Introduction to 5S

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Introduction to 5S
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What is 5S?

• An easy definition is Finding a place for
  everything and putting everything in its place.
• 5S is also the foundation for Continual
  Improvement (CI) and Lean implementation.

• An easy definition is Finding a place for
  everything and putting everything in its place.
• 5S is also the foundation for Continual
  Improvement (CI) and Lean implementation.

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What 5S Is Not
Must be embraced by the whole team.

• It is not
• A program
• A one time event
• Voluntary
• Something we tried before
• Too hard because we are busy

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What Does 5S Mean?

• English Japanese
• Sort (Seiri)
• Set In Order (Seiton)
• Shine (Seiso)
• Standardize (Seiketsu)
• Sustain (Shitsuke)

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What Does SORT Mean?

• SORT means we remove all items from the workplace
  that are not needed for current production
  (parts, tools, equipment, etc).

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Example of SORT
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What Does SET IN ORDER Mean?

• SET IN ORDER means we arrange items so they are
  easy to use, and labeling them so they are easy
  to find and put away.
• It also means operating efficiency.

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BEFORE
Example of SET IN ORDER
AFTER
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What Does SHINE Mean?

• SHINE means we sweep floors, scrub machines,
  apply a fresh coat of paint, and then we KEEP it
  that way. This way, everything will be in top
  working condition so that it may be used when it
  is needed.
• It also means preventive maintenance.

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SHINE
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What Does STANDARDIZATION Mean?

• STANDARDIZATION happens when the first three Ss
  are properly implemented and maintained.
• It means that racking, paint colors, labeling,
  operational layouts are designed in a standard
  fashion.
• Everything will be in place so everyone will know
  exactly what they are responsible for and,
  exactly when, where, and, how to do it.

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STANDARDIZE
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What is SUSTAIN?

• We SORT areas. We SET IN ORDER work places. We
  SHINE areas. With STANDARDIZATION it is easy to
  identify anything out of place. SUSTAIN is
  different. It isnt a single separate activity.
  We SUSTAIN when we have developed habits of
  always using the first 4 Ss together on a daily
  basis.

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When Does 5S Happen?

• ALL THE TIME!! 5S is a mindset and a culture. The
  5Ss are a part of each Associates workday.
  There will also be CI Events and WPO (WorkPlace
  Organization) Events. In an Event, Associates are
  taught how to implement the principles of
  Continual Improvement.

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How is 5S Implemented?

• By the associates! Who has a better idea to make
  our jobs easier than us? Our management is
  committed to improving how we work. We want to
  work smarter, not harder. Along the way, support
  will come from EVERYONE. We will teach the 5S
  process, and together we will implement it and
  make it work.

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What are the Benefits to Our Organization?

• Improved Safety
• Improved Customer Focus
• Improved Delivery
• Improved Productivity
• Improved Job Security

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Applications to P2

• Sort
• Identify waste stream components by origin and
  character
• Understand every process in waste generation and
  every component of the process
• Substitute or change processes
• Substitute or change raw materials
• Reduce waste quantity or toxicity

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Applications to P2

• Set in Order
• Properly maintain process
• Streamline work flow
• Operate within designed tolerances
• Check operating data often
• Operational control and efficiency

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Applications to P2

• Shine
• Clean up the process to determine where the dirt
  comes from
• Change employee behavior
• Recycling programs
• Integral to proper maintenance programs
• Audit yourself

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Applications to P2

• Standardize
• Document processes
• Follow written procedures
• Say what we do, do what we say
• Monitoring and measuring
• Training, competence, awareness

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Applications to P2

• Sustain
• Management commitment
• Objectives and targets
• Corrective and preventive action
• Internal audit prove it to yourself
• Voluntary programs prove it to others
• Management review

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Real Life Example

• Change diesel engine to reduce emissions
• Sort
• Base line emissions
• Set in Order
• Find better components turbo charger
• Shine
• Standardize
• We modified all vessels with similar engines
• Sustain
• New emissions and operating tolerances

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Emission Testing
Turbocharger Changeover
Before
After
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Summary of Criteria Pollutant Emission Results
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Q A

• Questions / Comments.?!

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