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5S PROCESSTHE FOUNDATION FOR VISUAL MANAGEMENT
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This document contains the confidential and
proprietary information of Gregory Cochran
& Associates, LLC.
Any disclosure, use, copying or distribution of
the information within this document is
strictly prohibited without permission from
Gregory Cochran & Associates, LLC.
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Learn The Benefits Of 5S
Understand The Definition And Meaning Of The 5s
Learn The Proper Strategy For Implementing A 5S Program
Apply 5S In The Workplace
5S Objectives
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What Is 5S?• 5S Enables Anyone To Distinguish Between Normal And Abnormal
Conditions At A Glance
• 5S Is The Foundation For Continuous Improvement, Zero Defects, Cost
Reduction, And A Safe Work Area.
• 5s Is A Systematic Way To Improve The Workplace, Processes, And
Products Through Production Line Employee Involvement.
When And Why Use It?
• To Create And Maintain An Organized, Clean, Safe, And High-
performance Workplace.
Duration?
• .5 To 3 Days
5S - Overview
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What Is 5S?
Defined
5S Is Process To Ensure A Clean, Orderly, Safe And Productive Workplace.
5SSUSTAIN
5SSUSTAIN
1S
Simplify
4S
Stabilize
Straighten
2S
Scrub
3S
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Benefits Of 5S
There Are 3 Key Benefits To Implementing A 5S Program
1. Safety
Reduce The Number Of Lost Time Accidents, Workman’s Compensation
Claims And OSHA Recordables.
2. Quality
Eliminate The Possibility Of Using Previously Rejected Parts Or The Wrong
Tools. Eliminate Contamination And Assure Compliance To Standard
Procedures.
3. Productivity
Eliminate Wasted Time Looking For Tools. Reduce Cycle Time, Reduce
Equipment Downtime Through Regular Cleaning And Inspection.
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What Are The 5S?
Simplify
(Seiri)
Straighten
(Seiton)
Scrub
(Seiso)
Stabilize
(Seiketsu)
Sustain
(Shitsuke)
Clearly Distinguishing Between What Is Necessary And What Is Unnecessary
And Disposing Of The Unnecessary.
Organizing The Necessary Items So That They Can Be Used And Returned
Easily.
Cleaning Floors, Equipment, And Furniture In All Areas Of The Workplace.
Maintaining And Improving The Standards Of The First Three S’s.
Achieving The Discipline Or Habit Of Properly Maintaining The Correct 5S
Procedures.
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Simplify
Identify Truly Needed Items By Asking Several Key Questions.
What Is It For?
Why Do I Have It?
How Often Do I Use It?
Does Someone Else Have The Same Thing?
Clearly Distinguishing Between What Is Necessary And What Is
Unnecessary And Disposing Of The Unnecessary
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Things Which Should Be Reviewed
Cabinets
Components
Documentation
Gages
Machines
Packaging Material
Parts
Prints
Shelves
Supplies
Tables
Tooling
Towels
Trash
PRODUCTION AREAS
Books
Business Forms
Cabinets
Catalogs
Correspondence
Equipment
Magazines
Paper
Parts
Records
Samples
Shelves
Supplies
OFFICE AREAS
Simplify
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Red Tagging Is A Tracking Process To Provide
Visual Identification Of Unneeded Items.
After All Obvious Items Have Been Thrown
Away, Remaining Items Are “Red-tagged” To
Assure Proper Disposition.
Red Tagging
Simplify
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Sample Red Tag
CELL / AREA
RED TAGTAG NUMBER
CATEGORY
1. Raw Material2. WIP3. Finish Materials4. Tools
5. Supplies6. Equipment7. Furniture8. Office Materials
9. Books/Magazines10. Other:
TAG DATE TAGGED BY
ITEM NAME
QUANTITY
REASON TAGGED
DISPOSITION REQUIRED
1. Discard2. In Cells Storage3. Long Term Storage
4. Reduce Inventory5. Sell / Transfer6. Other:
ACTION TAKEN DATE
CELL / AREA
RED TAG LOCATORTAG NUMBER
Should Be Full Size
(8.5” X11”)
Bright Red To Promote
Visibility
Should Have Pre-printed
Sequential Tag Numbers
Perforated Lower Section To
Record Location Of Tag
Simplify
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Step 5
▪ Evaluate Red Tag Items
▪ Dispose Of Truly Unnecessary
Items
▪ Retain Red Tagged Material If
There Is Proper Justification
▪ Discard Any Material Which Has
Been Red Tagged After A Pre-
determined Time
▪ Complete All Red Tag
Information. Returned To The
Red Tag Coordinator
Red-Tagging Process
Step 4
▪ Explain Red Tag Criteria
To Teams
▪ Ensure A Good Cross-
section Of People
Tagging Items To
Prevent “I Might Need
That”
▪ Red Tag Work Area As
Rapidly As Possible
▪ Determine What
Criteria Will Used To
Distinguish A Needed
Item From An
Unneeded Item
▪ Example: Save Only
The Items Needed To
Conduct Business In
The Area
Step 3
▪ Identify Red Tag
Targets
▪ Determine Location
For All Red Tag
Items During Event
Step 2
▪ Select Members From
Various Teams
▪ Select A High Level
Manager To
Participate As A Team
Member
Step 1
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Examine The Workplace
Identify Truly Needed Items
– What Is It For?
– Why Do I Have It?
– How Often Do I Use It?
– Does Someone Else Have It?
