5S and Visual Factory
Lean Manufacturing Series
© 2009 Factory Strategies Group LLC. All rights reserved.
Disclaimer and Approved Use
• Disclaimer
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This presentation is intended for use in training individuals within an organization. The
handouts, tools, and presentations may be customized for each application.
THE FILES AND PRESENTATIONS ARE DISTRIBUTED ON AN "AS IS" BASIS WITHOUT
WARRANTIES OF ANY KIND, EITHER EXPRESSED OR IMPLIED.
• Copyright
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This presentation is created and copyrighted by Factory Strategies Group LLC.
• Approved Use
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Each copy of this presentation can be used throughout a single Customer location, such as
a manufacturing plant. Multiple copies may reside on computers within that location, or
on the intranet for that location. Contact us for authorization to use this presentation at
multiple locations.
The presentation may be customized to satisfy the customer’s application.
The presentation, or portions or modifications thereof, may not be re-sold or redistributed without express written permission.
• Current contact information can be found at: www.factorystrategies.com
© 2009 Factory Strategies Group LLC. All rights reserved.
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Contents
1.
2.
3.
4.
Introduction
Background and History
Components and Implementation
Knowledge Check
© 2009 Factory Strategies Group LLC. All rights reserved.
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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.
© 2009 Factory Strategies Group LLC. All rights reserved.
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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.
© 2009 Factory Strategies Group LLC. All rights reserved.
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Components and Implementation
• 5S and Lean Manufacturing
• Elements of 5S
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Sort
Straighten
Shine
Standardize
Sustain
Safety
• Visual Factory
• Implementation plan
© 2009 Factory Strategies Group LLC. All rights reserved.
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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
© 2009 Factory Strategies Group LLC. All rights reserved.
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Types of Waste
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Overproduction
Excess inventory
Defects
Non-value added processing
Waiting
Excess motion
Transportation
Other Wastes:
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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
Before 5S
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After 5S - Cleaned, organized
and drawers labeled (less
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
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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.
© 2009 Factory Strategies Group LLC. All rights reserved.
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5S Examples – Sort and Straighten
See the difference?
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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
• Machines
• Small tools
• Dies
• Jigs
• Bits
• Conveyance equipment
• Cleaning equipment
Materials
• Raw material
• Supplies
• Parts
• Work-in-process
• Finished goods
• Shipping materials
• Cleaning supplies
Furniture
• Cabinets
• Benches, tables
• Chairs
• Carts
• Shelves
• Racks
Other items
• Charts, graphs, bulletin
boards
• Pens, pencils
• Work clothes
• Helmets
• 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
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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
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Ceilings
Aisles
Workstations
Corners, under
equipment
Loading docks
Walls
Doors
Pillars, posts
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Floors
Machines
Conveyance equipment
Plumbing, sinks
Cabinets, shelves, racks
Carts, Racks
Drawers, storage bins
Fixtures, power boxes
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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.
b.
c.
d.
Area Lead plus at least one person from outside that area
Post results (I will look for them!)
Review results with your group
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
© 2009 Factory Strategies Group LLC. All rights reserved.
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Red Tag Inspection Sheet
• Search
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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
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Machines, small tools
Dies, jigs, bits,
Conveyance equipment
Plumbing, electrical parts
• Look for unneeded furniture
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Cabinets
Benches, tables
Chairs
Carts
© 2009 Factory Strategies Group LLC. All rights reserved.
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Red Tag Inspection Sheet
• Search these storage places
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Shelves
Racks
Closets
Sheds
Search the walls
Items hung up
Old bulletin boards
Signs
© 2009 Factory Strategies Group LLC. All rights reserved.
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Red Tag Inspection Sheet
• Look for other unneeded items
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Work clothes
Helmets
Work shoes
Trash cans
Other
• Look for unneeded materials
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Raw material
Supplies
Parts
Work in process
Finished goods
Shipping materials
© 2009 Factory Strategies Group LLC. All rights reserved.
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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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•
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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
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F
Sort
E
Straighten
B
Shine
D
Standardize
A
Sustain
C
Safety
© 2009 Factory Strategies Group LLC. All rights reserved.
Description
A. Training, daily activities
B. Clean everything, inside
and out
C. A safety commitment in
all activities
D. Establish policies and
procedures to ensure 5S
E. Make it obvious where
things belong
F. Remove all unnecessary
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
© 2009 Factory Strategies Group LLC. All rights reserved.
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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
© 2009 Factory Strategies Group LLC. All rights reserved.
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Strategy is sometimes called the sixth "S".
oA) True
oB) 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
© 2009 Factory Strategies Group LLC. All rights reserved.
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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
© 2009 Factory Strategies Group LLC. All rights reserved.
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How can you implement 5S in your organization?
© 2009 Factory Strategies Group LLC. All rights reserved.
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Congratulations!!!
• You have completed the course.
• Please visit Superfactory (www.superfactory.com) for
more information on manufacturing excellence.
© 2009 Factory Strategies Group LLC. All rights reserved.
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