Professional Documents
Culture Documents
5S Basic Training Material v3.0
5S Basic Training Material v3.0
5S Basic Training Material v3.0
OBJECTIVES
Name, background
T
E
N
T
5S – Meaning &
Part 1 Benefits
5S - Meaning
Resources required:
1. Red Tags
2. Red Tag Record Forms
3. Camera for “before” and “after” pictures
9–
5S Standards - SORT
BEFORE
E RIALS
Y MAT
ES SAR
C
UNE
AFTER
10 –
5S Standards - SORT
11 –
2S-Set In Order
5S Standards – SET IN ORDER
Set in order
Arrange all required / necessary items and tools as per their:
Designated locations, containers,
Accessibility
Ergonomic aspect
Utilization criteria and ‘point of use’
Ask yourself
Note: Ensure
• Should this tool really be placed here? • There is place for everything &
• Why do we have this shelf, rack or cabinet? everything is in its place..
• FIFO method or perishable and
• Who uses this equipment? shelf life items
Comply with safety guidelines [for e.g. glass items at lowest racks]
Resources required:
1. Standards for labeling, marking, and color-coding
2. Labeling supplies
3. Tape for creating borders on work surfaces and floors
4. Paint and painting supplies
13 –
2S-Set In Order
5S Standards – SET IN ORDER
5S Floor Color Coding
Recommend 3M brand color tapes Color Use for
Use as few colors as possible [refer Yellow Moveable items, materials & equipment
[for e.g. racks, trolleys, HK machine,
to the table] vacuum cleaner]
Keep color coding areas clear for Blue Non moveable/ permanent fixed items
or fixtures [for e.g. table fixed to wall or
safety and compliance floor, workstations]
Red Defects, scrap and red tag items/ areas
Put tapes/ or paint in ‘L’ shape
manner [2 inches away from Black & Yellow Place which may expose people to any
[stripes] physical or health hazards [gas range,
equipment edges, generally in 4 electrical panels, doors]
sides]
16 – Title of the document or activity name – Month XX, 2012 – Insert tab > Header/Footer
5S Standards – Set in Order
Resources required:
1. Cleaning supplies such as brooms, dust pans, rags, degreasers, and floor
cleaner.
2. Personal protective equipment such as gloves and eye protection.
5S Standards – SHINE
21 –
4S-Standardize
5S Standards - STANDARDIZE
Resources required:
1. Support from those who can create documentation, job aids, and visual aids
2. Information and approval from those responsible for maintaining company procedures
3. Poster-making supplies for posting new standards in work areas
23 –
4) STANDARDIZE
Visual Management
24 – OE 5S Training
5S Standards - STANDARDIZE
25 –
5S Standards - STANDARDIZE
26 –
5S-Sustain
5S Standards - SUSTAIN
Resources required:
1. Management audit forms
2. Resources for communication and recognizing successes (newsletters, displays,
awards)
3. Presentation tools for sharing best practices with other work areas
4. Management commitment and focus on maintaining the new standards
28 –
5) SUSTAIN
Sustain W1 W2 W3 W4 W5
1 Definitive stickers and labels are clear and up to date
Tools used
2 There are no un-used material in the workplace/ areas.
3 All right status photos are in place
5S Audit
4 Area owners are sustaining their area. Sort
5 All yellow lines and other standardization are in place 5S Leader
6 Each area has the name of its owner displayed.
7
All Employees are using the Safety First & Continous
Improvements cards (Safety Observation System) Stabilise 5S Meetings
8 There are no objects outside the designated space
9 Tools and materials are at easy access Standardise
10 Documents are at their identified places
11 Shelves and cupboards are tidy
12 Corridors, circulation alleys and security areas are clear
13 Equipment, materials and all area are clean
Compliance
Challenges Shine
14 The Action Plan has been updated
Materials needed to do repairs or changes have been
Discipline
15
indentified and put in the Action Plan
16
The Action Plan has been looked into by Site Manager /
supervisor
Implementatio
17 Weekly 5S meetings have been held Sustain n
Inspection!!
Continuous Improvement
18 Meetings are conducted in front of the 5S board
19 Before-After pictures are changed regularily
20 Was there a Suggestion/ Observation this week?
Rewarding
Total score of the month
Approved by:
29 – OE 5S Training
5S Standards - SUSTAIN
30 –
Few more pictures
5S – Before & After
32 –
5S glance @ Volkswagen
· · page 33
Food Stores
Before
After
Before After
Before After
5S iceberg
38 –
5S Deployment
• Prepare Deployment/ Activities Chart [Gantt Chart] for 5S Activities with defined timelines and Responsibility
• Brief team on 5S Processes – SORT, STRAIGHTEN, SHINE, STANDARDISE AND SUSTAIN
Deplo • 5S Champion to conduct weekly 5S Audits; Review progress
y 5S • Click Pictures for Visual Management/ Understand progress areas/ difference..
Meth •
odolo Quantify benefits [whereas applicable]
gy
Nominate 5S Champion(s) area wise, who shall be responsible for the upkeep
of 5S implementation at all times…
40 –
5S Audit framework
Part 3 & Rewards
43 –
Audit Framework