Lean in Action
5S System: Techniques for Efficient Workplace
Organization
Management Meeting
Month X, 20XX
What is 5S?
• A visual method of workplace organization
• 5S helps to:
- Have needed material, tools, supplies, and documentation at
hand, organized, and identified
- Maintain a clean work area with tools and equipment in top
condition
- Standardize workplace organization
- Maintain a occupationally-safe, ESD-safe, FOD-free
workplace
2
Why employ 5S?
• An organized, clean workplace:
- Shortens Span Times
- Reduces the non-value added work of searching for
materials, tools, equipment and paperwork
- Reduces Floor Space requirements
- Prevents and detects errors and defects
- Raises team pride and job satisfaction
- Makes work easier to accomplish
• In short, an organized workspace
- enhances safety
- improves quality
- and reduces cost and cycle time
3
Elements of a 5S Program
1.Sort
2.Set in Order
3.Shine
4.Standardize
5.Sustain
4
5S - Down to Basics
SORT
SET IN ORDER
SHINE
STANDARDIZE
SUSTAIN
Remove all
non-essential
items from
around the
work area.
Any essential
items that do
not fit or work,
or are broken,
are tagged
for action.
A place for
everything
and
everything
in its place.
Arrange items
so they can
be found,
retrieved
and returned
easily.
Remove dust,
dirt & debris.
Cleaning will
also highlight
any previously
unforeseen
problems.
Prioritize
safety, quality
and reliability
issues.
Spread
through the
work place.
Checklists are
made showing
exactly where
and when
regular
maintenance
should take
place.
Everyone
who uses the
work area is
encouraged
to adopt the
new system.
Eventually
the new
arrangements
will become
the culture.
For 5S to be effective, everyone must take full
responsibility for their own area of work, while
supporting 5S throughout the shared workplace
5
Elements of a 5S Program
1.Sort
-
Eliminate the clutter
“When in Doubt, Throw It Out!”
-
Create a place for everything and put everything in its place
Arrange needed items so that they are easy to use and label
them so that “anyone” can find them and put them away
Use Visual Aids to aid understanding and minimize
complexity





Shadow Boards
Labels (“Return addresses”)
Clearly marked places for items that are movable
Area Identification signs
Lines on the floor
2.Set in Order
3.Shine
4.Standardize
5.Sustain
6
Sort: Workstations
What work
is being
Performed?
7
Sort: Workstations
Before
After
8
Sort: 5S Holding Area
• If unsure whether or not to
discard an item, a 5S
Holding Area should be
established
• Items should remain in the
area for a short period of
time, reassessed, and either
discarded or (if needed)
placed back into the work
area
• All items should have a 5S
Holding Tag for
identification (next slide)
• Items will be logged in a
database and tracked
9
Sort: 5S Holding Tag (example)
• Tag is used for
Date placed in
tracking and
Holding Area
maintaining items that
are in the 5S Holding
Individual that
tagged the item
area that are to be
item came from (stock,
reevaluated for either Area
assembly, Test area etc.)
disposal or for
Short description (include
P/Ns if necessary)
placement back into
appropriate area
Reason why in Holding Area
(obsolete, not needed, broken, etc.)
• 5S Holding Tag
should be filled out
completely and
logged into database
Proposed next steps to take
5S Holding Tag
Date:
Tagged By:
Location:
Item Description:
Why in Holding Area:
ACTION
1. Discard
2. Return to
3. Move to Common Holding Area
4. Other
CATEGORY
Used to track all items
1. Equipment
2. Tools
3. Flight Hardware
4. GSE
5. Supplies
6. Other
example
10
Elements of a 5S Program
1.Sort
2.Set in Order
- Organize and label, set boundaries and limits
“A Place for Everything and Everything in its Place”
•
•
11
Why: Makes things easy to locate, easy to put away, readily apparent if
missing
Results: No wasted time looking for tools or documents; they are
identified and on hand when needed
-
One-Step Rule:
-
45 Degree Rule:
-
Strike Zone Rule:
-
Higher the Pounds - Closer to Knuckles:
Nothing that is used daily is stored more than a step
away. Improve economy of motion, save valuable seconds, and make the job
less frustrating.
Arrange the immediate work area layout to minimize
twisting, especially applicable for bench work. If something weighs more than
a few pounds, make sure it is beyond immediate reach so the lifter must
reposition the body properly for lifting.
