HOME Copyright EASE Inc Tutorials© 1986-2002 The “5S” Philosophy An EASEworks® Manufacturing Tutorial START Ver 6

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Copyright EASE Inc Tutorials© 1986-2002

The “5S” PhilosophyThe “5S” PhilosophyThe “5S” PhilosophyThe “5S” PhilosophyAn EASEworks® Manufacturing TutorialAn EASEworks® Manufacturing TutorialAn EASEworks® Manufacturing TutorialAn EASEworks® Manufacturing Tutorial

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The “5S” PhilosophyThe “5S” PhilosophyThe “5S” PhilosophyThe “5S” Philosophy

Based on Japanese words that begin with SS, the 5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.

If you’re going to do it, do it RIGHT!If you’re going to do it, do it RIGHT!

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The first S S focuses on eliminating unnecessary items from the workplace.

Sort – (Seiri)Sort – (Seiri)Sort – (Seiri)Sort – (Seiri)

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An effective visual method to identify these unneeded items is called red tagging. A red tag is placed on all items not required to complete your job. These items are then moved to a central holding area. This process is for evaluation of the red tag items. Occasionally used items are moved to a more organized storage location outside of the work area while unneeded items are discarded.


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If you don’t use it, move it!

If you don’t use it, move it!


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Sorting frees up valuable floor space and eliminates such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material.

The Sort process also helps prevent the ‘hoarder’ job mentality (“I might need it”).


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A place for everything &

everything in its place

A place for everything &

everything in its place

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Set in Order – (Seiton)Set in Order – (Seiton)Set in Order – (Seiton)Set in Order – (Seiton)

1. What do I need to do my job?

2. Where should I locate this item?

3. How many do I need?

The second SS focuses on efficient and effective storage methods.

You must ask yourself these questions:

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Strategies for effective Set In Order are:

Set in Order – (Seiton)Set in Order – (Seiton)Set in Order – (Seiton)Set in Order – (Seiton)

Painting floors Outlining work areas and locations Shadow boards Modular shelving and cabinets

“A PLACE FOR EVERYTHING AND EVERTHING IN ITS PLACE”

“A PLACE FOR EVERYTHING AND EVERTHING IN ITS PLACE”

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Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutter-free work area and the Shine step will help create ownership in the equipment and facility.

Shine – (Seiso)Shine – (Seiso)Shine – (Seiso)Shine – (Seiso)

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Workers will also begin to notice changes in equipment and facility location such as air, oil and coolant leaks, repeat contamination and vibration, broken, fatigue, breakage, and misalignment. These changes, if left unattended, could lead to equipment failure and loss of production. Both add up to impact your company’s bottom line.

Shine – (Seiso)Shine – (Seiso)Shine – (Seiso)Shine – (Seiso)

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Once the first three of the 5S’s have been implemented, you should concentrate on standardizing best practice in your work area. Allow your employees to participate in the development and documentation of such standards. They are a valuable but often overlooked source of information regarding their work.

Standardize – (Seiketsu)Standardize – (Seiketsu)Standardize – (Seiketsu)Standardize – (Seiketsu)

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Standardize – (Seiketsu)Standardize – (Seiketsu)Standardize – (Seiketsu)Standardize – (Seiketsu)

Workplace Layout and Design

Materials Handling Analysis

Clear and Concise Work Instructions

Well Defined Work Methods

Safe (Ergonomic) Working Practices

Cycle Time Reduction

Training

Documentation

Standardize means establishing “Best Manufacturing Practices, including:

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This is by far the most difficult SS to implement and achieve.

Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things.

Sustain focuses on defining a new status quo and standard of work place organization.

Sustain – (Seiketsu)Sustain – (Seiketsu)Sustain – (Seiketsu)Sustain – (Seiketsu)

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The “5S” PhilosophyThe “5S” PhilosophyThe “5S” PhilosophyThe “5S” Philosophy

Once fully implemented, the 5S5S process can increase moral, create positive impressions on customers, and increase efficiency and organization.

Not only will employees feel better about where they work, the effect on continuous improvement can lead to less waste, better quality and shorter lead times. Any of which will make your organization more profitable and competitive in the market place

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Thank you for viewing this tutorial. Thank you for viewing this tutorial.

For further information about EASE For further information about EASE Inc, our clients, consulting services, Inc, our clients, consulting services, software products and software software products and software customization, or to end this tutorial, customization, or to end this tutorial, please select from the buttons at left.please select from the buttons at left.

Thank you for viewing this tutorial. Thank you for viewing this tutorial.

