• It maintains visual workplace (visual controls and information Systems).

5S Methodology

S1 Sort and Discard eliminatesnon-essential items from the workplace. A pleasant and efficient workplace is created.

S1 ort and Discard

S2 Shine and Inspect removes dirt, grime and dust from the workplace by thoroughly cleaning equipment, floors and walls.

S2 hine and Inspect

S3 Signpost and Order ensures that there is a place for everything and that everything is in its place. Everything must be sign posted so that it is visually clear where things belong.

S3 ignpost and Order

S5 Sustain refers to the discipline required to ensure that S1, S2, S3 and S4 are properly maintained and improved.

S4 Simplify and Standardise by applying ergonomic principles to the workplace to eliminate wasteful activities and make work safer and easier.

S5 ustain

S4implifyand

Standardise

5S Example - Workplace

Before

After

5S Example - Office

Before

After

5S Example - At home Before

After

S1 – Sort & Discard

S1: Sort and Discard

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Sort and Discard distinguish between necessary and unnecessary items and discard items that are not needed & unnecessary from the workplace.

“Keep only what is needed, only in the amounts needed andonly when needed”.

Why Sort and Discard?• Removes waste from the workplace• A clutter-free and efficient workplace is

created.• Makes the work place safer• Creates more space by getting rid of

unneeded items in the work place.• Makes it easier to visualise the process

S1: Sort and Discard Red Tag TechniqueRed Tagging is a visible way to identify what is not needed in the workplace. Red Tags ask “Why am I here?” and supports the first - “Sort and Discard”.

The Red Tag Technique involves the following steps:

4. Sort through the Red Tag items; dispose of those which are truly superfluous. Other items can be eliminated at an agreed interval when it is clear that they have no use. Ensure that all stakeholders agree.

5. Determine ways to improve the workplace so that unnecessary items do not accumulate.

6. Continue to Red Tag regularly.

1. Establish the rules for distinguishing betweenwhat is needed and what is not.

2. Identify needed and unneeded items and attach Red Tags to all potentially unneeded items.Write the specific reason for Red Tagging and sign and date each tag.

3. Remove Red Tagged items and temporarily store them in an identified

holding area.

S1: Sort and Discard – Red tagging Example

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S2 – Shine & Inspect

S2: Shine and Inspect

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Shine and Inspect meansthoroughly

cleaning grime,

the workplace, removing stains,spots,debris and eradicating sources of dirt.

Why Shine and Inspect?•A clean workplace is indicative of a

qualityproduct and process.

• Dust and dirt cause product contaminationand potential health hazards.

•A clean workplace helps to identify abnormal activities.

“Systemic cleaning and keeping the workplace neat should be the order of the day, not an occasional activity initiated when things go messy”.

S2: Shine & Inspect

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S3 Signpost & Order

S3: Signpost and Order

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Signpost and Order ensures that there is a designated and demarcated place for each and every item.

“A place for everything and everything in its place”.

Why Signpost and Order?•Keep things used together, kept together• Apply principles of Visual Management.•Eliminates time spent looking for items• Eliminate the need for excess items.•To arrange the workplace in a manner than promotes

workflow

S3: Signpost and Order Example

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S4 Standardise & Simplify

S4: Standardise and Simplify

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S4 Standardise and Simplify focuses on creating a simplified consistent approach with which tasks and procedures are performed in the workplace, as well as maintaining a clean and healthy work environment.

Why Standardise and Simplify?•Keep the workplace neat

enough for visual identifiers to be effective in uncovering hidden problems.

•Develop a system that will enable everyone in the workplace to see problems when they occur

•To define the standards by which employees must measure and maintain cleanliness

“To maintain a high standard of workplace organisation by keeping everything clean and orderly at all times”.

S4: Standardise and Simplify

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S5 Sustain

Do – S5 Sustain

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Sustain making a habit of properly maintaining the correct procedures from the previous four steps and strive for further improvementWhy Sustain?•To sustain Sort, Shine Signpost

activities everyday.• To maintain what has been

accomplished.•Develop a system that will enable

everyone in the workplace to see problems when they occur

•Team spirit and discipline are developed.•Enhance operation effectiveness in a

better working environment“Part of daily work and make a habit ofmaintaining established procedures”.

5S Benefits

Advantages of 5S

5S Implementation has the following benefits

• Increase space

• Improved productivity

• Elimination of time spent looking for things

• Accidents and mistakes minimised

• Work area easier to manage

• A clean and tidy workplace leads to improved employee well being and Increased motivation

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5S ImplementationProcess

5S Implementation ProcessIdentify team

membersSelect Area Identify

ChampionTake

Before Pictures

Conduct 5S Exercise

Conduct Regular Audits

Take After Pictures

Conduct Compliance

Reviews

Recognise& Reward

Way Forward

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Actions to be taken immediately after 5S training

o Identify 5S Champions

o Establish Red-tagging holding areas

o Conduct red-tagging

o Identify the Abnormalities

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Thank you