Store things above the knees and below the chest.
This will help to reduce the chance of back strain.
Locate heavy items to
eliminate bending, stooping or unnecessary arm movements during lifting.
Set In Order: Tool Crib Before Organization
12
Set In Order: Tool Crib After Organization
13
Set In Order: Unorganized Toolbox
14
Set In Order: Organized Toolbox
15
Elements of a 5S Program
1.Sort
2.Set in Order
3.Shine
Clean everything, inside and out
“Inspection Through Cleaning”
•
•
Why: Nobody works well around a mess; FOD can ruin or
delay a mission; a clean workplace promotes pride and
demonstrates an interest in quality; cleaning allows us to find
problems with equipment and tools in time to prevent delays
Results: A bright, clean, organized, work area that promotes
confidence, quality, and on time delivery
4.Standardize
5.Sustain
16
Shine: Before Cleaning
17
Shine: After Cleaning
Recognize and Reward the Team !!
18
Elements of a 5S Program
1.Sort
2.Set in Order
3.Shine
4.Standardize
Document the standard method for workplace organization
so we always do things in the same way
“Everything in a State of Readiness”
•
•
5.Sustain
19
Why: Standardizing the way we maintain a work area and perform our
work promotes consistency in how work is approached and accomplished,
and allows easier cross training and movement of personnel
Results: Standardized presentation of work areas, material and tools for
work
Standardize: Best Practices for Organization
Old way
New Standard
20
Standardize: Best Practices for Organization
Old way
New Standard
21
Standardize: Shadow Part Kits
22
Elements of a 5S Program
1.Sort
2.Set in Order
3.Shine
4.Standardize
5.Sustain
- Maintain discipline through systems and a supportive
culture
“Launching quality with persistence.”
•
Why: Without sustaining the first 4 Ss, they will die; promotes a
continuous improvement environment
•
Results: Ever improving quality, cycle times, on time commitments;
high motivation, recognition for excellence
23
Sustain: Teams set Standards to meet
Customer Demand
• Communications Board in the area shows the Continuous
Improvement List, Current Schedules and Metrics
• White board is for anyone to post any issue to be put on the
Continuous Improvement List
24
Sustain: Teams set Standards to meet
Customer Demand – Show progress
Publicity !
25
Sustain: Standard Assessment Score
(spider web chart)
(Assessed Work Area)
1S (Sort)
20
Current Assessment
15
Previous Score
12
10
5S (Sustain)
2S (Set in Order)
5
8
11
0
8
11
4S (Standardize)
26
3S (Sweep)
Getting Started
• Form 5S Teams:
- All players who regularly work in the work are/ center
- If you use tools, hook up & use test equipment, handle parts, or
regularly handle travelers, drawings or Work Procedures in the area,
we want you on the team
• Conduct 5S Kaizen event:
- Learn what a 5S workplace looks like
- Only needed things present
- Clean; dustless
- All things organized, arranged and identified
- Visuals help tell at-a-glance the state of the workplace (signs, posters,
arrows, charts, schedules, etc.)
27
Getting Started
• Plan for Success:
- Set team 5S goals
- Appoint 5S champion(s)
• First Steps:
- Post 5S team roster with leader, champions, and backups for
-
calibration, shelf life, job supplies
Create a 5S holding area
 Sort unneeded items and move them to the 5S holding area
- Conduct monthly 5S Assessments
 Using Standard 5S Assessment
28
Monthly 5S Scoring
Area
Ma
y
Jun
e
July
Aug
ust
Septe
mber
Octob
er
Nove
mber
100k Ante Room
72
68
50
54
60
64
64
100k Clean
Room
66
50
42
48
54
60
60
Component Test
Lab #1
60
60
76
78
78
90
90
Component Test
Lab #2
60
60
60
60
64
64
64
Electronic Work
Center
72
78
78
84
80
90
90
Expansion Bay
60
50
50
56
60
88
88
Harness Work
Center
44
42
58
64
64
64
64
Large Vibe
50
44
56
58
58
58
58
Mechanical
Work Center
80
86
86
86
94
94
94
Receiving
Inspection
76
72
74
78
82
78
78
RF Range
48
60
60
62
66
64
64
June
Shipping &
Receiving
70
66
80
82
82
82
82
July
Small Vibe
50
48
72
82
82
86
86
Stockroom
82
90
96
100
96
92
92
October
Thermal
66
74
70
70
66
72
72
November
TVAC
60
52
52
58
64
64
64
Propulsion Test
56
71
71
74
82
78
78
-- example only -SSG 5S Score
May -November 2007
Propulsion Test
100k Ante Room
100
TVAC
80
100k Clean Room
Component Test Lab #1
60
Thermal
40
Component Test Lab #2
20
Stockroom
Electronic Work Center
0
Small Vibe
Expansion Bay
Shipping & Receiving
RF Range
Receiving Inspection
Harness Work Center
May
Large Vibe
Mechanical Work Center
August
September
Levels of Achievement
SORT
SET IN ORDER
SHINE
STANDARDIZE
SUSTAIN
What Level
is Your Work
Area?
