5S Booklet

5S
The Japanese Foundation for

Improvement
www.completekaizen.co.uk
© Complete Kaizen 2007
Introduction
The 5S method has been described as the

foundation for improvement.
According to Japanese author and consultant,

Hiroyuki Hirano, unless you first apply the 5S
method you cannot achieve sustainable
operational improvement.
This presentation will introduce you to the 5S

method so that you can implement it in your
place of work.
The Benefits
According to a survey conducted by the Hong Kong

5S Association, and another by Andrew Scotchmer,
the benefits from applying 5S include:
• Improved Quality • Dynamic Teamwork

• Improved Productivity • Higher Staff Morale
• Improved Efficiency • “Can Do” Culture
• Improved Safety • Lower Operating Costs
• Improved Delivery • Professional Image
The Five Steps to Success
The name 5S refers to five words each

beginning with the letter ‘S.’ Originally these
were Japanese words but they can be translated
into English as:
• Sort
• Straighten
• Shine
• Standardise
• Sustain
Each ‘S’ is a step in the 5S method.
The 5S Ladder
The power of 5S is how it affects both the

physical and cultural aspects of our company.
The 5S Motivation Cycle
The 5S method helps build strong, dynamic teams

between all levels of the organisation and improves
staff motivation and morale.
Preparing the Foundation
Before you get started you need to choose your 5S

team. This team should consist of members of staff
who work in that department and are familiar with
the environment and it’s processes.
This is how 5S helps to create strong dynamic teams

within departments.
If your department is small enough you could, and

should, involve everyone. If not a team of no less
than six should be gathered from all levels.
Generate Improvement Ideas
With the team assembled, ask the other workers if

they have any suggestions about how they can
improve the immediate environment (show them
this presentation to start the discussion).
Later this suggestion system will be used as a

means of sustaining your improvements and
creating “buy-in” and a sense of ownership from
your staff.
Sort
This is the first step in a 5S campaign.
• Sort between necessary and unnecessary items in

your place of work
• Only leave what is immediately needed
• Discard broken equipment or furniture
During Sort we want to leave only those items that

are immediately needed in our place of work – the
bare essentials. Everything else should be removed
or discarded if broken.
Red Tags
In a 5S campaign, Red Tags are used to divide those

items that are unnecessary.
Red Tags are placed on items that are unnecessary

and contain information about the item and reasons
for its removal.
Tip
Don’t forget work-in-progress. Unless it is needed
immediately it should be removed from the
department and sent back to the preceding process.
When Red Tagging
• Go with your gut instinct

• Be ruthless
• Forget the “might come in handy” mentality
• Remember the “One is Best” rule
• If you have to think about it…
tag it!
Tip
Put an area aside to store the
tagged items in – a Red Tag
area. This means that all
unnecessary items can be
removed immediately.
One is Best
• One pen
• One set of tools per station
• One pad of “post-it” notes
• One block of printer paper
Much of what we have is unnecessary, yet costs us

money. Only have one of everything and thereby
benefit from better stock control.
Tip
Remove the standard ordering of supplies. Stocks
should only be replenished when they are needed, in
the amounts needed and “just-in-time.”
Straighten
This is the second step in a 5S campaign.
• Arrange the workplace in an orderly fashion to

ease the work being carried out there and to increase
the flow of work
• Everything has a clearly designated place
• Items are stored according to frequency of use
(regularly used tools are close at hand, others are
further away)
• Neat notice boards (remove obsolete notices)
Rearranging the Department
Often in old established departments, workstations

are positioned in a very inefficient way. When a
new starter begins, their workstation is located
wherever there happens to be a free space.
As such work goes back and forth throughout the

department , constantly retracing its steps, causing
waste in both time and motion.
Rearrange your department so work travels in a

single direction.
Make it Visual
The immediate environment should speak to us. We

shouldn’t have to waste time looking for what we
need. We should know where things are at a glance.
• Section off walkways from work areas and one

work area from another
• Use colour coding where necessary
• Each storage space should be clearly labelled as to
its contents
Tip
Remember the saying – “A place for everything and
everything in its place.”
Shine
Shine is the third step of a 5S campaign.
• Everybody is responsible for keeping the work

area clean and orderly
• Implementing Shine makes
 Cleaning and inspection a lot easier
 Errors stand out immediately
• Correct problems, such as items left in the wrong

place, as and when you find them (don’t leave for
someone else to sort out)
Total Productive Maintenance
Shine also introduces Total Productive Maintenance

