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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

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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

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Elements of a 5S Program

1.Sort

2.Set in Order

3.Shine

4.Standardize

5.Sustain

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5S - Down to Basics

SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN


Remove all A place for Remove dust, Spread Everyone
non-essential everything dirt & debris. through the who uses the
items from and Cleaning will work place. work area is
around the everything also highlight Checklists are encouraged
work area. in its place. any previously made showing to adopt the
Any essential Arrange items unforeseen exactly where new system.
items that do so they can problems. and when Eventually
not fit or work, be found, Prioritize regular the new
or are broken, retrieved safety, quality maintenance arrangements
are tagged and returned and reliability should take will become
for action. easily. issues. place. 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

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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

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Sort: Workstations

What work
is being
Performed?

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Sort: Workstations

Before

After

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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

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Sort: 5S Holding Tag (example)
Tag is used for
tracking and Date placed in
Holding Area
maintaining items that
are in the 5S Holding Individual that
tagged the item
area that are to be Area item came from (stock,
reevaluated for either assembly, Test area etc.)
disposal or for Short description (include
placement back into P/Ns if necessary)

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

Used to track all items

example

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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
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: 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.
- 45 Degree Rule: 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.
- Strike Zone Rule: Store things above the knees and below the chest.
This will help to reduce the chance of back strain.
- Higher the Pounds - Closer to Knuckles: Locate heavy items to
eliminate bending, stooping or unnecessary arm movements during lifting.

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Set In Order: Tool Crib Before Organization

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Set In Order: Tool Crib After Organization

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Set In Order: Unorganized Toolbox

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Set In Order: Organized Toolbox

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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

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Shine: Before Cleaning

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Shine: After Cleaning

Recognize and Reward the Team !!

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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
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
5.Sustain

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Standardize: Best Practices for Organization

Old way

New Standard

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Standardize: Best Practices for Organization

Old way

New Standard

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Standardize: Shadow Part Kits

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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

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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
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Sustain: Teams set Standards to meet
Customer Demand Show progress

Publicity !

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Sustain: Standard Assessment Score
(spider web chart)

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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.)

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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

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Monthly 5S Scoring

-- example only --
SSG 5S Score
May -November 2007

100k Ante Room


100
Propulsion Test 100k Clean Room

TVAC 80 Component Test Lab #1

60
Thermal Component Test Lab #2
40

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Stockroom Electronic Work Center
0

Small Vibe Expansion Bay

Shipping & Receiving Harness Work Center


May
June
RF Range Large Vibe July
Receiving Inspection Mechanical Work Center August
September
October
November
Levels of Achievement
SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN

What Level
Work place checks are
Necessary and
Tools, supplies and Work/break areas and Work place methods are not randomly performed and
LEVEL 1 unnecessary items are
materials are randomly machinery are dirty and consistently followed and are there is no visual
Just Beginning mixed together in the
located. disorganized. not documented. measurement of 5S
work area.
performance.

Work/break areas and


A recognizable effort has
Necessary and Designated location machinery are cleaned on Methods are being improved,

is Your Work
LEVEL 2 been made to improve the
unnecessary items are established for all items a regularly scheduled but changes have not been
Focus on Basics condition of the
separated. as needed. basis. Key items documented.
workplace.
identified.

Working environment changes


Designated locations are
Visual Controls are in are documented and 5S schedules and safety
All unnecessary items marked to make
LEVEL 3 place for labeling and performed the same by all practices have been
have been removed organization more visible
Make It Visual 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.

Area?
numbers, etc).
quantity levels.

A dependable, Documented method of


5S techniques are
LEVEL 4 documented method visual sweep to identify Substantial process Follow through with 5S
understood and practiced
Focus On has been established to items out of place or documentation is available and schedules and safety
continually. 5S schedules
Consistency keep the work area free exceeding quantity followed. practices is evident.
are posted and followed.
of unnecessary items. limits.

Waste is immediately There is a general


Dependable, documented Everyone is continually seeking
LEVEL 5 visible and triggers a Defined process to appearance of a confident
method of preventative the elimination of waste with
Focus on planned response with evaluate and improve understanding of, and
cleaning and changes documented and
Prevention root cause analysis and movement and motion. adherence to, the 5S
maintenance. information shared.
corrective action. principles.

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Lets 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.

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Lets 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.)

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Lets Go !
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

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Lean in Action
5S System: Techniques for Efficient Workplace
Organization

Management Meeting
Month X, 20XX

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