LEVEL 1
Just Beginning
Necessary and
unnecessary items are
mixed together in the
work area.
Tools, supplies and
materials are randomly
located.
LEVEL 2
Focus on Basics
Necessary and
unnecessary items are
separated.
Work/break areas and
Designated location
machinery are cleaned on
established for all items
a regularly scheduled
as needed.
basis. Key items
identified.
LEVEL 3
Make It Visual
LEVEL 4
Focus On
Consistency
LEVEL 5
Focus on
Prevention
30
Work/break areas and
machinery are dirty and
disorganized.
Work place methods are not
consistently followed and are
not documented.
Work place checks are
randomly performed and
there is no visual
measurement of 5S
performance.
A recognizable effort has
Methods are being improved,
been made to improve the
but changes have not been
condition of the
documented.
workplace.
Working environment changes
Designated locations are
Visual Controls are in
are documented and
5S schedules and safety
All unnecessary items
marked to make
place for labeling and
performed the same by all
practices have been
have been removed
organization more visible
quantity levels. Machines employees. Visual Controls are
developed and are
from the work area.
(color, outlines, labels,
are cleaned daily.
in place for labeling and
utilized.
numbers, etc).
quantity levels.
A dependable,
Documented method of
5S techniques are
documented method
visual sweep to identify
Substantial process
understood and practiced
has been established to
items out of place or
documentation is available and
continually. 5S schedules
keep the work area free
exceeding quantity
followed.
are posted and followed.
of unnecessary items.
limits.
Follow through with 5S
schedules and safety
practices is evident.
Waste is immediately
There is a general
Dependable, documented Everyone is continually seeking
visible and triggers a
Defined process to
appearance of a confident
method of preventative
the elimination of waste with
planned response with
evaluate and improve
understanding of, and
cleaning and
changes documented and
root cause analysis and movement and motion.
adherence to, the 5S
maintenance.
information shared.
corrective action.
principles.
Let’s Go !
•
•
•
•
Designate and identify location(s) for cleaning gear
Tape aisle ways and perimeter of work areas
Shadow box all needed tools; hang large tools on outline boards
Sweep/ shine floors; post a cleaning schedule w/ names &
assignments
• Clean in corners, around I-beams & columns; wipe off wire
molds, vents, equipment, cabinets so that there is no dirt, dust,
paper clips, loose pens, loose papers, sticky notes, throw away
or put away ANYTHING laying around
• Remove things from the top of cabinets, consoles, tables,
chairs, etc.
31
Let’s Go !
• ANYTHING that HAS to be stacked is stacked neatly (90°) in a
designated location
• Implement visual helps to indicate where things go, including
cleaning and safety gear
• Conscientiously conduct FOD and ESD surveillance
• Perform TPM on equipment
• Keep aisles clear; limit extension cords; no tripping or tipping
hazards; call attention to safety equipment locations
• Visually highlight equipment safety features (emergency stops,
stay out areas, etc.)
32
Let’s Go !
•
•
•
•
•
•
•
•
•
•
33
Post evacuation routes near exits
ID chemical storage cabinet locations and check frequently
ID and Wear protective equipment
Have MSDS sheets in a clearly marked area
Find a place for EVERYTHING; mark its perimeter and identify it
Maintain the 5S bulletin board
Evidence “clean-as-you-go” throughout the day
Assess the area monthly; discuss and act on results
Post results in 5S display area
Hang posters, signs, etc. to sustain 5S
Lean in Action
5S System: Techniques for Efficient Workplace
Organization
Management Meeting
Month X, 20XX