5S Improving safety & efficiency © Copyright NHS Improving Quality 2015

5SImproving safety & efficiency

© Copyright NHS Improving Quality 2015

5S Translation

Step Japanese Literal

Translation English

Step 1: Seiri Clearing Up Sort

Step 2: Seiton Organizing Set In Order

Step 3: Seiso Cleaning Shine

Step 4: Seketsu Standardizing Standardise

Step 5: Shitsuke Training & Discipline Sustain

Focus on using the English words - much easier to remember!


5S is a structured program to implement:

• Workplace organisation• Standardisation• Improved safety• Improved work efficiency • Improved productivity• Improved flow• Reduced variation • Reduced waste

Why 5S?


Before 5S


If only we had more space!


How safe is this?


How easy is it to find what you are looking for?


Is this a safe working environment?


• Is this SAFE?

Heater!

Open top bin


How clean is your working environment?


1. Sort 2. Set in Order3. Shine4. Standardise5. Sustain

5S in practice


SORT - Decide what is needed

• Define target area

• Remove everything

• Only put back necessary items

• Unnecessary items - Red Tag it!

• Holding area


A method for sorting

Dispose

UselessSorting

Red Tag / Holding

area

Unknown Useless

Item

Keep &

Store

Useful

Useful

ABC Storage


Where should we put this?

Frequency of Utilization Class

Keep within arms reach

Keep in local location

Keep in remote location

Daily or several times a day A YES MAYBE NO

Weekly B MAYBE YES NO

Monthly or quarterly C NO NO YES

A

BCF

req

uen

cy o

f U

se

Distance

Use this graph as a general guide for deciding where to store items along with the table below.


SET IN ORDER – arranging necessary items

• Think about how work FLOWS

• Put the items in the BEST LOCATION

• Use VISUAL MANAGEMENT - labels, tape, signs and shadow outlines, coloured areas • Mark off common areas with coloured tape and label them

‘A place for everything and everything in its place’


Clearly defined areas for equipment and samples


What you need, where you use it


SHINE – Cleaning the Workplace• Clean everything and find ways to keep it clean

• Cleanliness should be part of the daily work - not an occasional activity initiated when things get too messy

• “Everything in its place” frees up time for cleaning

• Create a plan to clean the area– How often?– By whom


STANDARDISE – Creating consistency

• How you are going to ensure the first 3S are being maintained and incorporated into everyday activities?

• Create a set of standards that everyone has to adhere to

• Visual Management is to facilitate easy understanding of these standards

• Standardising includes measuring, recording and training

• Ensure everyone is working the same way to improve– safety– work efficiency – productivity


Standardised workstation layout helps sustain


Looks just like the picture!


SUSTAIN – maintaining 5S• Train, communicate with and empower all staff

• Develop a system that enables everyone in the workplace to see problems when they occur.

• Develop schedules and check lists - 5S area audits

• Why sustain? • Cleaner• Safer• Improved quality • Improved Job Satisfaction• Improved Productivity

5S Score

0

2

4

6

8

10



an

5S No. 0 1 2 3 4 5 Tot

Average ###

1

2

3

4

5

0

4 5Best in Class results; Lab Manager/Section Lead review; Sustained for 1 month

Best Practice; World Class; General Manager review; Sustained for at least 6 months

Your general impression should tell you this is the best you have seen for a lab environment.

Minimum acceptable level sustained for at least 1 month

Bulletin Boards

Widespread activity; however still many opportunities for improvement

Only the current levels of work items and consummables in the area is needed for the work at hand. Scrap and rework items are placed in clearly marked containers.

Check Item

Not started; zero effort Activity started, slight effort

Consummables & work items.

Machines, benches, cabinets & furniture.Tools, fixtures & other equipment.

First Impression Overall

STEP 1: Sort

Description

No outdated, torn or duplicated notices/documents are displayed. All bulletins are arranged in a straight and neat manner.

5S Lab Area Audit0.0Location:

Date:Scored by:Score:

Previous Score:

STEP 1 TOTAL SCORE

Only the necessary items to perform the work at hand are located in the area. There are no unneeded equipment, tools or furniture in the area.All tools, kit and equipment in the area are used on a regular basis. Any items that are used less than once a day, are stored out of the way.

0 1 2 3

Tools available to sustain


BEFORE AFTER


BEFORE AFTER


Good inventory management & stock control

Missing manuals become obvious


Clear orderly working

BEFORE

AFTER


• Take lots of photos of the area before you start

• Designate a holding area and ‘red tags’

• Effective communication is paramount

• Give all staff plenty of notice to remove all personal items from the work area

• Everyone in the area should be involved

• You will need electrical tape to mark off areas and a labeller

Before you get started….


Documents

5S Improving safety & efficiency © Copyright NHS Improving Quality 2015