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The

5S Numbers Game
A fun and exciting way to present the 5S concepts to our team!

Introduction
Credits This exercise is based on an exercise from www.superteams.com which was adapted from one created by Kirt Tassmer of Stanley Fastening Systems. The original game was developed by RWD Technologies, Ltd.

This is a simple training game we will use to show how to perform 5S and to drive home important key points Hopefully you find it challenging (like the realworld) and have some fun along the way

Disclaimer This is for entertainment purposes only. 5S Supply is not liable for any unintended outcomes.

Behind all workplace successes and failures are the 5Ss.

From 5 Pillars of the Visual Workplace: The Sourcebook for 5S Implementation by Hiroyuki Hirano

Agenda
Before State Round 1 Sort Round 2 Simplify Round 3 Systematic Cleaning Standardize Sustain Round 4 Benefits Round 5

Instructions Round 1
Please wait until you hear the entire instructions before starting DO NOT turn over the page until asked to do so Individually, with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5) You will have 30 seconds to complete this task

3
12

2
7 14 24

884
19
28
38

32
96 43

22

58

97

65
25

11

17

64

95

15

5
37
71

54 31
53
63 1

35
45

100
56
57

41

51

GO! 66
46
94

59
70

27

33

10

76

77

78

79

48
87

72

89
42

85

Report Out Round 1

Record your highest number found and a comment on your Overall Scorecard sheet The instructor will ask for your score the lowest score is whats recorded for the entire group What was it like trying to do this? How did it feel? How can we apply this to everyday life?

Were there any quality issues? 2 Is this3an 8, 88, 4, 84??? 7

12

884
19
28
15

32
96 43

22

54 31 Which one is
56 the 51 and which one is the 9? 37
63

58

97

14 24

65
25

53

64 Why is 39 95 38 35 listed 100 45 twice? 56

57

11

17

41

59
70

66
76

71

6
1

46
94

27

33
10

78 Is this 66 or
77

79

99? 89 or 68? 72
87

48

89
42

85

Sort
To sort through, to sort out Guideline: If it is not needed in the next 30 days, Orange Tag it When in doubt, move it out! 5S Orange Tag Technique Place a Orange Tag on the item and move it to the 5S Orange Tag Holding Area Items will be dispositioned: keep, throw out, donate, scrap, shred, recycle, etc.

3
12

2
7

884
19
28
38

17 Lets orange tag 14 65 the 32 11 24 25 numbers we dont need 64 22 58 43 35 100 (51-100) and the duplicate 96 39. 45 53

97

95

15

54 31
63 1

41

51

56

57

59
70

37
71 6

66
76

46
94

27

33
10

77

78

79

48
87

72

89
42

85

3
12

2
7 14 24

884
19
28
38

32
96 43

22

58

97

65
25

11

17

64

95

15

5
37
71

54 31
53
63 1

35
45

100
56
57

41

51

59
70

66
76

46
94

27

33
10

77

78

79

48
87

72

89
42

85

3
12

2
7

884
19
28
38

14 65 Now lets move them to the 17 32 11 24 25 5S Orange Tag Holding 64 22 58 35 100 Area. 43 96

97

95

15

5
37
71

54 31
53
63 1

41

45

51

56

57

59
70

66
76

46
94

27

33
10

77

78

79

48
87

72

89
42

85

3
12

2
7 14 24

884
19
28
38

32
96 43

22

58

97

65
25

11

17

64

95

15

5
37
71

54 31
53
63 1

35
45

100
56
57

41

51

59
70

66
76 77

46
94

27

33
10

78

79

48
87

72

89
42

85

3
12

2
7 14 24
25

8
19
28
38

32
43

11

17

15

22

5
37
6
1

31
46

35
45

41

27

33
10

48

42

Instructions Round 2
Lets do the same exercise with the unneeded items removed from the work area - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5) You will have 30 seconds to complete this task

3
12

2
7 14 24
25

8
19
28
38

32
43

11

17

15

22

5
37
6
1

GO!
45
46

31

35

41

27

33

10

48

42

Report Out Round 2

Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is whats recorded for the entire group What was the exercise like this time? What can we learn from this?

