What is 5s?

Explain five s.
Benefits of 5s to the industry.
5s is a powerful tool that aims to improve workplace efficiency by keeping it clean, organized and safe in order to
eliminate waste and boost productivity.

5s stands for:
Sort

Make work easier by eliminating obstacles.

Reduce chances of being disturbed with unnecessary items.
Prevent accumulation of unnecessary items.
Evaluate necessary items with regard to cost or other factors.
Remove all parts or tools that are not in use.
Segregate unwanted material from the workplace.
Define Red-Tag area to place unnecessary items that cannot immediately be disposed of. Dispose of these items when
possible.
Need fully skilled supervisor for checking on a regular basis.
Waste removal.
Make clear all working floor except using material.

Set in order

Arrange all necessary items so that they can be easily selected for use.
Prevent loss and waste of time by arranging work station in such a way that all tooling / equipment is in close proximity.
Make it easy to find and pick up necessary items.
Ensure first-in-first-out FIFO basis.
Make workflow smooth and easy.
All of the above work should be done on a regular basis.
Maintain safety.
Place components according to their uses, with the frequently used components being nearest to the work place.

Shine

Clean your workplace on daily basis completely or set cleaning frequency

Use cleaning as inspection.
Prevent machinery and equipment deterioration.
Keep workplace safe and easy to work.
Keep workplace clean and pleasing to work in.
When in place, anyone not familiar to the environment must be able to detect any problems within 50 feet

Standardize

Standardize the best practices in the work area.

Maintain high standards in workplace organization at all times.

Everything in its right place.

Every process has a standard.

Sustain

Not harmful to anyone.

Also translates as "do without being told".
Perform regular audits.
Training and discipline.
Training is goal-oriented process. Its resulting feedback is necessary monthly.
 Self discipline
To maintain proper order

The 5 Steps are as follows:

Sort: Sort out & separate that which is needed & not needed in the area.
Straighten: Arrange items that are needed so that they are ready & easy to use. Clearly identify locations for all items so that
anyone can find them & return them once the task is completed.
Shine: Clean the workplace & equipment on a regular basis in order to maintain standards & identify defects.
Standardise: Revisit the first three of the 5S on a frequent basis and confirm the condition of the Gemba using standard
procedures.
Sustain: Keep to the rules to maintain the standard & continue to improve every day.

Progress Report:
Sort, this basically means designating things to its proper places and removing unnecessary items on the area. Set, it is
identifying at what group do these items belong to lessen clutter. Shine means keeping the area, items or surroundings clean
and tidy. And Sustain just simply means maintain, by means of implementing a system to monitor 5S so that it becomes part
of the culture.

Benefits of 5S workplace organization

5S relates to workplace organization and forms a solid foundation upon which many organizations base their drive for
continuous improvement. It is equally applicable & successful in all sectors helping to achieve high impact results.

It is a systematic and methodical approach allowing teams to organize their workplace in the safest and most efficient manner.

The discipline to check & repair equipment is included & adopted. The entire process is managed through the use of team
generated audit documents, completed on an agreed frequency by responsible owners within the Gemba.

Summary

Improved safety
5S becomes a fundamental business measure & key driver for Kaizen
Forms a solid foundation upon which to build continuous improvement
Employees gain a sense of ownership, involvement & responsibility
Reduction in waste as defined by Ohnos seven forms of waste
Improved performance in productivity, quality & morale leads to increased profitability

Sort is the first step in 5S, it refers to the sorting of the clutter from the other items within the work area that are
actually needed. This stage requires the team to remove all items that clearly do not belong in the working area and
only leave those that are required for the processes in question.

Set in order is the process of taking the required items that are remaining after the removal of clutter and arranging
them in an efficient manner through the use of ergonomic principles and ensuring that every item has a place and
that everything is in its place.

Shine is the thorough cleaning of the area, tools, machines and other equipment to ensure that everything is returned
to a nearly new status. This will ensure that any non-conformity stands out; such as an oil leak from a machine onto
a bright, newly painted clean floor.

Standardize is the process of ensuring that what we have done within the first three stages of 5S become
standardized; that is we ensure that we have common standards and ways of working. Standard work is one of the
most important principles of Lean manufacturing.

Sustain, ensuring that the company continue to continually improve using the previous stages of 5S, maintain
housekeeping, and conduct audits and so forth. 5S should become part of the culture of the business and the
responsibility of everyone in the organization.
A firm foundation for improvement

5S provides a firm foundation on which to build other improvements.

