Workshop 5S

Training material
Central team
29/12/2008

TRANSPORT
 5S

5S
WORKSHO
P
5S Workshop - 18/10/2007 - P 2
 5S : Goal

THE 5S IS THE BASIS OF THE WORK

ORGANIZATION
TO IMPROVE
• The Quality
• The Productivity (Efficiency)
• The Safety
• The ease to maintain
• The Reliability of equipments
• The Involvement of people
(apprenticeship to suggestions)
• The Standards (easy Factory to understand)

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 What are the 5S ?

Discipline
-Respect the standards
1 Organization
- Throw out and improve
(Shitsuke)
5
(Seiri)

Standardization
2 Order
- Set in order
-Define the standards
(Seiketsu)
(Seiton)

4
3 Cleanlines
s
- Clean
(Seiso) Livre d’Hirano : “JIT Factory Revolution”

5S Workshop - 18/10/2007 - P 4
 5S

5S
Sort Sustain / Improve

Set in order Standardize

Shine

5S Workshop - 18/10/2007 - P 5
 The goals of 5S

1 2 Set in order
Organization Improve the productivity
Sort the useable and useless in Thanks to the minimum of
order to keep only the items necessary time necessary to catch an
item
on the workstation
5 “One place for each item.
Discipline Each item on its own place”
Obtain the participation,
the communication and
personal involvement Cleanliness
Standardization Clean the tools, the equipment
Apply the 5S everyday. and pieces in order to have
Organize the workstation them as if they were new
with visual management Identify the causes of the
problems / mistakes

4 3

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 5S : We can change this …

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 … in that

5S Workshop - 18/10/2007 - P 8
 Steps of the 5S

STEP O

PREPARE THE WORKSHOP

5S Workshop - 18/10/2007 - P 10
 5S : Prepare the workshop (step 0)

Prepare the means for cleaning

Distribute Post-it + pens to all members ACTION PLAN
Stimulate them for use

1 idea
A.P.
Short sentence per post-it
understandable
by ever yon e JB

To be able to refind the writer

Each member of the group

note his remarks.
Note a problem, an idea
Bound the perimeter of the workshop

Take pictures of the current situation

Prepare the means for cleaning

5S Workshop - 18/10/2007 - P 11
 5S : Prepare the workshop (step 0)

Build a communication board compliant with the standard one

Progress
board on 5S Perimeter

5S
Peri meter

The Tea m 1
Leader:
Parti ci pants:

2
Photo de l' équip e
+ nom du pil ote Plan de la zone
+ li ste des partic ip ants
3
Start date :
End date :
pr é
v is io n n
e le
4

5 Weekly self -assessment with graphic

Before After Schedule of

meetings
PHOTO PHOTO

Action plan

PHOTO PHOTO

Draft of first
PHOTO PHOTO
instructions
for cleaning
post-it

PHOTO PHOTO

5S Workshop - 18/10/2007 - P 12
 5S : Prepare the workshop (step 0)
r
p é v i s i o n n e l l e

a
D t e F i n :
a
D t e d é b u t :
+ l i s t e d e s p a r t i c i p a n t s
+ n o m d u p i l o t e
P h o t o d e l ' é q u i p e

a
P r t i c i p a n t s :
P i l o t e :

' E
L Q U I P E

5 S
P E R I M E T R E D ' A C T I O N

IMPORTANT Every member of the group Tableau de

progression

participate in the realization

1

2 Plan de la zone
3
4 Audit hebdo. avec
5 suivi graphique

Avant Après Planning des

réunions

PHOTO PHOTO

Plan d'action

of these actions
PHOTO PHOTO

Instructions
PHOTO PHOTO provisoires
de nettoyage
post-it

PHOTO PHOTO

r
p é v i s i o n n e l l e

a
D t e F i n :

For the success of the

a
D t e d é b u t :

workshop this
n t s :

involvement is indispensable
5 S
M E T R E D ' A C T I O N

Tableau de
progression

1
2 Plan de la zone
3
4 Audit hebdo. avec
5 suivi graphique

Avant Après Planning des

réunions

PHOTO PHOTO

Plan d'action
PHOTO PHOTO

TEAM CONCEPT PHOTO

PHOTO
PHOTO

PHOTO
Instructions
provisoires
de nettoyage
post-it

5S Workshop - 18/10/2007 - P 13
 Steps of the 5S

STEP I

SORT

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 5S : Sort (step 1)