Simplify
Now that the area has been cleared out of unnecessary items, it is time to find a home for items that will remain Guideline: Any item that you want to keep after the 5S Orange Tagging Event needs to have a specific home A place for everything and everything in its place. Organize items to make them convenient to get and put away Use visual controls to help this process (signs, lines, labels, color-coding)

3
12

2
7

8
19
28
38

14 Lets rearrange the numbers 17 in 32 11 24 25 order that we will use them. 22

15

43

5
37
6
1

31
46

35
45

41

27

33
10

48

42

3
12

2
7 14 24
25

8
19
28
38

32
43

11

17

15

22

5
37
6
1

31
46

35
45

41

27

33
10

48

42

4
14 15

6 7

8
19

10

11

12

17

41

43
42

45
46

33

31

22 32

27
24
25

28

35

37 48

38

6 7

10

Did you notice that we had to work around a few things like the 19 11 14 17 numbers that were 15 already there? 27 28
12

41

43
42

45
46

33

31

22

24

25

32

35

37 48

38

Instructions Round 3
Lets do the same exercise with the numbers better organized - with a pen or pencil locate and strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5) You will have 30 seconds to complete this task

4
14 15

6 7

8
19

10

11

12

17

41

43
42

45
46

33

31

22 32

GO!
24
25

27

28

35

37 48

38

Report Out Round 3

Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is whats recorded for the entire group What was the exercise like this time? What benefits can you see from Sort and Simplify? Record on Scorecard sheet

Systematic Cleaning
Now that the area has been cleared out of unnecessary items, it is time to shine the items that remain Guideline: Get items to a like-new condition Clean and inspect or inspect through cleaning Everyone participates, make it simple and easy to get cleaning supplies and schedule it! If you find something out that may become an issue, fix it or have it fixed

6 7

8
19

10

For Shine we will make sure the numbers are in good working 11 14 15 17 order. So lets clean this mess up! 27 28
12

41

43
42

45
46

33

31

22

24

25

32

35

37 48

38

2
12

4 5
14 15

6 7

10

11
21

13

16
25

17

18 19
28 29
38

20

22 32

31
41

23
43

24

26
46

27

30
40

33 34 44

35

36

37

39

42

45

47 48

49

50

Standardize
We need to have standards for the first three Ss: Sort, Simplify and Systematic Cleaning Guideline: Make up the rules for the first three Ss and then follow and enforce them. Make up the rules and then follow them Dont forget to consider companywide policies like color-coding, signage, replenishment, etc Make the rules easy to follow

5 6 7 8 9 10 3 2 After looking at all the styles of font and sizes the team determined 13 14 17 11 some of these 15 16 be 18 19 20 that items can standardized. 21 24 25 22 27 28 29 30
1 12

31
41

23
43

26

32

33 34 44

35

36

37

38

39

40

42

45

46

47 48

49

50

1 2

9 10

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

11 12 13 14 15 16 17 18 19 20

41 42 43 44 45 46 47 48 49 50

1 2

9 10

Lets add 13 14 more visuals like 11 12 some 15 16 17 18 19 color-coding and lines.

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

20

41 42 43 44 45 46 47 48 49 50

1 2

9 10

11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

41 42 43 44 45 46 47 48 49 50

Sustain
Now that you have a well organized, clean and safe work environment, we must keep it that way Guideline: Its not something extra, its part of everyday work Make 5S part of everyday life. Sustain helps build the discipline we need to have a great Lean organization

Instructions Round 4
In order to Sustain our gains we must be able to recognize abnormal conditions Lets do a quick 5S Audit of the area Circle any defects that you find You will have 30 seconds to complete this task

16 12 11 13 14 15

17 18 19 20
40

21 22 23 34 25 26 27 28 29 30 31 32 33 24 35 36 37 38

41 42 43 44 45

GO!48 49 50 47

10

Report Out Round 4

How many did you find? The 2 is missing 9 is upside down 11 and 12 are mixed up 16 is not completely in its home 24 and 34 are in the wrong location 39 is missing 46 is askew How did you know?

