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Lean Manufacturing Tools

Lean manufacturing tools, techniques and philosophy | lean and related business improvement ideas.

5S Training

5S Training will help you with implementing one of the most important lean manufacturing tools; that of 5S , it is also one of the simplest to implement. 5S is a methodical way to organize your workplace to turn it into a safer, ergonomic, more efficient environment through organizing your layout and introducing visual management and standard ways of working. 5S is a team approach and requires the participation of everyone within the area in which is applied to be effective. 5S works by helping the team to eliminate the seven muda of lean manufacturing, the seven wastes; Transport , Inventory , Motion , Waiting , Over-processing , Overproduction , and Defects . The five steps of 5S are;

Train your employees in the steps of 5S

• 5S Seiri ;      Sort, Clearing, Classify
• 5S Seiton ;     Straighten, Simplify, Set in order, Configure
• 5S Seiso ;     Sweep, shine, Scrub, Clean and Check
• 5S Seiketsu ;     Standardize, stabilize, Conformity
• 5S Shitsuke ;     Sustain, self discipline, custom and practice

Some companies add safety as a 6th step making 6S .

Why 5S Training

Like any new discipline or skill it is important to ensure that your employees fully understand it and know how they should implement it. It is unlikely that if this is your first 5S program that all of your employees are fully conversant with 5S. Therefore you will need to either hire a 5S trainer or 5S consultant to help you with your 5S program, alternatively you could employ or train up an internal 5S training champion to lead your 5S program .

Free 5S Training Presentation

5S Training Exercise – Download free 5S training PDF

Training Exercise – Download free 5S training PowerPoint presentation

To access a full range of 5S training presentations and PDFs that are free to download visit our 5S Training Presentations .

5S Training Approach

5S is best learned through doing it, it is not a skill that lends itself to a few days away in a hotel training suite followed by several weeks of inaction and forgetfulness. I have run many 5S programs and seen others run them also and can say that in my opinion that by far the best approach is one of in-house 5S training and facilitation led by someone with experience in the disciplines of 5S. The 5S training should be preceded by ensuring that there are clear objectives for both the direction of the company and for the specific working area in which 5S is to be applied. Measures of performance should also be reviewed or set in place against which later improvements can be judged. 5S Training should then begin with an initial session to explain the aims of the 5S implementation in terms of the overall company as well as the individuals. This should then be followed with a brief presentation regarding the seven wastes of lean manufacturing and an overview of the steps of 5S. It is also useful at this point if you have a simple 5S simulation to run so that they can see the potential for improvement. The first session should very much focus on the first three of the 5S; 5S Sort, 5S Set in Order and 5S Shine. The team should be given an overview of what it is they are to be doing then let loose within the area with clear instructions to begin the first stage of 5S; Sort. The 5S trainer should aid the team and ensure that they stay on track, a deadline should be set for an hour or two (depending on the size and complexity of the area in question) and the team should sit to review what they have done and discovered. The team should progress through the first three stages over a period of 2 or three days at the end of which the 5S team should present back to management what they have achieved. They should also have at this stage a list of actions to be implemented over the coming weeks before implementing the next two stages. A break of a few weeks depending on outstanding actions should then be allowed, followed by the next session which should review and reinforce the first three stages of 5S then move onto the final 2 stages of 5S standardize and 5S Sustain.

Hiring an external 5S Consultant or Trainer

If you are hiring a 5S consultant be careful as the standards of 5S consultants vary considerably from your local expert who is trying to go it alone after losing his latest job to the big international consultants who will charge you something akin to your firstborn child but will deliver you their weight in gold. Unless you have a candidate in house or intend to hire a specific employee for the position I would recommend that you spend the money to have your employees trained professionally in the lean manufacturing tool of 5S.

In house 5S trainers

If you have a suitable expert or have someone that you intend to train up to be able train your employees then please ensure that you support them fully with the right tools and aids for their 5S training program;

• 5S Books to use as either a shared resource with your employees or more in depth for your trainer. You can also download 5S books to read on your PC or even your phone.
• 5S Posters to advertise and remind your employees as to what your aims are to train them in 5S.
• 5S DVD s for individual and group training; very useful for seeing examples of 5S in action.
• 5S Pocket Guides to use as giveaways in your training and as handy reminders.
• 5S simulations and games to use as part of your training package.
• 5S training materials that contain many of the above items.
• 5S supplies such as 5S red tags which can be very useful when you begin your implementation.

