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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.

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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.

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5S Diagram Template for PowerPoint

5S Diagram for PowerPoint is an application of the 5-step diagram design for PowerPoint presentations that you can download and use to create presentations on Lean Manufacturing and Kaizen using the 5S Methodology.

5S model is an organizational methodology to organize and monitor the flow of a process effectively. The 5S model and technique use 5 words: Sort, Straighten, Shine, Systemize, and Sustain. Each has its meaning, and the PowerPoint template depicts all of them in a sequence. Japanese started this concept of 5 stages, leading to the technique of Just in Time Manufacturing, one of the most used in the manufacturing industry. Different stages of the process are shown on the curved arrows .

This professional presentation template shows showing the flow of a process. The presentation template starts with an overview of the process, followed by a description of each stage. The first part elaborates on the Sort step dealing with selecting the necessary resources for the process and removing unnecessary ones. Required items can be listed in bullets for further analysis and monitoring. The next step is arranging all the resources appropriately and fully using them, the Straighten step. Shine includes the monitoring of the process and the environment around it. Systemize reflects quality inspection and modifications of the product to maintain a standard. The final stage is Sustain, which deals with storing and maintaining the products in a flow.

One thing to notice about this circular org chart template is the thin portion around the 5S diagram. It can add some text like the company’s motto or some motivational quote. The layout of this PPT template  animates with each stage by focusing only on one stage at a time as the presentation goes on and dims the other stages. It completes a rotation by covering all the stages and highlighting the main points adjacent to the 5S diagram. It can also be used as a 30-60-90-day plan template , with each curved arrow showing a regular interval of some days to make a project timeline .

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Lean Manufacturing Tools

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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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What Is the 5S Methodology?

The 5S methodology is best summarized by the philosophy, “a place for everything and everything in its place.”

You may have heard of “KonMari,” a home organization system invented by Marie Kondo. The KonMari method transforms cluttered homes into tidy and simplified living spaces. The 5S principles are similar to KonMari. However, saying that 5S is just about tidying is like saying successful manufacturing is just about speed - there is much more depth. So, let’s explore the true intent and meaning of 5S.

5S Japanese Words

5S originated as 5 Japanese words:

5S Meaning in English

In English, these 5S meanings are:

• Sort (Seiri): Eliminate that which is not needed.
• Straighten (Seiton): Organize what remains after sorting.
• Shine (Seisou): Clean and inspect the work area.
• Standardize (Seiketsu): Write standards for 5S.
• Sustain (Shitsuke): Consistently apply the 5S standards.

At their core, these 5S activities build the discipline needed for substantial and continuous improvement by creating (and sustaining) efficient and effective work areas.

Why Is 5S Important in Manufacturing?

While 5S was first developed in the context of the automotive industry, it is now widely considered an essential step for any lean manufacturing program, regardless of industry.

Embedding 5S as part of daily tasks within your company means much more than improved organization, sustained cleaning routines, and efficient activity flows. By using the 5S methodology, operators are encouraged to improve their overall work environment and reduce muda or waste .

Adherence to 5S standards is considered the foundation of Total Productive Maintenance (TPM) and an integral part of the Toyota Production System (TPS) . 5S also creates a stable platform from which Kaizen activities can be launched.

The bottom line - 5S is a low-investment, high-impact lean manufacturing tool that is predicated on people. It engages operators in “owning” their workspace and helps to instill a culture of quality, productivity, and improvement.

What Are the 5 Benefits of a 5S System?

The key benefits of a 5S system include:

• Creating space within your facility by removing unnecessary tools and equipment
• Reducing waste from unnecessary motion by organizing the workspace
• Reducing downtime and improving quality by consistently maintaining equipment
• Engaging operators by granting them more responsibility for their work environment
• Creating a safer work environment by ensuring it is clean and well-maintained

Now that you have a better understanding of why 5S is important and how it can benefit your manufacturing operations, let’s learn more about each of the 5S steps.

Sort (Seiri)

What is sort.

The Sort step separates items in your workspace that you know you need from items that you do not or may not need. Move the latter to a “red tag” holding area.

Why Do You Need Sort?

Sort enables you to have a more productive workspace by removing unneeded clutter (and eliminating distractions). It also is a first step towards opening up space that can be used for other things.

