Who is 5S Training for?
5S can be used by everyone. We all have workspaces whether they be personal or professional. Anybody who stores groceries in a refrigerator or cooks food in a kitchen, enjoys a hobby in their garage, plans material locations, or runs a manufacturing process can benefit from 5S. In our course, Texas students learn:
5S Training Course Overview:
Many a self-proclaimed Lean Sensei does what we call "Lean Gone Wrong"™ where they want to tape locations for everything including where to put the stapler on your desk, and put shadow boards everywhere. While these examples are good for workplace beautification, they are not great for workplace efficiency which is the true purpose of 5S. Often, they've lost their way and unfortunately generate a forgotten family of waste called overburden. In these sort of environments, the Lean Leader is feared and employees dread coming to work.
When practiced correctly, 5S generates the intended, healthy, mutually cherishing relationship between employees and management. This is because rather than burdening employees with unnecessary extra work, 5S makes their work easier and therefore in the process of doing so saves the company measurable dollars. A common additional advantage is increased revenue especially where 5S occurs along plant tour routes traveled by existing and prospective customers.
Example of 5S Gone Right
Have you ever been in a US Mint or Federal Bureau of Printing and Engraving Building? We have. It may be the ultimate pinnacle of 5S. We've seen horrific, nightmarishly filthly factories; so stuffed with junk that they were actually dangerous. And, we've seen pristine places as well such as Pfauter Maag Cutting Tools in Rockford, IL (white floors). But for as much criticism as they get, the US Government has them all beat when it comes to manufacturing money. That's the reason for this class' picture which is from inside the US Mint. Those are rolls of copper and nickel immaculately identified and staged for production. So, the picture has 2 meanings: one is that 5S should be about money (profit); not just doing 5S for the sake of 5S or beautification. Anyway, if we train you in Dallas / Fort Worth, let's save time for a tour of paper currency being printed!
What are the 5S's?
|S1 Sort. The first thing to do is sort out needed items from unneeded. We've seen factories where 70% of the material choking production lines and tripping operators are obsolete components that will never go into a finished assembly again. Move them out.
|S2 Set. Then, set needed material, tools, etc. in-place with things used most often closest to their point of use.
|S3 Shine. Further beautify the area. Make needed items presentable and easily identifiable; easy to reach. And, clean the area.
|S4 Standardize. Change your management system to reflect the improved condition. Update your organization's policies, procedures, work instructions, etc. preferably using a system of controlled documents. Remember to include all aspects of the change: not only practices, but standards as well. Color coding standards would be a common example. Most often forgotten are cleaning frequencies. These should also be included to support S3. Rev up, release, and train their users.
|S5 Sustain. Supervise, and audit to assure improved practices are being followed. Incorporate this into your formal audit schedule.