PRINCIPLE
Check all useless items or not identified on the workstation (visible or
not)

METHOD
Evacuate the useless items in a « lumber room » area
Lay down what seems not well ordered or what we are not sure about,
in a «To set in order / Pending decision »

GOAL
Aerate the workstation area

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 5S : Sort (step 1)

SORTING OUT – CLEAR THE AREA

Define an area « Lumber room» for every useless item
Pending decision
Define an area « To set in order/ pending decision » area

in which, the items with no use or no ordering defined,

will be laid down

Check accurately the complete perimeter 5S . Each hiding place has to be

checkedPeople are usually half-hearted : « It can be useful »
The key message is :
If we have a doubt, we do not throw out, we lay it in the
« To set in order / pending decision » area

5S Workshop - 18/10/2007 - P 16
 5S : Sort (step 1)

SORT-THROW OUT Area of « Lumber room »

TO THROW
OUT !!

Area for Pending ANALYZE FOR

Decision RE-USE

DUSTBIN

WAREHOUSE
OTHERS

5S Workshop - 18/10/2007 - P 17
 Steps of the 5S

STEP II

SET IN ORDER

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 5S : Set in order (step 2)

PRINCIPLE
One place for each item and each item has got its own place

METHODE
Define a place related to the frequency of use

GOAL
Find easily
Allow anyone to find it (Multi-skills)
Save time (Efficiency)

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 5S : Set in order (step 2)

UPHOLSTER : Check the frequencies of use

Electric cupboard Tools cupboard Table

Stock/ WIP Worker

1/ 1m
1/ 1m 2/ 5m
2/ 16m
4/ 15m 3/ 10m
3/ 3m
Each hour/ 8m
Each day/ 1m

5S Workshop - 18/10/2007 - P 20
 5S : Set in order (step 2)

One place for each item

Each item has got its own place
near the point of use
(Taking in account the frequency of use)

Missing

The lack of disposal is no longer permissible

The lack of disposal of an item must be visually obviou
Permanently, we have to lead actions to obtain
each item in its own place
Lead examplarily

5S Workshop - 18/10/2007 - P 21
 5S : Set in order (step 2)

EFFICIENCY of the DISPOSAL

Reduction of the time to act Screw 4 Screw 6 Nut 4 Nut 6

( breakdowns, planned stops, change over)

1 2 3 4 5 7

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 5S : Set in order (step 2)

EFFICIENCY of the DISPOSAL

Blank documents
available

B4 A4 ACTION PLAN

plan
Action
TRAVELLING
6 5 4 3 2 1
B3 A3 REQUEST
MINUTES
OF MEETING

B2 A2

12 11 10 9 8 7
B1 A1
Self service area
00 0:00' 00 00
0:00' 00 00
00 0:00' 00 00

FOURNITURES ADMINISTRATIVES

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 Steps of the 5S

STEP III

SHINE

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 5S : Shine (step 3)

PRINCIPLE
Obtain a clean workstation or workshop area.

METHODE
Organize one action of deep cleaning (repaint)
Find the improvements to correct abnormalities

GOAL
Act on root causes of smudge to eliminate the need to clean

5S Workshop - 18/10/2007 - P 25
 5S : shine (step 3)

Smudges
map
Eliminate the
root causes
of smudge US labels
ANALYZE

ACT ON ROOT CAUSES

Reduce the tasks Change the gasket
of cleaning

5S Workshop - 18/10/2007 - P 26
 5S : Shine (step 3)

Analyze : “5 why” on root causes of smudge and

abnormalities

Tool to find the original cause of a problem

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 5S : Shine (step 3)

Example of root causes analysis

• Why - the equipment has stopped ?
• Answer... - “Overload captor switched off !”
Why – the overload captor has switched off ?
Ans.... - “Lack of oil on the shaft !”
Why – the oil is missing ?
Ans... - “Oil pump no longer efficient !”
Why - Oil pump is no longer efficient ?
Ans... - “Driveshaft is worn !”
Why – is this driveshaft worn ?
Ans... “Oil filter plugged by dirts

5S Workshop - 18/10/2007 - P 28
 5S : Shine (step 3)

Raise an upgrade action plan

Issue Solution By who For when
Abnormality solution

Abnormality solution

Abnormality solution
Abnormality solution

Abnormality solution
Abnormality solution

5S Workshop - 18/10/2007 - P 29
 Steps of the 5S

STEP IV

STANDARDIZE

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 5S : Standardize (step 4)

PRINCIPLE
Define the rules to apply the 3 first steps.

