Registrations are open for Cohort 8, Aug 18, 2025! (Mon 300PM-500PM)
5S is a systematic approach to creating an organized workspace.
Visual Management:
A way to manage our space visually, making it easy to find what we need and know where things go.
More Than Cleanliness:
It’s not just about keeping things tidy; it’s about setting up our work areas to be more efficient and safer.
Foundation for Efficiency:
The starting block for working smarter in our daily tasks.
CURRENT STATE OF YOUR FILING ROOM, TOOL ROOM, SHOP, ETC
DIRECTIONS:
1.Obtain a pen and paper.
2.Prepare to record your score from each round and label as the gray top title.
3.Do not start until an instructor tells you so.
4. Press [Start Game] Below.
5. Click all the numbers in sequential order within the alloted time.
6. Each section will have an activity after the information.
REDUCING THE UNNECESSARY
GOAL: Keep only what is necessary for daily and essential tasks.
CLEANING UP THE SHOP FLOOR
Check each item around your workspace or machines. If it's needed for the job, keep it. If not, it's time for it to go.
Trash or recycle what you cannot use.
If something belongs to a different job, put it back where it comes from.
If unsure about something, hang on to it for the next step.
RED TAGGING
Attach a red tag to items without a clear purpose.
Note the location and date on the tag.
Move red-tagged items to a designated holding area
REVIEWING RED TAGS
Conduct regular reviews of the holding area.
Return items to their rightful place if needed.
After a set period (e.g., 30 days), reassess unclaimed items.
Reassign, sell, or discard items based on necessity and usage.
AN EXAMPLE OF A SHADOW BOARD FOR ORGANIZATION OF TOOLS.
ARRANGE AND IDENTIFY
GOAL: Organize your workspace to have a specific spot for each tool or material.
"a place for everything and everything in its place"
CREATE A SYSTEM
Regularly used tools should be within arm's reach.
Shared or rarely used items can be stored centrally.
Group items that are used together.
Draw up a 5S map for a clear layout of where everything will be going/belongs.
MAKE IT VISUAL
Label cabinets and shelves with the contents and where each item fits.
Consider using a shadow board for quick tool identification and return. You can use pegboards, masonite, foam cut-outs for tool boxes, etc.
If possible, use floor marking to designate work areas, paths and storage locations.
CLEANLINESS & INSPECTION
GOAL: Aim for a work area that doesn't just look clean but stays that way.
Shine is about maintaining cleanliness and functioning at all times.
MAKE IT A HABIT
Implement a daily and weekly cleaning schedule.
Assign each worker the task of cleaning their own space and tools.
Use cleaning as a form of inspection to spot potential issues early.
Implement having a clean workspace as a turnover process.
BENEFITS OF CLEANING
Workers become more familiar with their tools and workspace.
Potential hazards or malfunctions are identified and resolved quickly.
Personal responsibility encourages a naturally tidier workspace.
SHINE AS A TOOL FOR MAINTENANCE
Regular cleaning helps identify abnormal conditions like leaks or wear and tear.
These findings can feed into a proactive maintenance schedule.
The result is less unplanned downtime and longer life for tools and equipment.
MAKING IT ROUTINE
GOAL: Make the first three S's a standard part of daily work.
Ensure consistency in your processes by developing and following written standards.
DOCUMENTING BEST PRACTICES
Document the procedures for sorting, setting in order, and cleaning.
Use red-tagging process as part of standard operating procedures.
Emphasize that standards are "living" documents, open to improvement.
COMMUNICATING THE STANDARD
Utilize checklists for routine tasks to ensure adherance and easy verification.
Create job charts to define tasks, schedules and responsibilities.
Post procedure labels and signs to provide clear, on-the-spot guidance.
MAINTAINING THE MOMENTUM
Regularly review and update standards to reflect improvements or changes.
Train all employee on the standards to ensure uniform understanding and application.
Audit the processes periodically to confirm that standards are being maintained.
SEVERAL MONTHS PASS AFTER SUCCESSFUL 5S IMPLEMENTATION.........
BACKGROUND
The team has become complacent, 5S has deteriorated.
Important parts are no longer being stored correctly, tools are out of reach, we are inefficient, and the workplace organization has slipped.
SCENARIO
It's a regular workday at the mill. A critical piece of machinery has broken down.
It is missing 2 parts: A specific bearing and a collar.
We are losing $10,000 to 50,000 an hour.
Every 30 seconds that passes in the round is a "shift" of work.
DIRECTIONS
Find the 2 missing "parts" (numbers.)
THE CYCLE OF DISCIPLINE
GOAL: Commit to maintaining order and continuous improvement
5S is not a one-off task, but a perpetual cycle of re-evaluation and refinement.
LEADERSHIP ENGAGEMENT
Active participation from management in 5S activities and Audits.
Visible leadership support is crucial for the longevity of 5S.
KNOWLEDGE SHARING
ADAPTIVE TRAINING
REGULAR AUDITS
RECOGNITION AND ACCOUNTABILITY
Regular departmental tours to exchange ideas and best practices.
Collaboration and innovation across all levels.
Updating training materials to reflect changes in processes and equipment.
Continuous learning to keep up with evolving 5S standards.
Scheduled evaluations to measure adherance and identify areas for improvement.
Use of audits to celebrate successes and analyze shortcomings.
Incorporating 5S performance into individual and team evaluations.
Rewarding consistent applications of 5S principles.