(TPM).
This is an effective system for ensuring that all

equipment is in optimal working condition through
regular daily/weekly checks.
Always leave equipment in a clean, working

condition. This helps the next worker who needs to
use it.
Standardise
This is the forth step in a 5S campaign.
Whereas the last three steps brought about visible,

immediate change to our physical environments,
Standardise begins the cultural change. When we
have successfully and fully worked through the last
three steps, the physical changes made should then
become the “standard” for that work area.
Tip
Prominently display photographs of the area to
remind everyone working there how the area will
always be maintained.
Sustain
This is the final step in a 5S campaign.
This is by far the hardest of the five steps to

implement and the one with no end. Another
translation of the Japanese word Shitsuke is “self-
discipline” and it can take a lot to maintain the
benefits attained through the 5S change.
Tip
Remember, it is easy to fall back into bad habits and
let things go. Always check the 5S environment
through the use of audits and accreditation awards to
sustain the improvements made.
The 5S Kaizen Audit
The auditing process ensures that improvements

made are maintained and that the 5S method
ingrains itself into the culture of the organisation.
The 5S audit should be carried out weekly by a

member of the team. After this, a score is awarded
to the audit and at the end of the month each score is
added together and compared to the last months.
This score can then be plotted on a run chart to give
a visual representation to all workers of how the
environment has improved or where there is room
for improvement.
The 5S Kaizen Accreditation
For those departments

who can show that they
have consistently
achieved a high score on
the weekly audit, and that
improvements have been
made where needed, an
annual 5S Accreditation
certificate can be
presented and displayed
prominently.
Get the Idea
Suggestion tickets should be posted around the

workplace for staff members to complete if they
think of an idea to further improve the what they do.
These should be collected regularly and sent to the

manager who can then talk with the member of staff
whose suggestion it was. If found practical, the
suggestion should be implemented. The suggestion
then becomes the new standard for that operation.
This creates ownership and gives staff a sense of

contributing to the department – they become a part
of the solution.
Recap
• The 5S method is the foundation for improvement
• Without 5S other improvements will fail or be
difficult to maintain
• Work through the process methodically and
systematically
• Remember, “a place for everything and everything
in its place” and the “One is Best” rule
• Redesign work areas to increase flow and ease the
work
• Once complete, standardise the environment
through the use of photographs
• Complete an audit of the environment each week
This presentation was designed and
written by Andrew Scotchmer, author of
the book 5S Kaizen in 90 Minutes and
founder of Complete Kaizen, the 5S and
Kaizen consultancy.
Contact Andrew by emailing:

andrew@completekaizen.co.uk
5S Kaizen in 90 Minutes will be available

from high street retailers and online
stores from the 22nd February 2008. This
145 page illustrated book takes you
through each step in detail and includes
action plans and templates throughout.
Be sure to reserve yourself a copy from
Amazon today by visiting:
www.amazon.co.uk or www.amazon.com.

5S Booklet

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

5S Booklet

Загружено:

Авторское право:

Доступные форматы

5S

The Japanese Foundation for

The 5S method has been described as the

According to Japanese author and consultant,

This presentation will introduce you to the 5S

According to a survey conducted by the Hong Kong

• Improved Quality • Dynamic Teamwork

The name 5S refers to five words each

Each ‘S’ is a step in the 5S method.

The power of 5S is how it affects both the

The 5S method helps build strong, dynamic teams

Before you get started you need to choose your 5S

This is how 5S helps to create strong dynamic teams

If your department is small enough you could, and

With the team assembled, ask the other workers if

Later this suggestion system will be used as a

This is the first step in a 5S campaign.

• Sort between necessary and unnecessary items in

During Sort we want to leave only those items that

In a 5S campaign, Red Tags are used to divide those

Red Tags are placed on items that are unnecessary

• Go with your gut instinct

Much of what we have is unnecessary, yet costs us

This is the second step in a 5S campaign.

• Arrange the workplace in an orderly fashion to

Often in old established departments, workstations

As such work goes back and forth throughout the

Rearrange your department so work travels in a

The immediate environment should speak to us. We

• Section off walkways from work areas and one

Shine is the third step of a 5S campaign.

• Everybody is responsible for keeping the work

 Errors stand out immediately

• Correct problems, such as items left in the wrong

Shine also introduces Total Productive Maintenance

This is an effective system for ensuring that all

Always leave equipment in a clean, working

This is the forth step in a 5S campaign.

Whereas the last three steps brought about visible,

This is the final step in a 5S campaign.

This is by far the hardest of the five steps to

The auditing process ensures that improvements

The 5S audit should be carried out weekly by a

For those departments

Suggestion tickets should be posted around the

These should be collected regularly and sent to the

This creates ownership and gives staff a sense of

Contact Andrew by emailing:

5S Kaizen in 90 Minutes will be available

Вам также может понравиться