5 S/Visual Management

Requirements

• Safety rules are implemented and followed—SAFETY

FIRST.
• Every plant has to operate in a hospital-clean
environment.
• Visual management must be standardized across
areas, centers, and plants.
• Everything has its place and there’s a place for
everything.
• Tools must be readily accessible to those responsible
for performing housekeeping.
Operating Standards
32.0 WORKPLACE ORGANIZATION (5's)
All employees have received 5'S training and understand the 5'S
32.1
Methodology.
Employees on all shifts participate in the development of the standards for
32.2
their workstations.

32.3 There is a place for everything and everything in its place.

The 5'S process is used to control all items at the workstation and throughout
32.4
the plant.

32.5 Workplace organization standards are maintained equally on all shifts.

32.6 Excess or non-essential tools and equipment do not exist at the workplace.

32.7 Fixed position points are clearly indicated with marking or yellow paint.

32.8 70% operation complete mark is visibly marked on floor.

32.9 Start and stop points are identified with visual green and red arrows.

32.10 Items are labeled and yellow lines are used to mark designated areas
There is a 5'S housekeeping checklist that is porformed beforeand /or after
32.11
the shift.
32.12 Excess material is eliminated from the workplace.

Non-conforming material is properly identified and placed in a designated

32.13
area.
Attendance chart and vacation chart is posted visible for all employees in each
32.14
zone
Operating Standards
30.0 VISUAL MANAGEMENT

30.1 Abnormalities are easily identified by way of Audio/Visual indicators.

30.2 Safety equipment location and instruction are clearly and prominently displayed.

Everything is organized in such a manner that even a new employee can

30.3
understand the business.

30.4 Emergency instructions and evacuation plans are posted in appropriate areas.

Workplace organization standards are documented, communicated and displayed

30.5
on Job Board at each workstation.

Color coding is used to denote differences between alternatives. (ie car line,
30.6
model, option parts tools, equipment etc.)

30.7 Location of dunnage, salvage, scrap and refuse are clearly marked on the floor.

Containers are clearly marked (e.g. fluids, hazardous materials, recyclable

30.8
materials, gloves etc.).

Apppropriate key point charts are diplayed at work stations showing acceptability
30.9
limits of good and bad parts.

Preventive maintenance documents are current, posted on all tools and equipment
30.10
and are clearly visible to operator (e.g. PM logs signed and dates).

Charts are clearly visible and easily understood and display performance goals
30.11 and status (e.g. safety, ergonomics, quality, productivity, cost, attendance,
suggestions, etc.).
Attendance chart and vacation chart are posted visible for all employees in each
30.12
zone.
 Definition of the 5 S’s

• The 5 S’s is a tool that represents the basic

principles of housekeeping and workplace
organization.
– The Five S’s, collectively, are disciplines that
help create a safer, more organized, and more
competitive workplace.
– Successful implementation can lead to
improved equipment uptime and increased
productivity.
 Goals

Eliminate Failures/Reduce Variation

Enhance Worker
Productivity

Results:
Safety
Quality
Delivery
Cost
Morale
Improved Competitiveness
 Benefits

• Routine disciplines are established to keep the

workplace in order.

• Prompt problem detection is easier; problems

become more visible.

• Standards are clear.

• Process exists for the identification and removal

of nonessential materials and waste.
 Benefits
• The work area is well organized and materials
are in the proper locations so time is not lost
looking for equipment and materials; production
is maximized.

• Operation rates are more efficient and costs are

reduced due to the elimination of waste.

• MQAS (Manufacturing Quality Assurance

Systems) standards are supported .
Would you like to work in this place?
 After
Racks and Containers for Small Lot SOP
Andon Cord
Andon Board

Information
Scoreboard
Charts

5-S

Safety
Glasses Foot-printing Floor
On

Walking Aisle

Ergo Aid
Table
 The 5 S’s—What Are They?
The 5 S’s—What Are They?
 Preparation
• How do you know where to start?
• What do you do?
– Take pictures (time and date).
– Document specific problem areas
(organization, dirt, extra stock).
– Talk to operators, managers, and
supervisors.
 Sift—Definition
Sifting is separating the essential materials
from the nonessential.
• Nonessential items are those not needed for
present production.
• The goal of sifting is to simplify work
environment.
• The procedure that involves identifying the
nonessential items in a work area is called
“tagging.”
 Sweep—Definition

Sweeping involves removing

nonessential (tagged) items from the
work area.

• Defective and dead stock items are

eliminated.
• Excess stock is moved into storage.
• Stock for other operations is relocated.
Sift & Sweep
 Sort—Definition

Sorting involves organizing the essential

materials in the workplace.
• The goal of sorting is to eliminate wasted time looking
for materials and tools.

• Sorting leads to improved efficiency.

• Sorting contributes to a safer working environment!

Sort
 Sort—Organizing Strategies

• The basics • Labeling strategies

– What is it? – What? (item)
– Where does • Name
it belong? • Classification
– How many – Where? (position)
are there? • Shelf location
• District location
• Department/operation name
– How many? (quantity)
• Minimum quantity
• Maximum quantity
 Sanitize—Definition
Sanitizing is the regimented, scheduled
cleaning of the entire work area.
• The purpose of cleaning is to rid work
place of all dust and dirt (dirt is often the
root cause of premature equipment wear
and product failure).
• A cleaner workplace allows for quicker
problem detection.
• A clean workplace is a safer workplace.
 Sustain—Definition
To sustain is to perform the 5 S’s on an ongoing
and systematic basis.
• Sustaining is the continuation of sifting,
sweeping, sorting, and sanitizing.
• Sustaining is everyone’s responsibility!
• Checklists and Audit Charts are the
primary tools used to sustain the
implementation of the 5 S’s.
If nothing is done, nothing will improve.
 Visual Management
Definition: The use of signs, photos,
objects, visuals, etc., that will enable an
individual to immediately recognize the
standard and anything abnormal.
• Heavily supported by the 5 S’s
– Sift, Sort, Sweep, Sanitize, and Sustain
 Visual Management
Other tools that are supportive include:
Labeling, marking, and foot printing
Color coding
Work station identification
Downtime clocks
Floor measurement
Scoreboards
Control point standardization
 Benefits of a
Visual Management System
• Abnormal conditions apparent
• Progress of work indicated
• Easy to audit
• Established accountability
• Formal processes, procedures, and
standards established
Levels of the Visual
Management
6
Prevent
Abnormalities
(Error-Proof)

Stop Abnormalities
5
(Prevent defects from moving
on)

4 Warn about Abnormalities

(Build in alarms)

3 Build Standards into the Workplace

2 Share Standards at the Site

1 Share Information

Sift, Sort, Sweep, Sanitize, and Sustain

Workplace Organization