For further information about EASE For further information about EASE Inc, our clients, consulting services, Inc, our clients, consulting services, software products and software software products and software customization, or to end this tutorial, customization, or to end this tutorial, please select from the buttons at left.please select from the buttons at left.

EASE Inc.EASE Inc.

CLIENTSCLIENTS

CONSULTINGCONSULTING

SOFTWARESOFTWARE

CONTACT USCONTACT US

EXITEXIT

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EASE IncorporatedEASE Incorporated is an international corporation, founded in 1986.

EASEEASE is headquartered in Southern California with satellite offices in Europe and the United States.

EASE IncorporatedEASE Incorporated provides productivity improvement services through the application of the EASEworks®EASEworks® Software, training, consulting services and implementation support.

Who is EASE Inc?Who is EASE Inc?Who is EASE Inc?Who is EASE Inc?

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EASE CustomersEASE CustomersEASE CustomersEASE Customers

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The ServiceThe ServiceThe ServiceThe ServiceOur major focus is to offer sustainable productivity improvements and cost reductions for our clients. We can provide you with consulting assistance for. .

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Equipment Evaluation

Facility Layout

Establishing “Best Practices”

Competitive Benchmarking

Design Engineering

Process Engineering

Production Engineering

Implementing Ergonomic Improvements

Training and Training Support & Certification

Improving Labor Efficiency

Productivity Analysis

Implementing Lean Manufacturing

Manufacturing Engineering

ISO 9000 Implementation

Developing Work Standards

Process Mapping

EASE will provide engineers with extensive experience in YOURYOUR industry. Your engineers will have the ability to take over, with confidencewith confidence, where we leave off.

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SoftwareSoftwareSoftwareSoftwareEASEworks® Software modules cover:

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Work Standards Product Cost Estimating Line Balancing

Work Instructions Ergonomics Design For Assembly

EASE Inc. provides full training, start up assistance and consulting services for all modules.

Software customization services are also available.

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Phone:Phone:

Fax:Fax:

E-Mail:E-Mail:

Web:Web:

[email protected]

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(949) 348-7511

(973) 201-1600

www.easeinc.com

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Contact InformationContact InformationContact InformationContact Information

EASE IncEASE Inc.

27405 Puerta Real, #380

Mission Viejo, CA 92691

EASE IncEASE Inc.

27405 Puerta Real, #380

Mission Viejo, CA 92691

Ver 6

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SAMPLE ONLINE WORK

INSTRUCTION

SAMPLE ONLINE WORK

INSTRUCTION

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Full motion video can be displayed as part of a work

instruction

Full motion video can be displayed as part of a work

instruction

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Work tasks can be analyzed in great detail to evaluate alternative methods.

Work tasks can be analyzed in great detail to evaluate alternative methods.

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PROCESS STEPS

NECESSARY TO PRODUCE

OUTPUT

CONTRIBUTES TO CUSTOMER

DEMANDS?

CONTRIBUTES TO BUSINESSR

DEMANDS?

VALUE ADDED

ESSENTIAL NON-VALUE

ADDED

NON-VALUE ADDED

ASSEMBLY METALWORK PACKAGING

FINANCIALS SCHEDULING

MINIMAL MATERIAL HANDLING

MOVEMENT REWORK STORAGE

Determining Value/Non-Value Determining Value/Non-Value Added ActivitiesAdded ActivitiesDetermining Value/Non-Value Determining Value/Non-Value Added ActivitiesAdded Activities Value Added: Activities that

must be performed to meet customer requirements

Non-Value Added: Activities that do not contribute to meeting customer requirements. These activities can possibly be eliminated.

YESYES

YESYES

NONO

NONO

NONO

YESYES

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This chart illustrates Value Added/Non-Value Added, Walking and Internal Time.

This chart illustrates Value Added/Non-Value Added, Walking and Internal Time.

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This shows methods comparison and cost benefits.

This shows methods comparison and cost benefits.

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Here is a comparison of the value added.

Here is a comparison of the value added.

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Not only can existing working practices be evaluated, but alternatives can be considered and cost justified.

Not only can existing working practices be evaluated, but alternatives can be considered and cost justified.

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A leading beef processing plant uses EASE to compare the same task for training and work content across all of their plants.

A leading beef processing plant uses EASE to compare the same task for training and work content across all of their plants.

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HOME Copyright EASE Inc Tutorials© 1986-2002 The “5S” Philosophy An EASEworks® Manufacturing Tutorial START Ver 6