How Do You Implement Sort?

Separate necessary items (e.g., tools, parts, and materials) from unnecessary items. We recommend sorting items into four categories:

• Items needed in this work area. These are items you know that you regularly use in the context of this work area and thus will stay in this work area.
• Items needed in another work area. These are typically misplaced items. If an item is used in another work area, “sort” it into that area by delivering it to the team member responsible for that work area.
• Items you may need. For items you are unsure about, use the 5S “red tag” system. Mark such items with red tags, which at a minimum, should include the name of who tagged the item, why it is thought to no longer be needed, a proposed review date, and the name of the manager who must approve of disposal. Move the item to a red tag holding area, which should be organized by review month to make it easy to manage the area.
• Items you do not need. These are items that you are 100% confident are not needed. They should be immediately discarded, recycled, or donated, or sold if in good condition.

What Are Some Examples of Sort?

• Remove waste (or muda) from your workspace.
• Discard broken or old parts using 5S red tags.
• Responsibly recycle materials and papers.
• Separate everyday tools from special-case tools.
• Avoid overfilling your workspace with excess materials.
• Create an overflow area outside of the workspace for duplicate materials, tools, and parts.

Straighten (Seiton)

What is straighten.

The Straighten step thoroughly organizes the items that remain after sorting, making frequently used items easily accessible and providing every item a clear and easy-to-find home.

Why Do You Need to Straighten?

Straighten enables every item to have a specific home where it can be easily found and to which it can be easily returned. It reduces the waste from excess motion, as items are placed in more ergonomic locations. It is also the second step on the path to opening up space that can be used strategically toward the goal of improving production.

How Do You Implement Straighten?

After you’ve sorted items, it’s time to decide how you want to organize them. We recommend the following methodology:

• Provide easy access to frequently used items. The key to reducing waste from excess motion is to place frequently used items within easy reach.
• Group like items. Group the remaining items into logical categories and brainstorm the best way to organize and store each of these categories.
• Utilize visual designs. For each group, decide on the best way to make it clear when an item is missing or misplaced. A classic example is creating a shadow board for tools.
• Use containers. If it is appropriate for the type of item, consider organizing it within a container.
• Unleash the labeler. If an item is too big to put into a container, consider giving it a frame and putting a label on the item in addition to the frame.
• Be agile . Your initial straighten pass will likely deliver a significant improvement - but you are also likely to overlook some potential improvements. Plan a 5S team meeting with a focus on straightening at the one and two week points, and brainstorm further improvements as part of your initial implementation.

What Are Some Examples of Straighten?

• Give every item a distinct “home.”
• Use color as a way of organizing and creating meaning.
• Integrate shadow boards and other visual indicators into the plant floor.
• Dedicate a surface or area entirely to shadow boxes and tool storage.
• Dedicate another surface or area entirely to working.

Shine (Seisou)

What is shine.

The Shine step elevates the work area by ensuring thoroughly cleaned and inspected tools, equipment, and other items. It also can include routine maintenance on equipment, which is one of the ways it flows directly into TPM .

Why Do You Need to Shine?

Shine creates a work environment that engages and empowers operators by giving them more responsibility and agency over their work area. It also helps them to identify problems before they interfere with production. For example, in a clean work environment, it is much easier to spot emerging issues such as fluid leaks, material spills, metal shavings from unexpected wear, hairline cracks in mechanisms, etc.

How Do You Implement Shine?

After you’ve straightened items, it’s time to elevate the work area by cleaning, inspecting, and in some cases, performing routine maintenance. We recommend the following:

• Grab the metaphorical spray bottle. Using appropriate cleaners and cleaning tools, make the work area sparkle. With every sweep, mop, brush, wipe, wash, and wax, strive to return your workspace to its former glory. Be Miyagi.
• Find the source. The guiding principle of this 5S step is “clean to understand”. If there are any signs of leaks, spills, or unexpected debris, strive to understand the source. It is likely an early warning of a future problem.
• Inspect. After cleaning each item, take a moment to look it over and examine its condition. Does it need updating, maintenance, or repair?

What Are Some Examples of Shine?