METHODE
Write the process for Cleaning and for the 1st level of maintenance

GOAL
Formalize the visual standards for cleaning and maintenance of 1st
level dedicated to this workstation to maintain its rank
EASY FACTORY

5S Workshop - 18/10/2007 - P 31
 5S : Standardize (step 4)

Key step of the TPM

(Total Productive
Instructions sheet IS1
Maintenance)
(Preventive maintenance 1st level)

Weekly
CLEANING = CHECKING
INSPECTION

Visual Instructions (IS)

wrote and realized
by the workers
Follow up ( IS of maintenance 1st level )

5S Workshop - 18/10/2007 - P 32
 5S : Standardize (step 4)

SORTING MAP
The archive rules SERVICE: ________ 1 4

The identification
3 2

ARMOIRE N° __ 5

1- NOTICES

The responsability
8

7
IDENTIFICATION
FOLDER
2- TECHNICAL FOLDERS

FolderN° 2 Under the 3- BOOKS

Responsability of: xxxxxx SMED - KANBAN - 5S
4- DOCUMENTS OF THE DEPART
Archive rules 1- Monthly report minutes
2- General expenses
3- ........
Follow up 5- COMPANY DOCUMENTATION
1996 7- ...........
1997
1998
8- ...........
1999 9 -...........
6- ADMINISTRATIVE ASPECTS
7- SUPPLIERS DOCUMENTATION
8-

A4 B4
CLEANING INSTRUCTIONS
1 2 3 4 5 6

Copy rules
A3 B3

A2 B2
WEEKLY
7 8 9 10 11 12
A1 B1
FOLLOW UP
1996
1997
1998
1999

FOURNITURES
ADMINISTRATIVES

A E Z Soak the keys in the

R T
liquid to clean
EACH 6 MONTHS

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 5S : Standardize (step 4)

Levels
Surface roughness

Leaks
Vibrations

Warmth
Wear

INSPECTION
Stiffness e ll
Sm Air leak
Short circuit

Abnormal sound

5S Workshop - 18/10/2007 - P 34
 5S : Standardize (step 4)

Visual checking
AVOID
DEFECTS
(Communicate the
informations in order to
STOP THE DEFECTS avoid any gap according
to the standards)
WARN IN CASE OF DEFECTS

TAKE IN ACCOUNT STANDARDS

AT THE WORKSTATION
WRITE AND POST THE STANDARDS
SPREAD THE INFORMATIONS
Visual instructions
(Communicate the
useful informations)

ORGANIZATION OF THE WORKSTATION / 5S

5S Workshop - 18/10/2007 - P 35
 5S : Standardize (step 4)

GOOD

CLOSED

B
BAD

OPEN
Batch 99999
Batch 22222
Batch 55555

VISUAL MANAGEMENT
POKA-YOKE MANAGEMENT

EASY FACTORY

5S Workshop - 18/10/2007 - P 36
 5S : Standardize (step 4)

STANDARDS EASY FACTORY : Let know and apply Standards

« Easy factory » Floor marking standardization
Participate to the improvement of these Standards to new ones
 Surfa ce s :
• Fire lanes : walkways and forklift lanes should be separated either by another color or by a 8 cm
RAL 6032 wide yellow line RAL 1023 ; a standard pictogram (see Apsys pictograms) must be painted on the
walkways every 5 meters
walkways
RAL 7042 Forklifts
• Working areas lanes

RAL 3020 • Safety areas : fire-extinguishers, fire engines, …..

