Lean Tools:
6S
5-S Workplace Organization
 The foundation of a process is a clean and safe work
environment.
 5-S Standards are the foundation that supports all
phases of Lean. The system can only be as strong as
the foundation upon which it is built.
 When fully implemented, 5-S helps to reduce errors,
increase productivity, improve quality, improve
response time, and improve worker morale.
 It’s strength is dependent upon the employee’s
commitment to maintaining it.
2
5S System and Visual Management
Separate the needed items from the un-needed items.
Sort
5S
Set In
Order
Arrange needed items based on where they will be
used.
Shine
Maintain the work area for the needed items.
Standardize
Sustain
Ensure all S’s are consistently followed.
Maintain all S’s.
The 6th ‘S’ is for SAFETY!
3
Sort
When in doubt, remove it!
STEP 1: Clarify what is needed.
 Segregate what is needed and what is not needed
 No hoarding!
STEP 2: Dispose of things that are not
needed.
 Discard or donate what
is not needed
 Ask questions like how
many of these have you
used in the last week
or month?
STEP 3: With items that are needed, segregate according to frequency
of use.
 Use once a day versus use once a month
4
Set in Order
A place for everything, and everything in its place.
STEP 1: Decide place for storage.
 With unnecessary clutter removed,
the team determines appropriate
locations for items that are needed to
“add value.”
 Those items used several times per
day should be closer than those
items used once a month
STEP 2: Set up markings (Boundary Lines)
for storage locations.
 Clearly mark and arrange everything
neatly so what is needed can be
easily found.
STEP 3: Make upkeep easy.
5
Shine
Clean to inspect, inspect to detect, and detect to correct.
STEP 1: Conduct overall ‘Shining’.
 Clean up personal and working environment so there
are no areas untidy with dirt or other clutter.
 Top to bottom cleaning and inspection.
 By touching and observing equipment as they clean,
team members can spot early signs of trouble before
they cause break downs, accidents, and defects.
STEP 2: Improvement plans to prevent dirtiness.
6
Safety
How do we be safe and productive?..effective?...with
good quality?
STEP 1: Resolve all safety issues
STEP 2: Change things likely to cause injury, stress, or overburden
STEP 3: Check existing safety equipment
7
Standardize
You can see the perfection !
STEP 1: Make the new standards obvious to everyone.
 Turn proven temporary methods for keeping the
workplace uncluttered into permanent visual methods.
STEP 2: Maintain the conditions to the previous 3 S’s.
8
Sustain
Sustain the Gain. Pride of ownership!
STEP 1: Develop a system to determine
if the gains have been sustained.
 Turn proven temporary methods
for keeping the workplace
uncluttered into permanent
visual methods.
STEP 2: Develop a system to bring forward
future suggestions and trial
changes.
Board was placed in co-worker break room
to visually see if gains have sustained.
They are to insert current picture each
month.
9
Conducting a 6S – Points to consider
 Consider the area’s work schedule and determine the
best day and time to conduct the 6S.
 You can also pull everything out of an area and only
bring back in needed items.
 Respectfully challenge each other so that only needed
items are kept.
 Involve team members who represent every role that
utilizes the workspace.
 Be sure the coworkers from the area understand the
purpose and value of a 6S before you start. No one
should be surprised.
10
5S Examples
The following slides illustrate how 5S can be
utilized in a variety of projects to remove
process clutter, improve efficiency, and
reduce NVA-E and NVA-W.
11
Problem:
No space left in storage, storing supplies on the floor in other areas
Space was utilized by storing things no longer needed
…Some mistake 6S for simple housekeeping …
it actually builds a solid framework for visual management
From
This
To
This!
Lab Storage
12
Standardize Exam Room
Before
After
13
Respiratory Therapy Dept
Before
After
 Removal of unneeded items (cabinets, shelves, cart)
 Replaced storage shelves with open and visible shelving
(shelving was stored in another department’s storeroom!)
 Identified what should be stored in each area by colored
dots, magnetic shelf labels, different colored walls and tote
sizes
14
Respiratory Therapy Dept
 Removed unneeded items (cart, shelving, sink, old books)
 Replaced storage shelves with open and visible shelving
 Moved most used items to eye level
Before
After
15
Respiratory Therapy Dept
Before
After
 Removed unneeded items (exam table, extra supplies, old files
 Utilized different tote sizes and labels to indicate where every
item should be placed
 Utilized clear storage totes in order to see what was stored
there
16
6S at Work
A place for everything and everything in it’s place
Condensed from 3 drug sample closets to 1
Before
After
17
From your first cycle of 6S
1.) You want a showcase:
You want at least one department / work area in your hospital that
vividly captures the vision and the function of visual order to inform
and inspire others to “get on board”.
2.) You want results:
Improvement of the key performance indicators in your pilot area(s)
that are attributable to visual order. Such indicators as: productivity,
yields, defect, re-work, scrap levels, safety, on-time delivery, and overall
lead time.
3.) You want to learn about the process:
You want to learn about the implementation process itself - to see what
works, how people react, and what is needed and realistic to expect in terms
of outcome and support.
6S Exercise
 In your group, identify the 6S improvements that
could be applied to the simulation process or to a
work area you interact with daily.
 Identify what improvements need to be made at
each of the following steps:
Sort
Set in Order
Shine
Safety
Standardize
Sustain
19