The 5S Philosophy

An EASEworks® Manufacturing Tutorial

The “5S” Philosophy

Ver 6

Copyright EASE Inc Tutorials© 1986-2002


Based on Japanese words that begin with S , the 5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.

If you’re going to do it, do it RIGHT!

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Sort – (Seiri)

The first S focuses on eliminating unnecessary items from the workplace.

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Sort – (Seiri)

An effective visual method to identify these unneeded items is called red tagging. A red tag is placed on all items not required to complete your job. These items are then moved to a central holding area. This process is for evaluation of the red tag items. Occasionally used items are moved to a more organized storage location outside of the work area while unneeded items are discarded.

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Sort – (Seiri)

If you don’t use it, move it!

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Sort – (Seiri)

Sorting frees up valuable floor space and eliminates such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material.

The Sort process also helps prevent the ‘hoarder’ job mentality

(“I might need it”).

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A place for everything

& everything in its place

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Set in Order – (Seiton)

The second S focuses on efficient and effective storage methods.

You must ask yourself these questions:

1.

What do I need to do my job?

2.

Where should I locate this item?

3.

How many do I need?

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Set in Order – (Seiton)

Strategies for effective Set In Order are:





Painting floors

Outlining work areas and locations

Shadow boards

Modular shelving and cabinets

“A PLACE FOR EVERYTHING AND

EVERTHING IN ITS PLACE”

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Shine – (Seiso)

Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutterfree work area and the Shine step will help create ownership in the equipment and facility.

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Shine – (Seiso)

Workers will also begin to notice changes in equipment and facility location such as air, oil and coolant leaks, repeat contamination and vibration, broken, fatigue, breakage, and misalignment. These changes, if left unattended, could lead to equipment failure and loss of production.

Both add up to impact your company’s bottom line.

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Standardize – (Seiketsu)

Once the first three of the 5S’s have been implemented, you should concentrate on standardizing best practice in your work area. Allow your employees to participate in the development and documentation of such standards. They are a valuable but often overlooked source of information regarding their work.

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Standardize – (Seiketsu)

Standardize means establishing “Best Manufacturing

Practices, including:



Workplace Layout and Design

Materials Handling Analysis



Clear and Concise

Work Instructions

Well Defined Work Methods



Safe (Ergonomic) Working Practices

Cycle Time Reduction



Training

Documentation

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Sustain – (Seiketsu)

This is by far the most difficult S to implement and achieve.

Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things.

Sustain focuses on defining a new status quo and standard of work place organization.

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Once fully implemented, the 5S process can increase moral, create positive impressions on customers, and increase efficiency and organization.

Not only will employees feel better about where they work, the effect on continuous improvement can lead to less waste, better quality and shorter lead times. Any of which will make your organization more profitable and competitive in the market place

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Who is EASE Inc?

EASE Incorporated is an international corporation, founded in 1986.

EASE is headquartered in Southern California with satellite offices in Europe and the United

States.

EASE Incorporated provides productivity improvement services through the application of the EASEworks® Software, training, consulting services and implementation support.


EASE Customers


The Service

Our major focus is to offer sustainable productivity improvements and cost reductions for our clients. We can provide you with consulting assistance for. .



Equipment Evaluation

Facility Layout



Establishing “Best Practices”

Competitive Benchmarking



Design Engineering

Process Engineering



Production Engineering



Implementing Ergonomic

Improvements



Training and Training Support &

Certification



Improving Labor Efficiency



Productivity Analysis

Implementing Lean Manufacturing



Manufacturing Engineering

ISO 9000 Implementation



Developing Work Standards

Process Mapping

EASE will provide engineers with extensive experience in YOUR industry. Your engineers will have the ability to take over, with confidence , where we leave off.


Software

EASEworks® Software modules cover:

 Work Standards

 Product Cost Estimating

 Line Balancing

 Work Instructions

 Ergonomics

 Design For Assembly

EASE Inc. provides full training, start up assistance and consulting services for all modules.

Software customization services are also available.


Contact Information

EASE Inc

.

27405 Puerta Real, #380

Mission Viejo, CA 92691

Phone:

Fax:

E-Mail:

Web:

(949) 348-7511

(973) 201-1600 sales@easeinc.com

www.easeinc.com

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SAMPLE ONLINE

WORK

INSTRUCTION


Full motion video can be displayed as part of a work instruction


Work tasks can be analyzed in great detail to evaluate alternative methods.


Determining Value/Non-Value

Added Activities

Value Added: Activities that must be performed to meet customer requirements

PROCESS

STEPS

CONTRIBUTES

TO CUSTOMER

DEMANDS?

YES

VALUE

ADDED

ASSEMBLY

METALWORK

PACKAGING

YES

NO

FINANCIALS

SCHEDULING

MINIMAL

MATERIAL

HANDLING

NECESSARY

TO PRODUCE

OUTPUT

NO

CONTRIBUTES

TO BUSINESSR

DEMANDS?

YES

ESSENTIAL

NON-VALUE

ADDED

MOVEMENT

REWORK

STORAGE

NO

NON-VALUE

ADDED

Non-Value Added: Activities that do not contribute to meeting customer requirements. These activities can possibly be eliminated.


This chart illustrates

Value Added/Non-Value

Added, Walking and

Internal Time.


This shows methods comparison and cost benefits.


Here is a comparison of the value added.


Not only can existing working practices be evaluated, but alternatives can be considered and cost justified.


A leading beef processing plant uses EASE to compare the same task for training and work content across all of their plants.


The 5S Philosophy

An EASEworks® Manufacturing Tutorial

The “5S” Philosophy

Ver 6