5S

Red Tag

Date 13/12/11

5S

Sort Set in order Shine Standardise Sustain Safety

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.

BEFORE

RED TAGGING

Red Tag

Date 13/12/11

Exercise

Numbers game

Numbers game

Using a pencil or pen strike out the numbers 1 – 50 in order within the next 30 seconds…

Good luck!

SORT – 6S

8

3035

10

1

26

4642

48

2

16

32

24207

33

3

18

19

15 29

43

12

38

45

34

475

11

13

44

22

4

6

17

3149

4125

14

28

39

9

50

27 36

23

40

2137

B

A

D

C

F

E

H

G

I

J

K

L

M

N

P

O

Exercise

Numbers game

Numbers game

Same rules as before…

Good luck!

SORT – 6S

8

3035

10

1

26

4642

48

2

16

32

24207

33

3

18

19

15 29

43

12

38

45

34

475

11

13

44

22

4

6

17

3149

4125

14

28

39

9

50

27 36

23

40

21

37

5S

Sort Set in order Shine Standardise Sustain Safety

SET IN ORDER

Organise, arrange and identify everything in the work area for the most efficient and effective retrieval and return to its proper place.

Commonly used tools should be readily available. Storage areas, cabinets and shelves should be properly labelled. Clean and paint floors to make it easier to spot dirt, waste materials and dropped parts and tools. Outline areas on the floor to identify work areas, movement lanes, storage areas, finished product areas, etc. Put shadows on tool boards, making it easy to quickly see where each tool belongs.

Labelling / Set order

Exercise

Numbers game

Numbers game

Same rules as before…

Good luck!

SET IN ORDER – 6S

8

30

35

101

26

46

4248

2

16

32

24

20

7

33

318

19

15

29

43

12

38

45

34

47

511

13

44

22

4

6

17

31

49

41

25

14

28

39 9

50

27

36

23

40

21

37

5S

Sort Set in order Shine Standardise Sustain Safety

SHINE

Once you have everything, from each individual work area up to your entire facility, sorted (cleaned up) and organised, you need to keep it that way. This requires regular cleaning, or to go along with our third S, "shining" things up.

Regular, usually daily, cleaning is needed or everything will return to the way it was. This could also be thought of as inspecting. While cleaning it's easy to also inspect the machines, tools, equipment and supplies you work with.

Cleaning and tidying

5S

Sort Set in order Shine Standardise Sustain Safety

STANDARDISE

The good practices developed in steps 1 - 3 should be standardised and made easy to accomplish. Develop a work structure that will support the new practices and make them habitual. Update and modify the standards to make the process simpler and easier.

One of the hardest steps is avoiding old work habits. It's easy to slip back into what you've been doing for years.

Use standards to help people work into new habits that are a part of your Five S program.

Procedures

Exercise

Numbers game

Numbers game

Same rules as before…

Good luck!

STANDARDISE – 6S

8

30

35

101

26

4642 48

2

16

32

24

20

7

33

3

18 1915

29

43

12

38

45

34

47

5

11 13

44

22

4 6

17

31

4941

25

14

28

39

9

50

27

36

23

40

21

37

5S

Sort Set in order Shine Standardise Sustain Safety

SUSTAIN

Have a formal system for monitoring the results of your Five S program.

Don't expect that you can clean up, get things organised and labelled, and ask people to clean and inspect their areas every day — and then have everything continue to happen without any follow-up.

Continue to educate people about maintaining standards.

Monitoring systems

Safety the extra S

Sort Set in order Shine Standardise Sustain Safety

Do we need to say any more?

The last S should be incorporated into ALL of the previous 5!

If you are going to do

a job, do it SAFELY

For example:In addition to red tagging unwanted items in the sort stage, you could also yellow tag items which are hazardous / unsafe / potential pollutants and ensure that they are properly housed and managed!

Can you think of any other ways we can incorporate HSE into 5S?

Yellow Tag

Date 13/12/11

Benefits of 5S

Numbers game

Numbers game

In the final game, 2 numbers are missing… Which 2? Call out the missing numbers as soon as you see them…

Good luck!

Missing inventory – 5S benefits

8

3035

10

1

26

42

48

2

16

32

24207

33

3

18

19

15 29

43

12

38

45

34

475

11

13

44

4

6

17

3149

4125

14

28

39

9

50

27 36

23

40

2137

B

A

D

C

F

E

H

G

I

J

K

L

M

N

P

O

Benefits of 5S

Numbers game

Numbers game

How much easier is it now?

Good luck!

Missing inventory – 6S benefits

8

30

35

101

26

42 48

2

16

32

24

20

7

33

3

18 1915

29

43

12

38

45

34

47

5

11 13

44

4 6

17

31

4941

25

14

28

39

9

50

27

36

23

40

21

37