Throw Away Anything You Know You Can
Use Red Tagging For Items That You Are Unsure Whether Or Not
They Are Needed
Strategy
5SSUSTAIN
5SSUSTAIN
1S
Simplify
4S
Stabilize
Straighten
2S
Scrub
3S
Simplify
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Straighten
Organize The Necessary Items So That They Can Be Used
And Returned Easily
Place All Necessary Items In The Best Location And Visually Organize The
Area
First Decide Where All Items Should Be So That The Organization Is Easy To Use And
Understand
Choose Proper Storage Methods That Minimize Inventory And Promote Visual
Management
Visually Indicate Locations So Items In Use Can Be Returned And Missing Items Are
Easily Identified
Make Sign Boards That Clearly Explain Inventory, Equipment, And Other Items So Anyone
Can Understand The Workplace
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Proper Locations
Storage Methods
Location Marking
Shadow Boards
Sign Boards
Straighten
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Identify Critical Items, Parts, And Areas Within Factories With Common Colors
Which Provides For A Common Understanding For Any Associate Or Visitor.
Standard Color Guide Purpose
Straighten
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Safety
International Green
Quality
International Blue
Standards
Federal Safety Yellow
Defects
Federal Safety Red
Maintenance
Pure White
Safety Equipment, First Aid, Safety Posters,
Notices
Inspection Points, Quality Notices & Instructions,
Gauging
Operation Standards, Location Marks, New
Tooling, Good Part Storage
Scrap, Bad Parts, Warranty Materials, Dull Tools
Repair Tools, TPM Materials, Machinery,
Cleanliness
Standard Color Guide
Straighten
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Straighten
Organization Of A Packing Area Makes Packing
Parts Easier And Faster – Everything Has A
Designated Location
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Cleaning Floors, Equipment, And Furniture In All Areas Of The
Workplace
Establish A Clean Workplace.
– Clean Up The Area.
➢ Sweep & Wash Floors
➢ Clean In, Under, And Around Equipment And Furniture
➢ Eliminate All Trash From Workplace
– Keep In Mind: How Do Things Get Dirty? - Fix The Root Cause Of The Dirt.
Scrub
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Eliminate Excess Storage Areas And Flat Surfaces
Make Changes To Equipment That Make It Easy And Quick To Clean And
Eliminate Dirt And Leaks At Their Source
Use Check List To Establish Daily Cleaning And Organization Activities
Institute 5S Patrols To Monitor 5S Progress
Maintaining And Improving The Standards Of The First Three S’s
Stabilize
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Develop A Habit Of Simplifying, Straightening, Scrubbing And Stabilizing
Your Workplace
Everyone Has To Accept 5S As A Personal Goal
People Follow Examples (Good And Bad); Set A Good Example
Achieving The Discipline Or Habit Of Properly
Maintaining The Correct 5S Procedures
Sustain
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Summary – 5S Implementation
Clean The Workplace Thoroughly
Simplify
Straighten
Scrub
Stabilize
Sustain Make 5S A Part Of Our Daily Life
Sort Everything In The Work Area
Organize The Entire Work Area
Make Changes To Maintain The First Three S’s
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Summary
5S Is A Foundation For Improvement
Visual Management Is The Ultimate Goal
It Is Up To Each And Every One Of Us To Make 5S A Personal
Goal
Get Help on Your Continuous Improvement Journey
One of the things you will find as you move along your Lean journey is that
going it alone is much harder than if you had a coach. A good coach will push
you to greater and greater levels of self-sufficiency. Regardless of where you
are on your journey, we can help.
If you are just beginning your concerted continuous improvement efforts, we can
help you chart your course and teach you what you need to know to start
leading change on your own. For those who are further along your journey, we
can help by teaching you more advanced topics, reviewing what you are already
doing, and helping you improve your improvement processes.
© Gregory Cochran & Associates, LLC. All Rights Reserved. For the exclusive use of Gregory Cochran & Associates ,
LLC with no reproduction or distribution permitted without the permission of Gregory Cochran & Associates , LLC
Ways We Support Our Clients
On-site Coaching / Consulting: In this traditional form of consulting, we come to
you and work hand-in-hand with you to bring about change in your organization.
Lean assessments, Kaizen facilitation, and policy / strategy deployment
coaching are popular ways to use this form of support.
Remote Coaching / Consulting: Remote consulting puts technology to use so we
can help you in a variety of ways. Need a quick answer? Want a charter
reviewed? Interested in a second opinion about a new layout? Want us to review
a video of your process and offer suggestions? With email, telephones, videos,
screen sharing, and video chatting at our disposal, we can give you quick
answers without much investment.
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Ways We Support Our Clients Continued
Lean Help in the NE Ohio Area: There are a lot of factors that go into choosing a
coach. Getting a good fit is the most important. But there are some special
benefits to having a continuous improvement expert right in your own back yard.
▪ Just in Time training. Want to do a large scale kaizen? No problem! But, having a local Lean coach
also allows you to do smaller, Just in Time projects as well. These mini improvement events can
yield big gains, but more importantly they require less planning time on your part and have less
impact on your team’s production than a traditional kaizen.
▪ You save on travel expenses. No airfare. No lodging. Using a local coach saves you money.
▪ You can get help on much shorter notice. When your Lean coach is nearby you don’t have to wait
for the help that you need. There is no need to work around airline schedules or worry about
weather causing delays for your consultant.
www.GetLeanCoach.com For More Information And Free Tools
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LLC with no reproduction or distribution permitted without the permission of Gregory Cochran & Associates , LLC