Monitoring 5S training effectiveness

I mentioned earlier about ensuring that you have a set of objectives in place for your business and your 5S implementation program, these measures of performance will enable you to judge the improvements generated by your 5S training program. You should also use feedback from your employees as to what they feel was the effectiveness of the 5S training course, these 5S training courses can vary enormously and although they may generate benefits there may still be scope for far greater improvements. I have often run 5S training courses in a company where they have already gone through the 5S process and made huge improvements. Sing the praises of the implementation of 5S around your company, publicize and celebrate the improvements that have been made to ensure that those involved feel valued for their contribution and that the rest of your employees will be keen to participate and even compete.

If you have any questions about conducting lean training or would like to add anything to lean manufacturing tools please leave a comment below.

Related posts:

• How to run an In House 5S Training Course
• 5S Training Materials
• 5S Training Simulations and Games

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2 comments for “ 5s training ”.

Great article! If you are interested, I have posted instructions/video for a great 5S game/ice breaker at http://www.leanbestpractices.info

I want to attend 5S Training Course. Plz share with me address and schedule in pakistan (if any)

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5S - BASIC TRAINING

Sep 27, 2014

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5S - BASIC TRAINING. What is 5S and why do we want to do it? . ALOK SHARMA 2262010. What is 5S ?. Seiri – Sort (housekeeping) Seiton – Systematic Arrangement (workplace organization)

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Presentation Transcript

5S - BASIC TRAINING What is 5S and why do we want to do it? ALOK SHARMA 22\06\2010

What is 5S ? • Seiri – Sort (housekeeping) • Seiton – Systematic Arrangement (workplace organization) • Seiso – Shine (Cleanup) • Seiketsu – Standardize • Shitsuke – Sustain (Self Discipline)

What is 5S ? 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts. 5S is one of the activities that will help ensure any company’s survival.

5S 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order - A place for everything and everything is in its place 3. Shine - The area is cleaned as the work is performed 4. Standardize - Cleaning and identification methods are consistently applied 5. Sustain - 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or dangerous conditions

Some New Words Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes Some Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvement Muda-(pronounced “moo da”) - waste Gemba-(pronounced “gim ba”) – workplace Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.

KAIZEN: What it is? • Process Improvement • Observation • Use of New Paradigms • Short Time • Zero Investment • Human Development & Empowerment • Profits & Savings - Plenty

KAIZEN KAI ZEN ALWAYS GOOD CONTINUAL IMPROVEMENT CHANGE FOR THE BETTER

KAIZEN IS A JOURNEY FROM: EVENT RESULT GROSS ENFORMENT OF CHANGE TO CAUSE TO PROCESS TO MICRO TO INDUCEMENT OF CHANGE

KAIZEN IS CONTINUAL IMPROVEMENT IMPROVEMENT IMPROVEMENT TIME TIME CONTINUOUS CONTINUAL

KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE OBSERVATION INTELLIGENCE PHYSICAL EFFORT PARADIGM OF HIGH PRODUCTIVITY & QUALITY

KAIZEN AT GEMBA GEMBA: PLACE OF WORK • GEMBA is where . . . • Value is added • Actual work is done to meet customer requirement • Problems are solved • Staff is responsible for providing support, not for giving instruction

1. 5S Principles • Elimination of waste • Every body is involved, Co-operative effort • Attack root cause • Human being is not infallible

2. Objectives • Improve housekeeping • Make every individual responsible for housekeeping • Beautify by simple means • Productivity improvement by saving time, space etc.

