guide to implementing 5s principles

Guide to implementing

5’ SPRINCIPLES

5S’S Sort Stabilize Shine Standardiz

e Sustain

SSSSSeiri

eiton

eiso

eiri

hitsuke

SortThe First S

eiri

1st S - SortKeep what is neededEliminate what is notIdentify what is out of place

X - Tag

Check the Dark Corners and Healing Walls

SortHere Is A Good Example

How can it be improved?

X-Tag

Select a X-Tag leader Identify what is not needed Attach X-Tag Move to holding area Determine time to hold Move to facility holding area Tag all Safety problems

X-Tag

Never used Once or twice a

year Once a month Once a week Once a day or

more

Give, sell, or throw away

Store in a distant place

Store in the facility

Store in the area

Keep at the workplace or

carry

How often is it used? What to do with it.

X-Tag Rule of Thumb

X-Tag

Name:

Date: Removal Date

Location:

Reason for X-Tag:

StabilizeThe Second S

Operator

2nd S - Stabilize A place for everything and everything in

its place outlines labels shadow boxes

Designated responsibilities color coded maps X-Tag leaders

Make everything easy to find, use, and return

Does this look well stabilized?

Outlines or Footprints

A little out of place

The Third S

3rd S - Shine

Cleaning is inspection Make cleaning everyday

work Assign responsibilities

color coded maps rotate cleaning

responsibilities Utilize downtime & help

others

Is This Your Locker Room?

Before and After

A well shined facility

StandardizeThe Fourth S

4th S - Standardize X-Tag procedures Holding areas Cleaning

procedures Location of items Operating

procedures

A Place For Everything

Even rags, gloves, and trash

Communicating What Goes Where

Simple but effective

SustainThe Fifth S

5th S - Sustain

Make it a habit It takes doing something 21 times

before it becomes a habit Proper training and communication

Inform all employees (especially new ones)

Support and cooperation from everyone

Does it appear that communication is taking

place?

Visual Ranges Make It Easier to Sustain

Sustain

Everyone needs to do their part to keep things where and how they

belong

5S’S

Sort X - Tag Keep what is

needed Stabilize

A place for everything

Everything in its place

Shine Cleaning is

inspection Standardize

Rules for the first 3 S’s

Sustain Make it habit Cooperation

CATEGORY ITEM Yes No OBSERVATIONSHave unnecessary items been X-tagged?Are items neatly arranged?Are walkways/work areas clearly outlined?Are designated areas marked for incoming material?

SORT Are materials located in designated areas?(Organization) Are designated areas marked for outgoing material?

Is outgoing material located in designated area?Are information boards orderly?Is indicated information found?Is information current?Do excess materials have a specific location?Are excess materials in their location?Is there a place for everything?Is everything in its place?

STABALIZE Is it easy to see what belongs where?(Orderliness) Are things put away after use?

Are tools organized and located in specific place?Are only red containers being used for scrap?Is rejected material properly identified?Is rejected material stored in a designated area?Is process scrap located in separate containers?Is defective material located in separate containers?Are sort and stabilize complete?Are work areas clean?Are aisles clear?Are tools clean?Is any material found on the floor?Is equipment clean?

SHINE Do machines show evidence of old oil leaks?(Cleanliness) Is cell inventory correctly identified?

5S Checklist

5S Checklist Audits performed

for 5S’s Visual display of

current standings and progress

Emphasis on Sustaining

5S Audit

Points Needing Attention

7

5S Supportive Strategies Color coding Point of use Safety

Color coding things is a fast, easy way to separate different items and to visually determine if something is

misplaced

Scrap

- Tubing

- Mixed scrap-banding, cold rolled, stainless

- Process scrap

- Manufacturing scrap

Examples

Color Coded Scrap Hoppers

Different color for each part number

Colors correspond to colors of:

cells toolinggages

4 fixtures

4 settings

Part Color Coding

Color Coded Dies

Color Coded Tooling

And Storage Rack

Point of Use

Safety: The 6th - S

Is of great concern when considering workplace

organization and the 5S’s