• Wipe down equipment.
• Examine the wear of your tools.
• Disassemble larger objects to inspect the state of their parts.
• Investigate a recurring unclean spot or mess.
• Make sure to follow proper cleaning procedures to prevent damage to equipment.

Standardize (Seiketsu)

What is standardize.

The Standardize step is a bridge between the first three 5S steps (Sort, Straighten, Shine) and the last step (Sustain). In this step, your goal is to capture best practices for 5S as standardized work for your team.

Why Do You Need to Standardize?

Standardize makes 5S repeatable. It transforms 5S from a one-off project to a reproducible set of activities.

How Do You Implement Standardize?

It’s time to make sure all your hard work continues to pay dividends into the future. Set expectations for the future with a documented 5S process. To do so, we recommend that you:

• Document in pairs. Have one team member walk through each 5S task as another team member documents it to ensure nothing important is missed.
• Capture the essence. We are huge proponents of simplicity (and agile ). Capture the essence of each task and no more. Otherwise, your documentation will be difficult to maintain.
• Prefer checklists. Checklists feel easy. Short checklists feel even easier. A great format is providing a name for each task that serves as a quick reminder and a more detailed description for training.
• Organize to simplify. Organize your checklists by role, by shift, and by frequency (daily, weekly, monthly). This will make the 5S process much less intimidating to your team.

What Are Some Examples of Standardize?

• Write down your 5S practices.
• Create “implementation” checklists and “audit” checklists.
• Create “kits” that contain the materials needed to perform a specific task.
• Use photos and other simple visuals as part of your training materials.
• Build a schedule for tasks.

Sustain (Shitsuke)

What is sustain.

The Sustain step ensures that 5S is applied on an ongoing basis. It transforms your standardized 5S processes into regularly completed tasks.

Why Do You Need to Sustain?

Iterative 5S processes lock in your gains and ensure further and continued progress.

How Do You Implement Sustain?

Once you’ve standardized, it’s time to continually act upon those standards. We recommend you:

• Create a schedule. Embed 5S practices as scheduled tasks (by role, shift, and frequency).
• Teach through demonstration. Instruct employees on how to conduct 5S tasks through demonstration and training. Showing employees what is expected of them will prepare them to conduct tasks on their own.
• Supervise to solo. After initial 5S training for employees, gently supervise while they continue to form habits. It is easy to make mistakes or fall off course, so patiently and helpfully offer corrections when needed.
• Adapt as necessary. When giving or receiving feedback on tasks, see where changes can be made to make the tasks easier and more efficient. Standardized work is intended to be living documentation.

What Are Some Examples of Sustain?

• Hold a demonstration meeting to explain complex or multi-step processes.
• Perform periodic check-ins after initial training.
• Teach employees to run 5S audits.
• Respond to mistakes with additional training.
• Encourage supervisors and operators to communicate openly and constructively to find ways to improve your 5S implementation.
• Set quarterly audit reminders for reviewing the red tag holding area.

The Bonus S of 5S

Now that you know how to implement each step in the 5S methodology and foster a culture of continuous improvement in your factory, you are ready to learn the bonus S: Safety!

5S is meant to help you improve productivity in your factory, but it is also meant to help create a safe, positive work environment for your team. While preventing workplace injuries is very important - also important is that 5S will make your plant a great place to work. Everyone enjoys a safe, clean, and logically laid out work environment, and it will motivate your employees, leading to better results on the plant floor.

How Does Each of the 5S Steps Contribute to Safety?

• Sort removes items from the plant floor, creating more space. Of course, this space can be used to hold new tools and equipment, but it can also be used to create larger aisles and more open spaces in the factory, removing tripping hazards. Even something as simple as decluttering drawers can prevent injuries (e.g., accidental encounters with a sharp object when rummaging for the tool you need).
• Straighten gives every item a logical home near the location where operators will use it. This prevents operators from rushing around looking for what they need, avoiding chaos on the plant floor that could cause safety hazards. For example, operators could slip, trip, or bump into one another if they have to constantly hurry around looking for tools.
• Shine cleans the workspace and maintains equipment. This prevents leaks or spills from leaving slick spots on the floor and ensures operators have functioning tools so they don’t have to dangerously jerry-rig solutions.
• Standardize makes clear to everyone what needs to be done and to whom each task belongs so tasks are completed on a regular basis. Confusion regarding ownership of responsibilities can cause important jobs to be missed. For example, equipment that is not consistently maintained will likely create safety concerns.
• Sustain ensures your initial 5S efforts are not in vain, keeping your staff happy and on top of any new safety concerns as they arise. One of the most dangerous things you can have in your factory is unmotivated employees who do not care about maintaining the condition of their workplace. Ensuring their efforts to implement a 5S program are recognized and sustained will provide continued motivation.