SEIRI = Sorting Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items Activity Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Success Area saved or percentage of space available Indicator

SEIRI = Sorting Japanese Meaning : The Japanese meaning of “Seiri” is to straighten and contain. - Get rid of waste and put it in order according to rules

1 ‘S’ - SEIRI Respiratory System 1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body

1S – SEIRI : SORTING • Sort for . . . • Not Needed at All • Needed but not Now • Needed but not here • Needed but not so much Quantity 1 ‘ S’ WANTED UNWANTED

What is unnecessary Seiri = Sorting 1. Item is not needed 2. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts

Organization Frequency of use Storage Method Throw them out *Things you have not used in the past one year LOW *Things you have used once in the last 6-12 months Store at distance OR Keep in store *Things you have used only once in the last 2-6 months Store it in central place in your zone AVERAGE *Things used more than once a month Store it in central place in your zone *Things used once a week Store near the workplace HIGH *Things used daily or hourly Store near the workplace

Identifying unnecessary Seiri = Sorting • 1. Parts & Work in Process (WIP) • Things fallen back behind the machine or rolled under it • Broken items inside the machine • Things under the racks/ platform • Extra WIP • Stock of rejected items • Items accumulated over period for rework • Material awaiting disposal decision • Material brought for some trial, still lying even after trial • Small qty of material no longer in use Contd..

Identifying unnecessary Seiri = Sorting • 2. Tools, Tooling, Measuring devices • Old jigs, tools not in use are lying • Modified tools, tooling for trial, are lying after trial • Worn out items like bushes, liners, toggles etc. lying • Broken tools, bits, etc. may be lying • Measuring equipment not required for the operation • being performed , is lying • 3. Contingency Parts • Many times storage place for contingency parts become • a last refuge for broken parts, surplus items and things • nobody is likely to use Contd..

Identifying unnecessary Seiri = Sorting • 4. Shelves and Lockers • Shelves and lockers tends to collect things that nobody • ever uses , like surplus, broken items etc. • 5. Passages and Corners • Dust, material not required seem to gather in corner • 6. Besides Pillars and under the stairs • These places tends to collect junk, spittoon etc. • 7. Walls and Bulletin Boards • Old out dated notices which have lost their relevance • Posters or bulletins on wall • Dust, remains of torn notices, cell tape pieces Contd..

Identifying unnecessary Seiri = Sorting • 8.Floor, Pits, Partitions • Defective parts • Protection caps, covers • Packing material • Hardware items , small items • Even tools, tooling • Items dropped on the floor are never picked • 9.Computer Hard Disk • Many unwanted, outdated, temporary files pile up

Improvement methods Seiri = Sorting 1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system e.g. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system e.g. How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.

Dealing with papers Seiri = Sorting How to Reduce Papers on Your Table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material e) For information

Dealing with papers Seiri = Sorting How to Reduce Papers on Your Table ? 4 D Principle DO DELEGATE DELAY DUMP

2 ‘S’ Seiton : Systematic Arrangement PLACE FOR EVERYTHING, EVERYTHING IN ITS PLACE Arranging things in systematic way

2 ‘ S’ - SEITON 2 ‘S’ – In our body there is a fixed place for every organ.

SEITION = Systematic Arrangement Meaning To determine type of storage and layout that will ensure easy accessibility for everyone. Activity - Functional storage - Creating place for everything and putting everything in its place Success - Time saved in searching Indicator - Time saved in material handling

SEITION = Systematic Arrangement Japanese Meaning: Dictionary meaning of Seiton is “to be correctly prepared” and “to prepare correctly”. In short these means : (a) arrange correctly in accordance with the correct method of doing activities and (b) make thorough preparations so that activities can be done even if they occur abruptly

Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide where things belong • Decide how things should be put away • Obey the Put away rules

Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide where things belong • - Standardize Nomenclature • - Determine an analytical method of storage • Decide how things should be put away • -Name & locations to everything. • - Label both item and location • - Store material functionally • - Prevent mistakes with coding by • shapes & colour • contd..

Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide how things should be put away • - Follow (FIFO) first in first out rule • - If two identical items are to be located, • then store them separately, • - colour code them. • Obey the rules • - Put the things back to their location after • their use

Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Colour codes 3) Outline markings 4) Labels

Seiton = Systematic Arrangement Usage Frequency • Store frequently used material • near the workplace and less • frequently at some distance • Heavy material should be • stored at lower levels/layers • Place directly on the material • handling device for ease of • handling Weight & Shape of the Material Functional Storage

Seiton = Systematic Arrangement • Same category of material • may be stored in one location. • e.g, Allen Screws, Oil Seals Category • All items required for an • operation may be stored in • one location. • e.g, Allen key, spanner etc • hand tools required for • setting m/c Operation Wise Functional Storage

Seiton = Systematic Arrangement • Outlining and Placement Marks • - Mark boundaries of dept., aisles, Machines • - Follow straight line, right angle rule • - Nothing shall be kept outside the boundaries • Stands and shelves • - Keep only required number of • stands and shelves • - Standardize height, size • - Provide casters where necessary so that • it can be moved

Seiton = Systematic Arrangement • Wires and Ducts • - Colour code • - When there are multiple connections – • bundle the wires, label them and make sure • that they are in straight line /right angle • and firmly anchored. • Machine-tools & Tools • - Put the tools in the order you need them • - Location of the tool should be such that • it can be put away with one hand • - Try to eliminate some hand tools by • permanently attaching it to the bolt head

Seiton = Systematic Arrangement • Blades, Dies, Other important consumables • - Store them in the protected place • - Maintain these things regularly by • applying rust preventive, oiling etc. • WIP- Work In Process • - Designate a place for each component/part • - Decide on how much quantity to be stored • - Ensure that there is no damage to good part • during transit, they do not get rusty and • they are not mislabeled

Seiton = Systematic Arrangement • Oils • - Reduce number of oils used (Standardize) • - Colour code for oil • - Safety aspects - fire prevention, • pollution, leak, spillage • Instrumentation & Measuring Devices • - Label them, show direction of flow

Before sort after sort

3 ‘S’ Seiso : Cleaning KITSUI KIKEN KITENOI (DANGER) (PROBLEM) (DIRT) Clean the surroundings !

3 ‘ S’ - SEISO 3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc

SEISO = Cleaning Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection Activity - Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection Success - Reduction in machine down time Indicator - Reduction in no. of accidents

SEISO = Cleaning Japanese Meaning : Dictionary meaning “to clean up” and “getting rid of dirt and unclean items” While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

Seiso = Cleaning • Here cleaning means more than just keeping • things clean. Cleaning should be viewed as a • form of Visual Inspection • Preventive measures should be taken to tackle • problems of dust, grim, burrs, leakage etc. • Root cause of the problem should be identified • and it should be eliminated

Seiso = Cleaning • 5 Minutes Every day for cleaning • Devote 5 minutes everyday for cleaning your • work area • Participation of everyone is required • Attack hard to clean places regularly

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Basic Training. Collaborative Practice in Long Term Care Setting Jo Ann Fisher, MSN, FNP-C. Basic Training. Objectives. Define the scope of practice of the NP/PA Describe the components of a collaborative agreement

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BASIC Training

BASIC Training. OIMA: a Bible study method. Observation. Observation : What do I see ?. The Skill of Observation. Examples of Good Observations. Key Words Words that are repeated Therefore, but, so Structure Grammatical – Subject and verb of the passage.

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Basic Training. Tile Laying System. MUREXIN AG / Michael Maier Version: Oktober 2007. Tile Laying System. Preparation. TLS - Preparation. Penetrating Primer LF. for absorbent substrates ready-to-use one component solvent free Consumption: appr. 0,15 kg/m² Delivery units: 1 and 5 kg

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5S Methodology | What Is 5S Methodology? | 5S Methodology Explanation | Simplilearn

