5S and Visual Factory

Lean Manufacturing Series

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Disclaimer and Approved Use
•  Disclaimer
▫  This presentation is intended for use in training individuals within an organization. The
handouts, tools, and presentations may be customized for each application.
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•  Approved Use
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Contents
1.  Introduction
2.  Background and History
3.  Components and Implementation
4.  Knowledge Check

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Introduction
•  5S is a method to improve and sustain workplace
organization
•  5S represents 5 disciplines for maintaining a visual
workplace (visual controls and information systems).
•  These are foundational to continual improvement and a
manufacturing strategy based on "Lean
Manufacturing" (waste removing) concepts.
•  Reduces clutter
•  Reduces the time it takes to look for tools and equipment
•  “A place for everything and everything in its place”
•  Improves how the operation appears to customers – always
be “tour ready”
•  Creates pride in the workplace
•  Many companies have a standard that any tool must be able
to be found within 60 seconds.
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Background and History
•  Taiichi Ohno created the original “4S” concept of
workplace organization and visual control at Toyota
during the early 1950’s.
•  The concept was further refined into “5S” during the
1960’s and 1970’s.
•  U.S. manufacturers added a sixth “S” for “safety”
during the 1990’s.

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Components and Implementation
•  5S and Lean Manufacturing
•  Elements of 5S
▫  Sort
▫  Straighten
▫  Shine
▫  Standardize
▫  Sustain
▫  Safety
•  Visual Factory
•  Implementation plan

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Elements of 5S
•  Sort
▫  Remove all unnecessary materials and equipment
•  Straighten
▫  Make it obvious where things belong
•  Shine
▫  Clean everything, inside and out
•  Standardize
▫  Establish policies and procedures to ensure 5S
•  Sustain
▫  Training, daily activities
•  Safety (often called “6S” or “5S + 1”)
▫  A safety commitment in all activities

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Types of Waste
•  Overproduction
•  Excess inventory
•  Defects
•  Non-value added processing
•  Waiting
•  Excess motion
•  Transportation
•  Other Wastes:
▫  Untapped Human Potential
▫  Inappropriate Systems
▫  Wasted Utility Resources
▫  Wasted Materials

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First the Bad and the Ugly - Life Without 5S
•  The Good, Bad and the Ugly

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The Good – After 5S

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After 5S
•  Clear, shiny aisles
•  Color-coded areas
•  Posted processes, metrics and other current
information
•  Always “customer tour ready”

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5S Examples

After 5S - Cleaned, organized

and drawers labeled (less
Before 5S time and frustration hunting)

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Sort
•  Identify clutter and disposition
•  When in doubt, move it out
•  Red tag exercise (more later)

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Straighten
•  Make it obvious where things belong
▫  Lines
–  Divider lines
–  Outlines
–  Limit lines (height, minimum/maximum)
–  Arrows show direction
▫  Labels
–  Color coding
–  Item location
▫  Signs
–  Equipment related information
–  Show location, type, quantity, etc.

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5S Examples – Sort and Straighten

See the difference?

•  Sort - All unneeded tools, parts and supplies are removed from the area
•  Straighten - A place for everything and everything is in its place

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Straighten Check Sheet
Equipment Materials
•  Machines •  Raw material
•  Small tools •  Supplies
•  Dies •  Parts
•  Jigs •  Work-in-process
•  Bits •  Finished goods
•  Conveyance equipment •  Shipping materials
•  Cleaning equipment •  Cleaning supplies

Furniture Other items

•  Cabinets •  Charts, graphs, bulletin
•  Benches, tables boards
•  Chairs •  Pens, pencils
•  Carts •  Work clothes
•  Shelves •  Helmets
•  Racks •  Work shoes
•  Trash cans
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Shine
•  Clean everything, inside and out
•  Prevent dirt and contamination from reoccurring
•  Remove outdated material (like old posted charts,
news, and metrics!)
•  Results in
▫  Fewer breakdowns
▫  Greater safety
▫  Product quality
▫  More satisfying work environment

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 5S Examples - Shine

•  The area is cleaned as the work is performed (best) and\or there is a

routine to keep the work area clean.