Overall, the 5S process is worth the initial organizational work for the rewards in safety, production improvement, and employee motivation.

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Get your team up to speed on 5S with this comprehensive slide show presentation.

5S programs can have a profound impact on your facility's organization and production. In order for this change to happen, employees companywide need to be educated on the importance of 5S and its benefits. This presentation will help you accomplish that task.

• Information presented in simple, accessible format
• Includes in-depth explanations of the 5S steps
• Demystifies 5S's unique red tag strategy
• Educates teams about 5S methodology in engaging ways

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5s (Workplace Organization) Implementation

Published by Derek Copeland Modified over 9 years ago

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Presentation on theme: "5s (Workplace Organization) Implementation"— Presentation transcript:

The Five Ss.

Toyota 5S System SCM 462 Dr. Ron Lembke.

LT6 5S + 1   CONTINUOUS IMPROVEMENT OFFICE.

Understanding 5S.

5S training Office Environments.

5S BASIC TRAINING What is 5S and why do we want to do it?

 Sort the necessary from the unnecessary  Use the Red-Tag technique to highlight unneeded items  Manage all removed items Separate the essential from.

Ch-3 5s1 5S Workplace Organization. Ch-3 5s2 5S 5S Contents: S1 --- Sort out. Get rid of the stuff you don’t needed. S2 --- Set in order. Place the stuff.

Productive Maintenance

Making your Portable Restroom business Lean and mean – How to boost productivity and increase your bottom line.

Introduction to 6S.

SCM 494 Dr. Ron Tibben-Lembke

5S Essentials Five action verbs.

Why 5S? Workplace organization required when:

1 © 2005 Superfactory™. All Rights Reserved. Lean Office - 5S and Visual Controls Superfactory Excellence Program™

Lean Training 5S. Agenda What is it? What’s it for? How does it work? When do you use it? What’s an example?

CONTINUOUS IMPROVEMENT PROGRAM

Introduction to 5S. What is 5S? An easy definition is: Finding a place for everything and putting everything in its place. 5S is also the foundation for.

 There are five primary 5S phases: 1.Sort. 2.Straighten. 3.Shine. 4.Standardize. 5.Sustain. The 5 S's Kamalnathan, MIM.

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Training Presentation/Powerpoint:

5s implementation guidebook, eight steps of 5s implementation.

Description

The 5S Implementation Guidebook explains the 5S concept in a simplified, step-by-step format so as to serve as a quick 5S implementation reference.

This 5S Implementation PPT training presentation provides you with practical guidelines on how to implement 5S in your organization. Following a Plan-Do-Check-Act approach, the guide includes key steps such as setting up a 5S steering committee, defining a 5S implementation plan, developing a communications campaign, training and education, selecting model areas, company-wide rollout, conducting 5S audits, and management review and improvement. It also provides guidelines for red-tagging and techniques and tools for sustaining 5S.

This guidebook offers you detailed information on how your organization could integrate each ‘S’ into your work processes and systems so as to build a culture of continuous improvement.

Note: This training package includes:

5S Implementation PPT Guidebook (PowerPoint format)

5S poster (PDF format, in color and monochrome, printable in A3 size)

Office 5S poster (PDF format, in color and monochrome, printable in A3 size)

Learning Objectives​​

Acquire knowledge on the 5S management concept and principles

Learn the step-by-step approach to 5S planning and implementation

Learn practical tips and strategies to sustain 5S

1. 5S Management Techniques

Set In Order

Standardize

2. Guidelines for Red-Tagging

Overview of Red-Tagging​

Steps in Red-Tagging

3. 5S: Step-by-Step Implementation

Step 1: Establish a 5S Steering Committee

Step 2: Define a 5S Implementation Plan

Step 3: Launch Communications Campaign

Step 4: Provide 5S Training & Education

Step 5: Start 5S Pilots

Step 6: Mass Rollout

Step 7: Conduct 5S Audits

Step 8: Review & Improve

4. Sustaining 5S Implementation

Role of Management​

Role of Employees

Techniques & Tools to Sustain 5S

5. Keys to Success

You may also be interested in the following 5S-related training presentations and checklists (sold separately):