16 12 11 13 14 15

17 18 19 20
40

21 22 23 34 25 26 27 28 29 30 31 32 33 24 35 36 37 38

41 42 43 44 45

47 48 49 50

10

Instructions Round 5
Lets do the same exercise after applying our 5S principles - with a pen or pencil strike out the numbers 1 through 50 in sequential order (1, 2, 3, 4, 5) You will have 30 seconds to complete this task

1 2

9 10

11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

41 42 43 44 45 46 47 48 49 50

GO!

Report Out Round 5

Record your highest number found and a comment on your Overall Scorecard sheet The lowest score is whats recorded for the entire group What was the exercise like this time? What benefits can you see from Sort and Simplify? How can we apply this to everyday life?

Before & After State

Before Excess materials Excessive search time Large area Cluttered Difficult After The correct materials Minimal search time Smaller area Clean, neat & organized Easy

3 Before 32
96 43
12

2
7 14 24

884
19
28
38

22

58

97

65
25

11

17

64

95

15

5
37
71

54 31
53
63 1

35
45

100
56
57

41

51

59
70

66
76

46
94

27

33
10

77

78

79

48
87

72

89
42

85

1 2 After 11

9 10

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

12 13 14 15 16 17 18 19 20

41 42 43 44 45 46 47 48 49 50

Benefits of 5S
What benefits did we realize by applying 5S to our simulated workplace? Quality Cost Delivery/Service Quantitative Qualitative _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________

Wrap-up
Can we apply this to the real world? Share an Ah-ha something you learned, something thats new, something thats different or something that made an impression on you ________________________________ ________________________________

Thank You for participating

Follow us @ www.blog.5Ssupply.com Twitter.com/5Ssupply LinkedIn Group 5S Supply YouTube.com/5Ssupply www.5Ssupply.com 888 4 LEAN 5S 5S Simplified. Everything you need all in one place!

Participant Forms & Tips and Tricks

Instructor Notes
This section has the forms and instructor notes to use during this training exercise Items needed:
PowerPoint presentation (if desired) Pens or pencils, enough for each participant Stopwatch, timer or watch with seconds hand to time each round (30 seconds) One copy each of the forms for each participant (see next slide)

Forms
Print the Overall Scorecard form single sided Print the Rounds 1, 2, 3, 4 and 5 forms double sided with the words Please do not turn over until told to do so. on the front and the exercise on the back

Overall Scorecard
Handout the Overall Scorecard at the beginning when you are explaining the exercise Ask the participants to record their individual scores on this sheet and any comments or take-aways from the round

Overall Scorecard
Exercise Round 1 Round 2 Round 3 Round 4 Number Comments _________________ _________________ _________________ _________________ _________________ _________________ _________________ _________________

Round 5

Round 1
Please do not turn over until told to do so.

TOP

3
12

2
7 14 24

884
19
28
38

32
96 43

22

58

97

65
25

11

17

64

95

15

5
37
71

54 31
53
63 1

35
45

100
56
57

41

51

59
70

66
76

46
94

27

33
10

77

78

79

48
87

72

89
42

85

Round 2
Please do not turn over until told to do so.

TOP

3
12

2
7 14 24
25

8
19
28
38

32
43

11

17

15

22

5
37
6
1

31
46

35
45

41

27

33
10

48

42

Round 3
Please do not turn over until told to do so.

TOP
1

4
14 15

6 7

8
19

10

11

12

17

41

43
42

45
46

33

31

22 32

27
24
25

28

35

37 48

38

Round 4
Please do not turn over until told to do so.

TOP

12 11 13 14 15 16

17 18 19 20
40

21 22 23 34 25 26 27 28 29 30 31 32 33 24 35 36 37 38

41 42 43 44 45
Circle the defects. How many did you find?

47 48 49 50

10

Round 5
Please do not turn over until told to do so.

TOP

1 2

9 10

11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

41 42 43 44 45 46 47 48 49 50