Stable repeatable processes are predictable.

What is 5S? : 5S (or 5c) is a systematic approach to workplace organisation and housekeeping. Encouraging ownership and self
discipline to sustain and further develop working practices.

It aims to : Improve safety. Remove waste from the workplace. Increase quality. Provide an environment where
continuous improvement is embraced. Makes abnormalities immediately visible.
Improved profits: Reduce costs, streamline labor costs, and improve quality.

More efficient workforce: Make work easier with standard procedures. What needs to happen, happens.
Safer workplace: Improve safety by keeping your workplace clean and organized.
Fewer defects: Reduce errors and defects by making it easier to identify and solve problems.
Better communication: Ensure your workforce has the information it needs to operate efficiently by creating a visual 5S factory.

Benefits to the company from using the 5S methodology include raising quality, lowering costs, promoting safety, building
customer confidence, increasing factory up-time, and lowering repair costs.

What Will 5S Cost?

While 5S can be done on any budget, the 5S system requires some resources to become an effective tool. At minimum, there will be some
costs related to:

Training employees
Cleaning and organizing the workplace
Getting tools and supplies to support 5S (labeling, demarcation, tagging, and so on)
SORT

"Sorting" means to sort through everything in each work area. Keep only what is necessary. Materials, tools, equipment and supplies that
are not frequently used should be moved to a separate, common storage area. Items that are not used should be discarded or recycled.

Don't keep things around just because they might be used, someday.

5S Sorting itself involves five steps:

1. Cleaning
2. Classifying
3. Ownership
4. Red Tagging
5. Recycling / Reassignment

Cleaning
The purpose of "sorting" is to identify unnecessary items and eliminate them from the workplace. To do this first requires cleaning up the
workplace so you can see what you have. Clean up accumulations of dirt, debris, oil, grease, broken tools, excess materials, and scrap. As
you do this you'll also be involved with the second step of 5S sorting.

Classifying
As you are cleaning up you'll find tools, equipment, materials and supplies. As each item is found, classify it as to the type of object. Scrap
metal might go directly to a recycling bin. An item classified as tool might go to a collection area for further identification.

Ownership
In some cases, as items are found or classified their ownership may be obvious. For example, pallets might be collected in one area so
they can be returned to the shipping department. It may be immediately obvious where a tool belongs and that tool can be directly returned
to its correct storage location. In other cases determining ownership may require asking some questions or doing a little research.

Once ownership is determined the owner can decide what to do with the item - store it, pass it on to another work area or department, or
dispose of the item. However, in some cases the ownership of an item may not be readily apparent. This brings us to the fourth step in 5S
sorting, red tagging.

Red Tagging
If an item cannot be identified, or if it cannot be classified, or if ownership cannot be determined, then it should be red tagged. Red tagging
involves marking items with a red tag so that each item can be evaluated and dealt with appropriately. Red tagged items are collected in an
area that allows potential owners to examine them and determine what should be done with the items for which they are responsible.

Recycling / Reassignment
Red tagged items that are not claimed after a reasonable amount of time, such as 30 days, may be recycled, disposed of, or if they are still
useful they can be reassigned. A simple approach for reassigning items is to, at the end of the 30 day red tag period, provide a seven day
period in which any supervisor may take any red tagged item with an expired read tag. These items are then reassigned to that
supervisor's work area.

Sorting
In some cases the five steps of 5S sorting may happen simultaneously. We can clean, classify, determine ownership, and red tag in just a
few seconds. In other circumstances the process may be more involved and the steps more distinct. But the objective is the same, clean
up and get rid of unused items.

Basic 5S Principle: Don't keep things around just because they might be used,
someday
With 5S sorting you are taking the first step toward making a work area tidy, organized, and arranged so that it is easier to find the things
you need. The result will be that waste is eliminated and additional space will become available. Obsolete fixtures, molds, jigs, scrap
material, waste, and other unused items and materials are disposed of or recycled. Broken equipment and tools are repaired or thrown out.

An additional benefit is that cleaning up not only makes things look nice, it makes it easier to spot maintenance needs such as an oil leak. It
improves safety. It eliminates clutter and confusion. It removes tools, equipment, supplies and waste that interferes with getting the job
done.

5S sorting is simple, common-sense, and it begins a journey that results in eliminating waste, and improving safety, quality, and
productivity though the implementation of the five basic principles of 5S.