5S Techniques

5S for the Office

5S Audit Checklist for Manufacturing

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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• respiratory system sorts oxygen

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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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How to Build a 5S Implementation Roadmap

Crafting a strategic roadmap for implementing 5s in manufacturing.

5S Overview

5s overview – what is it, is 5s right for you, top 5s benefits for manufacturing companies, 5s best practices, 5s planning, how to build a business case for 5s implementation, pain points solved with 5s, how to gather data to support your 5s business case, 5s implementation roi calculator, 5s implementation, 5s simple implementation plan, how to train frontline staff on 5s, 5s sorting implementation, 5s set in order step implementation, 5s shine implementation, 5s standardize implementation, 5s sustain implementation, 5s auditing, 5s auditing best practices, what is 5s auditing, checklist for a successful audit: what every manager needs to know, best practices for manufacturers developing your audit checklist, 7 tips to ensure successful 5s audits, measure the real impact of your 5s audits with cycle-based activity timing, how to establish 5s audit criteria, how to create a 5s audit checklist, 5s auditor: how to train them efficiently, scheduling 5s audits: implementation guide, how to conduct successful 5s audits, 5s audit scorecard: how to score a 5s audit with weever, 5s action plans: implementation guide, 5s audit reporting: comprehensive guide, 5s audit digitization, how to build your 5s digitization project plan, 5s audit digitization benefits, 5s audit software comparison matrix, what can software do to enable 5s auditing, how to choose the right software platform for 5s auditing, step-by-step facility-wide implementation roadmap, 5s audit digitization roi calculator, free 5s audit digitization presentation template, free resources, 5s audit scorecard, free 5s audit form templates.

For manufacturing organizations eyeing an efficiency overhaul, implementing the 5S methodology stands as a transformative strategy. Crafting an implementation plan or roadmap is pivotal to ensure a smooth transition and successful adoption of 5S principles. Let's delve into a step-by-step guide on constructing an effective implementation plan that aligns with strategic goals and drives organizational excellence.

What is the 5S Methodology?

The 5S methodology embodies a structured approach to workplace organization and efficiency. It entails the systematic arrangement, cleanliness, and standardization of workspaces to optimize productivity, safety, and quality.

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Steps-by-Step Guide to Writing your 5S Implementation Roadmap

Building an implementation plan for 5S adoption in manufacturing isn't merely a roadmap; it's a strategic blueprint for organizational transformation.

By defining phases, setting objectives, allocating resources, anticipating challenges, and adopting best practices, organizations chart a path towards enhanced efficiency, safety, and sustained excellence through the power of the 5S methodology.

1. Define Phases, Objectives and Activities

Start by delineating clear phases, mirroring the fundamental principles of 5S: Sort, Set in Order, Shine, Standardize, and Sustain.

Each phase should encompass specific objectives aligned with overarching organizational goals, emphasizing productivity, safety, and cost-efficiency.

Detail the activities and tasks required for each phase. Establish timelines for these tasks, ensuring clarity and specificity. Activities may include workspace assessments, training sessions, setting up visual management tools, establishing cleaning schedules, and conducting regular audits.

You might consider the 3 phase approach outlined here ⇒

An example of the roadmap could look like:

Phase 1: Planning

Objectives:

• Develop Roadmap: Outline a detailed plan including timelines, objectives, and resource allocation for the 5S implementation.
• Training Programs: Develop comprehensive training sessions to educate staff on 5S principles and their significance in enhancing productivity, safety, and cost-effectiveness.

Timeline: 2-4 weeks

Phase 2: Optimization (The "Blitz")

• Sort: Evaluate and declutter workspaces, identifying and removing unnecessary items.
• Set in Order: Establish designated places for necessary items, optimizing workflow.
• Shine: Implement cleaning schedules and maintenance routines for enhanced safety and cleanliness.