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Shine Check Sheet
•  Ceilings •  Floors
•  Aisles •  Machines
•  Workstations •  Conveyance equipment
•  Corners, under •  Plumbing, sinks
equipment •  Cabinets, shelves, racks
•  Loading docks •  Carts, Racks
•  Walls •  Drawers, storage bins
•  Doors •  Fixtures, power boxes
•  Pillars, posts

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Standardize
•  Establish guidelines for the team 5-S conditions
•  Make the standards and 5-S guidelines visual
•  Maintain and monitor those conditions

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Typical Team Standards
•  Sort
▫  Amount of inventory
▫  Tools that belong in the area
▫  How often to remove scrap
•  Straighten
▫  Location of aisleways
▫  Location of tools, equipment
•  Shine
▫  Cleaning schedule
▫  Maintenance tasks
▫  Checklist of what to look for as cleaning is performed

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Sustain
•  Determine the methods your team will use to maintain
adherence to the standards
•  5-S concept training
•  Before and after photos
•  Checklists, standards and procedures
•  Daily 5-minute 5-S activities
•  Monthly 5S Audit

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Safety
•  Does not replace the existing site safety plan
•  During 5S audits also review all areas for safety

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5S Implementation
1.  Begin reviewing your areas for 5S
2.  Discuss 5S with each of your groups (brief group
meeting)
3.  Red tag sorting process (one time)
4.  Brief, simple daily 5S individual activity (“just look
around”)
5.  Brief 5S checklist or procedure for each area
6.  Monthly 5S audit beginning __________
a.  Area Lead plus at least one person from outside that area
b.  Post results (I will look for them!)
c.  Review results with your group
d.  Take corrective action

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Red Tag Process
•  One-time activity to remove or disposition clutter
•  To be started within two weeks of this training
1.  Identify clutter, unused equipment, etc
2.  Fill out and attach red tag
3.  Note in red tag log
4.  Red tags must be dispositioned within 30 days

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Red Tag Inspection Sheet
•  Search
▫  Floors
▫  Aisles
▫  Operation areas
▫  Workstations
▫  Corners, under equipment
▫  Small rooms
▫  Offices
▫  Loading docks
▫  Inside cabinets

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Red Tag Inspection Sheet
•  Look for unneeded equipment
▫  Machines, small tools
▫  Dies, jigs, bits,
▫  Conveyance equipment
▫  Plumbing, electrical parts
•  Look for unneeded furniture
▫  Cabinets
▫  Benches, tables
▫  Chairs
▫  Carts

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Red Tag Inspection Sheet
•  Search these storage places
▫  Shelves
▫  Racks
▫  Closets
▫  Sheds
▫  Search the walls
▫  Items hung up
▫  Old bulletin boards
▫  Signs

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Red Tag Inspection Sheet
•  Look for other unneeded items
▫  Work clothes
▫  Helmets
▫  Work shoes
▫  Trash cans
▫  Other
•  Look for unneeded materials
▫  Raw material
▫  Supplies
▫  Parts
▫  Work in process
▫  Finished goods
▫  Shipping materials

© 2013 Gemba Academy LLC. All rights reserved. 29

Visual Factory
•  Mark-off the inventory locations
•  Mark-off equipment/machine locations
•  Mark-off storage locations (cabinets, shelves, tables)
•  Visually indicate amount of allowed inventory
•  Keep metrics, wall charts, and other information
current
•  Label all cabinets, shelves, etc with their contents
•  Posted production status, upcoming jobs

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 Knowledge Check

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Name the five “S” components. (Mark all that apply)

a)  Sort

b)  Straighten

c)  Shine

d)  Standardize

e)  Sustain

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Match the 5S component name with it's description by
dragging the description to the name.

Name Description

□ 
A.  Training, daily activities
B.  Clean everything, inside

□ 
F
Sort and out

□ 
E C.  A safety commitment in
Straighten
all activities
B

□ 
Shine D.  Establish policies and
D procedures to ensure 5S

□ 
Standardize E.  Make it obvious where

□ 
A things belong
Sustain
C F.  Remove all unnecessary
Safety materials and equipment

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What are some ways in Straighten that you can
make it obvious where things belong? (Mark all that
apply)

1.  Lines
2.  Labels
3.  Signs

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Performing Shine results in which of the
following? (Mark all that apply)

1.  Fewer breakdowns

2.  Slower processing
3.  Greater safety
4.  Product quality
5.  More satisfying work environment

© 2013 Gemba Academy LLC. All rights reserved. 35

What are some ways your team can Sustain 5S?
(Mark all that apply)

1.  5-S concept training

2.  Before and after photos
3.  Checklists, standards and
procedures
4.  Daily 5-minute 5-S activities

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Strategy is sometimes called the sixth "S".
o A) True
o B) False

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Which of the following are a part of the “red
tag” activity? (Mark all that apply)

1.  One-time activity to remove

or disposition clutter
2.  Identify clutter, unused
equipment, etc
3.  Fill out and attach red tag
4.  Note in red tag log

© 2013 Gemba Academy LLC. All rights reserved. 38

What are some ways that you can maintain a
Visual Factory? (Mark all that apply)
1.  Mark-off the inventory locations

2.  Mark-off equipment/machine

locations

3.  Visually indicate amount of

allowed inventory

4.  Label all cabinets, shelves, etc

with their contents

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How can you implement 5S in your organization?

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Congratulations!!!
•  You have completed the course.

•  Please visit Superfactory (www.superfactory.com) for

more information on manufacturing excellence.

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