SET IN ORDER

This is the second step in a 5S program: organize, arrange, and identify everything in a work area, as well as throughout the facility, so that
items can be efficiently and effectively retrieved and returned to their proper storage location.

A variety of names have been used for the second step of 5S. These names include:

Set in Order
Systematic Organization
Systematize
Straightening out
Simplify

This step could also simply be called "put away." Put things away in a logical storage location that makes commonly used tools and
materials convenient and easy to access.

The Basics of 5S Set in Order

The basic focus of this part of 5S is to create efficient and effective storage systems such that anyone can find the tools, materials, and
supplies they need, and anyone can return those tools, materials, and supplies to their proper storage locations.

A second key principle of Set in Order is that the most commonly used tools should be readily available. Those items that are not
frequently used should be kept out of the way by storing them in a remote location.

Labeling 5S Set in Order

To accomplish these goals, storage areas, cabinets, and shelves should be clearly marked with signs and labels. Place labels on the
outside of doors to identify the storage space. Label the interior shelves so that individual items can be consistently and easily returned to
their proper storage locations.
Frequently used tools are often stored on shadow boards. The tools hang on the shadow board, with color coded "shadow" labels marking
the location of each tool. The "shadows" match the shape and size of the tool, making it easy to see which tool goes where.

Don't forget about the floor. Clean and paint floors to make it easier to spot dirt, waste materials and dropped parts and tools. Use
DuraLabel floor marking tape to outline areas on the floor so that it is easy to see work areas, movement lanes, storage areas, finished
product areas, etc.

Apply 5S Set in Order Principles to Any Workplace

The key principle in "5S Set in Order" is: a place for everything and everything in its place, with everything properly identified and labeled.

Items that are used frequently should be stored close to where they are used.
Items that are used infrequently should be stored in a common area further from the location where they are used.
If several items are used together, then store them together. For example, drill bits should be stored in the same location as
drills.
Store things in place people would logically look to find them.
Identify all items (including tools, jigs, molds, bits, etc.) and label them so that anyone can identify and return them to their proper
storage location.

The 5S Map
A 5S map is tool that can help show what needs to be done in the 5S Set in Order step. A 5S map is a diagram, or floor plan, that provides
an overview of a work area, a process, a department, office, or work station. It provides a picture that shows where machines, storage
areas, work in progress, supplies and workers are located. It should also include a short description of the tasks that are done in the area.

Use a 5S map to identify:

where equipment and machines are located (where the work is done)
where storage areas are needed
how those storage areas should be arranged
how people move around in, or move through a work area

The 5S map serves as a visual aid to help identify logical storage areas, and ways to position equipment and machines that will make
access to needed tools and materials easier.

The Office and 5S Set in Order

5S Set in Order applies to offices. For example, work areas in offices should be identified by signs or placards. Papers, blueprints,
catalogs, invoices, and other paper materials should be appropriately filed. Have bookshelves for frequently used manuals, books, and
catalogs. Label filing cabinets, drawers, bookshelves, and other storage locations. This process allows for stored materials to be easily
identified and returned to their proper place.

There are two important parts to 5S Set in Order - putting everything in its proper place, and setting up a system so that everything can be
returned to its proper place. This second step in 5S is where good labeling and identification practices are important. The equipment, tools,
and materials you use, as well as their proper storage locations, need to be clearly identified and labeled.

5S Set in Order not only applies to individual work areas. The overall facility should also be systematically organized, including the proper
placement of easy-to-understand labels and signs throughout the facility. Piping, valves, control panels, major equipment, doorways, minor
equipment, instruments, storage areas, offices and files should all be clearly identified.

SHINE

5S Shine - Keeping It Clean

Once you have everything, from each individual work area through your entire facility, sorted (clutter and debris cleaned up), and
organized, its important to keep it that way. This requires regular cleaning, or to go along with the theme of having five words that start with
the letter S, "shining" things up.

5S shine involves more than pushing a broom around a work area once a week. It involves regular, usually daily, cleaning. The work area
should be returned to the condition it was in when the day started - including putting away all tools, materials and supplies used that day.

While cleaning it's easy to inspect the machines, tools, equipment, and supplies you work with.

5S Shine - Inspecting
Having a clean work area has many advantages. One of the more significant is that it makes it easy to spot fluid leaks and equipment that
needs maintenance. When a work area is clean machine operators can notice malfunctions such as fluid leaks, vibration, and
misalignment, and breakages. These problems, if not addressed, can result in equipment failure, safety hazards, and loss of production.

