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Benefits of 5S
5S
Safer Work Area
More organised
Best place to make good
quality parts
Less Wastes
Better working
environment
5S – Shift Out
• Why?
– Only have the equipment you need in the work area – NOTHING
MORE!!
– To remove all inherent problems and start from fresh
• How?
– Take everything out of area
– Decide what is needed and what is not
– Use red tags on problem items
3. Use Red Tags
Used For
Homeless Items
Broken Items
Safety Problems
Quality Problems
RED TAG LOGTag
#
Problem Solution
Use this to track your red tags
5S – Shift Out
Remember:
1) Shift Out once / month
2) Create a “Central Red Tag Area”
3) Ensure each cell has its own supply of red tags
4) Train the operators and supervisors from the area before you do 5S
What to do with shifted out items
What How
Throw it away Dispose of useless items
Modify It Change it to another useful item
Sell It Sell to other companies
Return It Return items to your suppliers
Other Departments Lend to other departments
Give to other departments
5S - Shine & Sort
• Why?– We will be able to see the actual condition of the machines and work
area
– We will be able to find problems we would not normally be able to see
• How?– We clean everything from top to bottom and use red tags
• Homeless
• Broken
• Safety Problems
• Quality Concerns
• Wastes
• What do we need?– Rags, brushes, brooms, red tags, degreaser, gloves, safety glasses,
photographs
5S – Set in Order
• Why?– Everything must have a home
• How?– A place for everything
– Everything in its place
– Remember safety
– Remember how often you use it
– Constant quantity
• What do we need?– Tape, pens, labels
5S – Standardize
• Why?– We need to keep 5S going – don’t loose it!
• How?– We must make it easy to maintain
– We must have a daily check sheet
– We must use visual management
– Everyone must understand their responsibilities
– We show other shifts / operators
• What do we need?– Photographs, Cell standard
5S – Standardize
Purpose : To list the standard layout, tools and equipment for the cell or area
Responsible: Area Leader
Work instructions, Job cards, Process Sheets need to be visable and displayed the
right locations
Green area charts and measures need to be updated
No extra tools, machines, material, scrap, should be in the area
Area must be clean and tidy
All containers with stock/parts must be labled, including raw material
All tools and machines must be clean and tidy
Scrap need to be contained and clearly marked
5 S Work Area Standard
PhotoDescriptions
Notes : The objective of this document is to standardise the work environment to ensure that it
is kept in a optimal working condition.
5S - Sustain
• Why?
– It is easier if everyone follows the rules, understands the benefits
and help us to improve
• How do we achieve this culture?
– It becomes a habit to keep 5S
– We share our knowledge with everyone
– We lead by example
– Our management supports us it
– We involve everyone
And then…everyone wins!
Before you start
• Plan for model area downtime
– Build up stock
– Have a before photo, then After Photo (from the same angle)
– SAFETY SHUTDOWN
– Remind zone staff of training date
• Plan for use machines e.g. forklift
• Arrange cleaning materials
• Arrange for red tags
• Arrange for yellow tape
• Demarcate Red tag area
5S- Implementation
AREA LAYOUT
5S LOG SHEET
CELL LAYOUT
5S
IMPLIMENTATION
PLAN
5S STANDARD
CELL AUDIT SHEET
RED TAG GRAPH
5S
AUDIT GRAPH