5S and Visual Factory

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Contents
1.
2.
3.
4.

Introduction
Background and History
Components and Implementation
Knowledge Check

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 1950s.
The concept was further refined into 5S during the
1960s and 1970s.
U.S. manufacturers added a sixth S for safety
during the 1990s.

Components and Implementation

5S and Lean Manufacturing
Elements of 5S

Sort
Straighten
Shine
Standardize
Sustain
Safety

Visual Factory
Implementation plan

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

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

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

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
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

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
Aisles
Workstations
Corners, under
equipment
Loading docks
Walls
Doors
Pillars, posts

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

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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
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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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Knowledge Check

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

F
E

D
A
C

Sort
Straighten
Shine
Standardize
Sustain
Safety

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

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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

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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

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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

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How can you implement 5S in your organization?

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Congratulations!!!
You have completed the course.
Please visit Shmula (www.shmula.com) for more
information on operational excellence.

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