5S Shine - Who is Responsible for Cleaning?

5S shine is not just the job of a janitor or a cleaning crew, it is everyone's responsibility.

Every work area should have a person, or group, assigned to clean that area. The best approach is to have those who work in an area also
be the ones who are responsible for cleaning that area at the end of each day. This results in:

work practices that help to keep the work area clean throughout the work day.
those who are cleaning are also able to inspect the equipment and spot problems.
those cleaning know the safety hazards that exist in their work area (no need for a cleaning crew that needs to have safety
training).
those cleaning can identify and properly store unusual tools, dies, bits, jigs, etc

No area should be left uncleaned. See the workplace through the eyes of a visitor. For example, if you are leaving at the end of the day
and spot some scrap paper just inside the front door, pick it up. Take the responsibility for keeping your entire workplace clean, if doing so
can be done safely.

When done on a regular, frequent basis, cleaning and inspecting generally will not take a lot of time, and in the long run will most likely
save time.

STANDARDIZE

The fourth step in 5S is to make your 5S practices effective and efficient. This is accomplished by simplifying and standardizing.

5S Standardize - Turning Good Practices into Good Habits

The 5S practices developed in steps one through three should be standardized and made easy to accomplish. Develop a work structure,
and written standards, that will support the new practices and turn them into habits. Every workplace is different, and it is likely that the 5S
practices initially implemented can be improved. As you gain more experience with 5S in your workplace, update and modify your 5S
standards to make each process simpler and easier.

One of the hardest steps in 5S is changing old work habits. It's easy for people to slip back into old habits. Its what a person is familiar
with. It feels comfortable. But, those habits probably need to be changed.

5S Standardize - Use Standards to Change Habits

With standards established everyone knows what they are supposed to do, how they should be doing it, and when it needs to be done. In
other words, standards produce new habits that result in 5S being effectively and efficiently implemented.

Making people aware of the new standards, and helping them to remember the new standards correctly, is commonly done using labels,
signs, posters, and banners.

For example, use your DuraLabel printer to create large format signs, placards, and scoreboards. There is no need to pay the high cost of
an outside service, and then wait for them to produce the 5S visual communication tools you need. You can make the 5S labels, signs and
placards you need quickly and easily using the versatile DuraLabel printer you already are using to make safety, maintenance,
operations, compliance, and traffic control labels and signs. With DuraLabel it's easy to make the labels and signs needed to support your
5S program.

Labels and signs are not just used to help workers remember standardized 5S practices. They are an integral part of every aspect of 5S.
When you think 5S, think visual communication. For example:

Using visual cues is the most effective way to communicate needed information. That's why a shadow board, mentioned in the
5S Set in Order step, is so effective. It uses color labels in the shape of each tool to make identifying tool storage locations
incredibly easy.
With 5S everything should be clearly marked and identified. Labels and signs are the best way to identify storage locations, work
areas, equipment, tools, and separate pathways for foot and motorized traffic.
Labels and signs provide operating, cleaning, and preventive maintenance procedures at the locations where that information is
most needed, on the equipment and machines.

5S Standardize - Other Tools to Help Implement 5S Standards

Other tools that are used to help establish 5S standards include:

checklists
job cycle charts
scheduling of "five-minute" 5S periods

5S Standardize Checklists
5S checklists are commonly used as an auditing tool to ensure the standards are being followed. A 5S checklist involves more than
verifying that work areas are clean. For example, checklist items should include ensuring operating and maintenance practices that support
5S goals are being followed.
5S Standardize Job Cycle Charts
A job cycle chart lists each 5S task that is to be done in a work area, and gives the schedule (frequency cycle) for performing each task.
Each task is either assigned to a particular worker, or to a job duty. An example of a job duty would be operating a machine. Whoever
operates the machine that day, has the 5S task of cleaning that machine at the end of the shift.

Workers can then use the Job Cycle Chart as a checklist that identifies what they need to do and when it needs to be done.

5S Standardize Five Minute 5S Periods

A "Five Minute 5S Period" can be an intense, quick clean up (shine) of a work area, or it can look for abnormalities in all of the five steps of
5S. The goal is for 5S abnormalities to be spotted and immediate 5S action (sort, Set in Order, or shine) to be taken to correct the
abnormality.