 Line s :
8 cm

White line RAL 9010 • Boundaries between working areas and fire lanes
5 cm

Yellow line RAL 1023 • Location of garbage cans, cupboards, racks, ……

5 cm

Blue line RAL 5017 • Parts storage on the border lines, location for parts entering warehouses or
primary parts shops
 Inte rrup
20 cm
te d line
10 cm
s :
• Location for parts getting out of warehouses or primary parts shops
5 cm 5 cm

• Non-conformity areas

• Jigs & tools storage

5 cm

5S Workshop - 18/10/2007 - P 37
 5S : Standardize (step 4)

Equipment magnets During the

reparation of the
equipment :
MAGNET
When the
When the YELLOW With
equipment is out
equipment is in MAINTENANCE
of order :
good working noticed on an
order : MAGNET ORANGE
YELLOW Triangle
MAGNET GREEN
200 mm 200 mm 200 mm
200 mm

200 mm

200 mm
MAINTENANCE

These magnets must be posted on all equipments

(CMS equipt, machining, robot, etc…)

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 5S : Standardize (step 4)

Colors and indications on doors for pedestrians

Green color for barriers and doors of pedestrians passages

Name of the workshop

600 * 200 mm

2 standard warnings about

safety 450 * 150 mm

A striped black / yellow

in front of the door
Yellow RAL 1003

5S Workshop - 18/10/2007 - P 39
 5S : Standardize (step 4)

Example of procedure to check and clean

Task Who Frequency When Equipt Comments

Rag
Clean the grid of Every
the furnace
pm
Tuesday
End of shift Metal brush WARM !
Gloves
Clean the grease
1 Thursday Rag Do not use
on the exhaust Night shift End of shift
out of 4 Solvent alcohol
wheel
Clean the Begin of Rag
closed network
am Everyday
shift Gloves -
1 Tuesday Begin of Rag Check the
Change oil am
out of 2 shift Oil box Maxi level.

...

5S Workshop - 18/10/2007 - P 40
 5S : Standardize (step 4)

Example of procedure to check and clean

5S Workshop - 18/10/2007 - P 41
 Steps of the 5S

STEP V

SUSTAIN

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 5S : Sustain (step 5)

PRINCIPLE
Follow up of the respect of rules and Standards

METHODE
Audit by the responsible of cleaning and maintaining operations (1st
level)

GOAL
Insure the sustainability of the actions
Stimulate the proposals of suggestions
Improve the rules and Standards

5S Workshop - 18/10/2007 - P 43
 5S : Sustain (step 5)

Define a suitable audit

5S Workshop - 18/10/2007 - P 44
 5S : Sustain (step 5)

Measure the performance

Improve
Continuous progress

Weekly Audit
Action plan
Graphic display

5S Workshop - 18/10/2007 - P 45
 5S : Sustain (step 5)

WEEKLY AUDIT Action plan

IDEA

INVOLVEMENT POST-IT

OF ALL
MEMBERS OF
THE TEAM
5S Workshop - 18/10/2007 - P 46
 Steps of the 5S

STEP VI

BEST PRACTICES
DEPLOYMENT

5S Workshop - 18/10/2007 - P 47
 5S : Best practices deployment (step 6)

•Collect and register the good practices : WORKSHOP 5S

xxxxxx
•To share with the other teams GOALS

•To duplicate in the other workshops BEFORE AFTER

and save time
PHOTO PHOTO

•To obtain a common visual PHOTO PHOTO

management system PHOTO PHOTO

•To provide ROE to Industrialization PHOTO PHOTO

department for the improvement to HOW WE HAVE SUCCEEDED

take into account for the design of the
equipments in the future

5S Workshop - 18/10/2007 - P 48
 5S : Synthesis

5S Workshop - 18/10/2007 - P 49
 5S : Synthesis

MAIN ROLE OF THE LEADER

THE RESPECT OF THE SCHEDULING
THE METHODOLOGY AND THE RESPECT
AND OF THE STANDARDS OF THE DUE DATES
Progress board of 5S
THE INVOLVEMENT Schedule of
The full participation of meetings

all members of the Team

Tableau de
progression

1
2 Plan de la zone
3
4 Audit hebdo. avec
5 suivi graphique

Avant Après Planning des

réunions

PHOTO PHOTO

Plan d'action
PHOTO PHOTO

Instructions
provisoires
PHOTO PHOTO
de nettoyage

POST-IT
PHOTO PHOTO

5S Workshop - 18/10/2007 - P 50
 5S : Synthesis

Make the equipments better than new

improvement
initial status
maintenance

worn
upgrade

5S Workshop - 18/10/2007 - P 51
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