This presentation on 5S Methodology will take you through everything you need to know about the workplace organization method, 5S. This video also covers a number of different topics like the basics of the 5S methodology, its benefits and the process of 5S, like Sort, Set in order, Shine, Standardize, and Sustain. So now, let's jump in and learn about the 5S methodology. Learn to develop your organizational projects with the Lean Six Sigma Green Belt certification online program. Aligned to the IASSC exam, this online six sigma certification integrates lean and the DMAIC methodology with case studies to provide you the skills required for an organization's growth. About Simplilearn SIx Sigma green belt course: This Lean Six Sigma Green Belt course provides an overview of Six Sigma and the DMAIC methodology and is aligned to the leading Green Belt certifications at ASQ and IASSC. In this Lean Six Sigma Green Belt course, you will learn how to measure current performance to identify process issues and how to formulate solutions. Six Sigma Green Belt Training Key Features: - 56 hours of high-quality blended learning - 33 PDUs offered - 4 simulation test papers, 4 real-life projects - Aligned to ASQ and IASSC Eligibility: Lean Six Sigma professionals are in high demand due to their ability to use problem-solving techniques to reach business solutions and assuring quality control throughout the process. The Lean Six Sigma Green Belt certification is ideal for Quality system managers, Quality engineers, Quality supervisors, Quality analysts and managers, Quality auditors, and any individual wishing to improve quality and process within an organization. Learn more at https://www.simplilearn.com/quality-management/lean-six-sigma-green-belt-training

1.77k views • 59 slides

5S Plan Diagram Template for PowerPoint

The 5S Plan Diagram Template for PowerPoint is an engaging presentation template for discussing the 5S methodology. It is an efficient approach to organizing the workspace for a more productive outcome. The 5S’s in this model represent the five significant steps in building a highly organized workspace with nothing extra. Professionals of every field can opt for this methodology and apply it to make remarkable changes. For example, a technician may arrange his shop with this method and settle everything. By creating a clean workspace, he and his team members can work efficiently without wasting time to find the necessary tools. Likewise, lab practitioners, bakers, event managers, or accountants can also settle their workspace to save precious time. Another aspect of this methodology can be to make operational processes well organized by clearing unnecessary steps. This way, the 5S method is a wholesome approach for better outcomes due to proper organization and preset working protocols. 

In this 5S Plan Diagram Template for PowerPoint , we created a 5-step bars infographic diagram. The first slide shows five 3D bars arranged in an ascending order concerning their sizes. Each has an extended base in the front direction, and they carry distinct color fills. The front side of each bar has meaningful graphical icons, and the upper parts mention the titles. We provided an editable text box with every vertical bar to mention the necessary details. The gradually increasing sizes of the shapes indicate the increasing stability of the workspace with every step, i.e., sorting, setting in order, shining (to make everything neat), standardizing, and sustaining. The following slide of this 5S Plan Diagram Template for PowerPoint has a similar diagram but is in a horizontal direction. Presenters can conveniently add the necessary information using the provided text boxes. The color scheme and fonts can also be changed according to the theme requirements. So, download and try this PPT template to create your presentations about the 5S methodology now!

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5s Diagram Presentation Templates

Knock knock 5s method - “a place for everything and everything in its place.” 5s stands for sort, straighten, shine, standardize, sustain. go for it get our free 5s diagram powerpoint templates and google slides themes with colorful shades to match your company's brand. it's that easy.

Craft Successful 5S Presentations with Our Ready-Made Free 5s Diagram PowerPoint Templates and Google Slides Themes!

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How to Create a 5 Steps Infographic in PowerPoint

5s Diagram PowerPoint Presentation

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What is the 5s diagram.

A 5s Diagram provides an overview of a process, station, or work area. It is a five-step methodology for making a more productive and organized workspace: Sort, Straighten, Shine, Standardize, and Sustain.

What are 5s Diagram PowerPoint Templates?

The 5s Diagram PowerPoint Templates can help to display growth and improvement strategies. It is an effective tool for communicating the five-step methodology.

Where can we use these 5s Diagram Slides?

5s Diagram Slides can be used in any work environment to present floor plans, flowcharts, and more.

How can I make 5s Diagram Slides in a presentation?

Find pre-designed templates from the internet and edit them with your own data to instantly make 5s Diagram Slides. Our tips and tricks will also help you learn how to make creative slides.

Who can use 5s Diagram PPT Templates?

Management professionals can use 5s Diagram PPT Templates to impressively present the five-step methodology.

Why do we need 5s Diagram PowerPoint Slides?

The 5s Diagram PowerPoint Slides can help you present information visually, which will help your target audience easily understand the concept.

Where can I find Free 5s Diagram PPT Templates?

Visit Slide Egg to find 27+ pre-designed professional-looking 5s Diagram PPT Templates.