The "Five Minute 5S" does more than fix 5S problems. Its main objective is to train workers in the principles of 5S. Having workers do a
"Five Minute 5S" helps them to focus on the priorities of 5S and to remember the principles that underlie a successful 5S program.

5S Standardize
With the standardize step of 5S old habits are changed and new work practices established. The new practices are documented in written
standards which ensure that 5S goals are achieved in an effective and efficient manner.

SUSTAIN

With the first three steps of 5S completed sort, set in order, and shine and with the best practices that efficiently and effectively result in
those three steps being accomplished having been set in standards, you might think you are done. But, there is another critically important
step, without which 5S will eventually fail. The fifth and final "S" is called sustain.

5S Sustain A Commitment To Success

If we were not looking for a word that started with the letter "S" this final step might have been called commitment. It is on on-going
commitment to the standards created in the 4th S. It is a commitment to actively do all parts of 5S, not just the first two or three. It is a
commitment to not sit back, rest and think the job is done, but instead to change habits and create a new standard of work place
cleanliness and organization.

Changing entrenched habits is difficult, and people will tend to return to the way they did things in the past. One goal of 5S Sustain is to
change those habits.

In addition, the results of using 5S can open the door to 5S failure. For example, implementing 5S tends to open up free space... and free
space tends to attract clutter. A second goal of 5S Sustain is to prevent new problems from being created.

In the sustain step of 5S you'll need to train people to clean, organize and inspect their work areas every day, and not let clutter accumulate
in any location. The overall goal of 5S Sustain is to ensure the 5S standards that resulted from the first four steps of 5S continue to be
followed, and that standards are modified or created to address situations not anticipated during the initial implementation of 5S.

What Is 5S Sustain?
5S Sustain is defined as: on-going training and maintaining the established 5S standards.

Training is crucial for 5S success. People need to be reminded about the requirements of the established 5S standards. When there are
changes that will effect your 5S program -- such as new equipment, new products, new work rules -- make the needed changes in the
standards to accommodate those changes, and provide training on the new standards.

The following are a few tools and tips to help sustain 5S:

Make 5S A Part Of Your Performance Evaluation System

Everyone, from upper management to the janitor should have 5S as a part of their individual job performance goals. Include an evaluation
of 5S performance as a part of each annual employee review. Without this level of commitment to 5S, it will become secondary in
importance and will slowly become ignored and ineffective.

Make 5S Performance Results Public

5S performance goals should always be specific and measurable. Audits should be conducted on a regular basis, such as weekly, to
measure how well each work area is meeting their 5S goals. The audit results should be posted so that everyone can see them and see
how well their work area is doing compared with others in the company. In addition, having a system that gives monthly or quarterly
rewards to employees who are employed in areas that met or exceeded their 5S goals serves as an incentive to meet 5S targets.

5S Training
Training does not necessarily mean gathering everyone together in a classroom. An effective way to have on-going training, and to
maintain adherence to standards, is to use custom 5S posters and signs. By using custom posters and signs the message can be tailored
to the specific department or situation. This improves both communication and retention of the message.

It is important to change posters and signs on a regular basis. A message that remains in place for an extended period of time eventually is
ignored and becomes invisible. By changing your posters and signs, and keeping the messages fresh, they will continue to draw attention,
be seen, and be remembered.

How is this accomplished? If you have a DuraLabel custom label printer, it's not a problem. You can quickly make the custom posters,
placards, signs and labels you need, whenever they are needed.

Your company newsletter can be another effective training tool. Feature 5S success stories as well as tips for improving compliance with
5S standards. Use the newsletter to promote 5S related contests and competitions... and, of course, announce the winners.

Department Tours
Use department tours so that workers in one department can see what is being done in other departments. This type of "cross pollination"
helps to spread good ideas and inspires people to come up with new ways to do an even better job of implementing 5S.

Management Support
Without management's visible commitment to 5S, it is difficult to get lower level employees to fully commit to making 5S a success.
Managers should be involved in 5S through activities such as:

conducting 5S inspections
listening to, talking with, and offering advice to employees
providing 5S related seminars for employees
participation in 5S promotional events

Sustain Is Not The End of 5S

5S Sustain is not the final step of 5S. It is an ongoing process that also involves going back to the beginning and repeating the 5S process
to find additional areas of improvement. The changes resulting from 5S can remove barriers that were hiding other problems that could not
be seen. Going through a second, and third iteration of the complete 5S process has the benefit of revealing the need for additional
changes.