APPROACH TO 5S

5-S, a housekeeping program, is an integral part of the Lean process. The 5-S’s are Sort, Straighten, Sweep, Schedule and Sustain. When 5-S is performed as the first step of a Lean effort, processes become more visible and identified “trash” is cleaned out. While change is often perceived with a sense of apprehension, participants in the 5-S program begin to taste change as something that can be positive and even fun. 5S clearly communicates that management is willing to allow the employees to be involved in the process of change. The goal of the program is to have a plant and office area that is customer ready at all times. 5-S creates a neat, clean and orderly facility that will become a source of lasting pride for all employees.

The benefits of a 5-S implementation include:

• An organized, efficient workplace for improved productivity
• A cleaner work place for improved safety
• Reducing inventory and supply costs
• Recapturing valuable floor space and minimizing overhead costs
• Contributes to “how we feel” about our product, our company, and ourselves
• Provides an always-ready customer showcase to promote business

Three different levels to serve three different objectives:

5-S Blitz – This session is one week in length and involves working with a team from a particular area or process line in the facility. The week includes a combination of classroom work and plant floor work. In the classroom, the team will learn the basics of 5-S including definitions, benefits, and scoring system. On the plant floor, the team performs an initial 5-S evaluation to establish a base line. Then the 5-S training is actually implemented in the team’s work areas to give them an enhanced understanding of the 5-S principles while making positive, visible changes to the work environment. An inspection and “score” follow. Teams then learn and develop a plan for sustained, ongoing improvements to make the work area “world class”.

General Workforce Training - This training is 1 ½ - 2 hours in length and involves groups of 15-20 participants. It is a condensed version of the 5-S Blitz activity in which the general workforce learns the basics of 5-S in a classroom setting and then moves to the plant floor to see examples of 5-S. This training is an excellent supplement to the 5-S Blitz Activity as it motivates your associates to sustain the gains made during the blitz.

Independent 5-S Audits – Once the initial 5-S program is put into place in your facility, maintaining the integrity of program and the scoring is essential to continued improvement. TAG offers a program for recommended quarterly audits of your program by one of our associates. These unannounced audits are performed with an eye for improvement opportunities and serve to keep your scoring system properly calibrated.

Ratings

1. SORT (Disposal)

Clearly distinguish between what is needed and kept/what is unneeded and thrown out. Keep only what is necessary in the work area. Store often used items at the work area, store infrequently used items away from the work area and dispose of unneeded items.

2. STRAIGHTEN (Arrangement)

Organize the way necessary things are kept, making it easier to find and utilize them. Everything has a place and everything in its place, providing an efficient way to find items. Not having to search for items saves time.

3. SWEEP (Cleanliness)

Floors, walls, ceilings, equipment and furniture are kept in like new condition. The area is kept clean on a continual basis because a dirty environment cannot produce a quality product. A clean workplace is indicative of a quality product and process.

4. SCHEDULE (System Methodology)

Each department maintains a schedule to insure that the first three S’s - Sort, Straighten and Sweep are maintained, preventing regression back to an unclean environment. Items are returned to their designated places after use. The need for special clean-up efforts, which cost time and money, are eliminated. Clean while the task is small – routinely when a task is complete.

5. SUSTAIN (Disciplined Culture)

Practice and repeat the process until 5-S become a way of life. Housekeeping is built into the everyday processes in a continuing, sustaining way. Commitment and discipline toward housekeeping is essential in taking the first step to becoming a World-Class producer.