5S Training Course: Unleashing the Power of Efficiency

Introduction

5S is much more than ‘a place for everything and everything in its place’. It comprises five principles to make people highly efficient and effective in their work. The purpose is to help people do perfect work every time, preventing mistakes, ensuring reliable equipment, removing useless variation, delivering quality products quickly, and maintaining safety.

Course Outline

Important Lean Concepts

• The 7 Wastes and Others
• The Value Stream Concept
• The Hidden Factory
• Elimination of Waste and Loss with 5S
• Our 5S Training Objectives

Purpose of 5S

• 5S Creates a Visual Factory
• The 5S Cycle
• 5S Activities Explained
• The Purpose and Payoff of 5S
• Remove the Roadblocks in the Way
• 5S Program Overview

5S Program Steps

• Workplace Observation
• Set a Target Area Vision
• The Power of a Shared Vision
• What You See Before 5S
• What You See After 5S
• After 5S – Easy to Find, Easy to Do
• One-Day Work Area Log

Sort

• Sort – keep only what is needed Today
• Red Tag Process
• Red Tag Inspection List
• Red Tagged Items Log
• Decide What to do With Dispossessed Items

Straighten

• Straighten – find it fast; faster
• Put Order and Sense into the Workplace
• Set-in-Place to Make Life Easy
• Visual Control of Tool Storage
• Visual Management of Inventory and Stock
• Straighten the Workflow
• Straighten Check Sheet

Shine

• Shine – see problems when they are small
• 5S Examples – Shine
• Shine Check Sheet
• Plan Who, What, How to Clean

Standardize

• Standardize – the same rules for all
• Set Standards for Condition and Use of Tools and Equipment
• Being Visual – know exactly what is happening
• Use Visual Management to Show Status
• What Visual Management Would Help Here?

Sustain

• Sustain – ‘this is how we do it here
• Weekly and Monthly Feedback on Performance
• Workplace Measurement Checklist – tracking your performance weekly
• Tracking Your Performance Monthly

5S Implementation

• What of Your 5S Implementation?
• Plan/Prepare 5S Kaizen Blitz

Workshop Exercises

• 5S Experiment #1 – Sort, Straighten, Shine
• 5S Experiment #2 – Refine the Layout
• 5S Experiment #3 – Fastest Process
• 5S Experiment #4 to #7 – Standardize and Sustain

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