Timeline: 2 months

Phase 3: Normalization

• Standardization: Develop standardized procedures and visual management tools to maintain the improvements achieved during the Blitz phase.
• Sustain: Establish systems for regular audits, continuous improvement, and employee engagement to sustain the 5S practices.

Timeline: Ongoing, integrated into daily operations

2. Resource Estimation and Allocation

Estimate the resources—time, personnel, and budget—needed for successful execution. Consider factors like scope, workforce involvement, training needs, and material/equipment costs. Allocate resources judiciously to ensure a balanced approach.

Personnel: Identify team members or champions responsible for leading and coordinating the 5S implementation. Consider assigning roles such as project manager, team leaders, and frontline staff involved in the process.

Training Programs: Develop training materials and sessions on 5S principles. Allocate resources for educating employees at all levels to ensure understanding and successful implementation.

Budget: Allocate funds for various aspects, including training, necessary equipment, materials for organizing workspaces, signage, and potential consulting or external support.

Time Allocation: Define a timeline for the implementation plan, including milestones, deadlines, and phased rollouts for different 5S stages.

Equipment and Materials: Identify and procure necessary equipment, storage solutions, labels, cleaning supplies, and visual management tools required for organizing workspaces and sustaining 5S practices.

3. Identify Potential Issues and Mitigation Strategies

Anticipate potential challenges such as resistance to change or resource constraints. Propose proactive strategies to mitigate these challenges effectively. Develop contingency plans to address issues promptly, fostering adaptability and resilience.

Read our Ultimate Guide for 5S Auditing

Best practices: navigating the implementation journey.

Follow these best practices to ensure an efficient and successful planning process:

Engage Stakeholders

Involve stakeholders from the outset, ensuring alignment with organizational goals. Maintain transparent and consistent communication channels to garner support and manage expectations throughout the implementation process.

Foster a Culture of Ownership

Encourage employee involvement and ownership in the 5S journey. Cultivate a culture that values continuous improvement, empowering staff to contribute ideas and innovations.

Regular Evaluation and Adaptation

Periodically assess progress against set objectives. Adapt the plan as needed, embracing flexibility to address emerging challenges or opportunities effectively.

Automate 5S Auditing to ensure compliance and radically increase workstation productivity.

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• Automate schedules to ensure compliance.

Ultimate Guide to Success with 5S

How-to instructions, best practices, and customer stories to help you set up and manage a highly effective and impactful 5S program.

Continue Learning about 5S

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• Guy Kawasaki

Remember: Less is more.

A strong presentation is so much more than information pasted onto a series of slides with fancy backgrounds. Whether you’re pitching an idea, reporting market research, or sharing something else, a great presentation can give you a competitive advantage, and be a powerful tool when aiming to persuade, educate, or inspire others. Here are some unique elements that make a presentation stand out.

• Fonts: Sans Serif fonts such as Helvetica or Arial are preferred for their clean lines, which make them easy to digest at various sizes and distances. Limit the number of font styles to two: one for headings and another for body text, to avoid visual confusion or distractions.
• Colors: Colors can evoke emotions and highlight critical points, but their overuse can lead to a cluttered and confusing presentation. A limited palette of two to three main colors, complemented by a simple background, can help you draw attention to key elements without overwhelming the audience.
• Pictures: Pictures can communicate complex ideas quickly and memorably but choosing the right images is key. Images or pictures should be big (perhaps 20-25% of the page), bold, and have a clear purpose that complements the slide’s text.
• Layout: Don’t overcrowd your slides with too much information. When in doubt, adhere to the principle of simplicity, and aim for a clean and uncluttered layout with plenty of white space around text and images. Think phrases and bullets, not sentences.

As an intern or early career professional, chances are that you’ll be tasked with making or giving a presentation in the near future. Whether you’re pitching an idea, reporting market research, or sharing something else, a great presentation can give you a competitive advantage, and be a powerful tool when aiming to persuade, educate, or inspire others.

• Guy Kawasaki is the chief evangelist at Canva and was the former chief evangelist at Apple. Guy is the author of 16 books including Think Remarkable : 9 Paths to Transform Your Life and Make a Difference.

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