I know this is not part of ISO 9K:2K, but does anyone have any information regarding how to implement 5'S. I have seen it and am interested in implementing into a manufacuring company. Thanks for any help you can provide.

Hi Donna...

"Gemba Kaizen" by Masaaki Imai has a pretty good section on 5S. You might want to take a look at it.

Cheers!!

Mike

P.S. Oh yeah... Varsity Chili Dogs rule! I miss those... :D

[This message has been edited by Michael T (edited 29 June 2001).]

I notice that you are in Athens, Carrier Transicold has a 5 S program. You may want to get a hold of them.

:) What are you looking for specific. Are you looking for the Japanese version or some thing to just appear more organized and disciplined. The Toyota production systems are all developed with 5-S in mind. The Japanese philosiphy is if you look unorganized you prob are. The overall view of 5-s is a snap shot of management. Are you moving that way or just inquiring? I have lots of stuff comming from 11 years with Toyota's systems and dealing with the Japanese.;) good luck may the force be with you!

While 5-S iis not 9001:2000 requirement it's implementation can support work environment and infrastructure

I lost a detailed response I typed up for you, but will try to do service with a shorter response (hoping my computer doesn't wig out and lose it too!)

We are using 5S as a tool for Lean Manufacturing (eliminating the source of waste in processes). We first told everyone about 5S, assembled a team, selected an application area and implemented the steps. From seeing what improvements have taken place, most of the nay-sayers have been put to rest and folks are begining to become excited about what they can do.

This week we're having a Kaizen Event, with 4 areas being tackled by 4 teams using 5S as a springboard, as well as QCPC. I am going to be very tied up this week, but will try to keep an eye on this thread to see if you post any more specific questions.

If I remember correctly ISO 9004-2000 mentions 5 S. I just looked and this is my 100th posting.:p

Didn't I read here somewhere that when you get to 100 posts that you are to send the moderators a bottle of whiskey?:lick:

Originally posted by Al Dyer
Didn't I read here somewhere that when you get to 100 posts that you are to send the moderators a bottle of whiskey?:lick: Wrong again, Al. :thedeal:

Al, its in the mail :lick:

This does pertain to the standard (y2k version):

I would use 5S when identifying and evaluating effectiveness of the processes you have in place. Remember to capture the 'AS IS' :evidence: status, then the 'After' :evidence: so you can show continuous improvement.

5S should be used throughout the facility not just in production/manufacturing/machining areas like TPM.

I'll try to attach a file showing a sample 5S questionaire along with the evaluation criteria when I get back to the office Monday. Please remember this information is subjective...It's up to your company to set it up for themselves and customize the questions to suit your needs.

FYI. Found this site to be interesting.

*** Dead Link Removed ***

Thanks for sharing that site. I really liked the link to their TPM page and am sharing it with our sites TPM Coordinator. Our company has it's own plan but it is good to see what others have done to compare.

Eileen

Originally posted by E Wall

I'll try to attach a file showing a sample 5S questionaire along with the evaluation criteria when I get back to the office Monday. Please remember this information is subjective...It's up to your company to set it up for themselves and customize the questions to suit your needs.Send it to me in an e-mail and I'll post it if you can't. I'd like to see it.

BTW - Excellent link, Sam! Thanks!

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. For a beginner it is a must to read Gemba Kaizen" by Masaaki Imai. But it is useful to understand also the Japanese terminology [see this glossary covering only a limited vocabulary relating mainly to what in North America are referred to as KAIZEN, or Continuous Improvement (CI) ***DEAD LINK REMOVED*** workshop activities].

How to start? Managerial decision, defining the time schedule for steps, training for all, small exercises per line/machine as audit, defining 5S check list for audit, standardizing 5S audit, defining and standardizing 5S suggestion system, defining 5S team, a poster, a communication panel with improvements (before/after), periodically analysis, involving small group activities, rewarding.
And success it is coming soon.

Do not forget. Once you implemented 5S, this is also a useful tool for Total Productive Maintenance (TPM).

vio

Sam, that site is an excellent source of info.

Hi Sam....Sam...i was browsing this forum, because, im going to prepare a project of 5's in my organization, and i wanted to enter to the site that you recomended, but, i could not get in. Can you guide me to another site so i can learn more about this subject.

**If someone read this and have more info or knows sam, please notify tis message.

Thanx

Telefonia,

I had no problem accessing that page. May be you should try again.

If you can't get there, try some of these:
http://www.graphicproducts.com/tech/five_s/

http://www.tpmonline.com/papakaizen/articls_on_lean_manufacturing_strategies/5s.htm

http://www.mfgeng.com/5S.htm

- Atul.

:bigwave:

There are lot of sites as well litrature is available. But on actually, how 5S is to be applied in a manufacturing industry. That means how to start with 5s? What is the first step to go with.
In my mind should we divide the complete unit into several units or part and start implementing 5s in each unit after giving the shop floor worker the complete training in training room. Is this training should be conducted on job site.
My second question, what is the role of leadreship or higher management in 5S. In my mind it is the shop floor people who has to accomplish all 5s. but than what about leadership role

5S is usually part of our ISO9000 consulting package for manufacturing companies although it is in no way related to the standard requirements.Here are the steps how we usually start it.

1/ Discuss first with client management
2/ Ask them to prepare a 5S team
3/ Organize a small training/meeting where
3.1 We do small presentation on 5S (around 40 minutes)
3.2 Show a short video on 5S (you can get a good one from Asian Productivity Organisation http://www.apo-tokyo.org/)
3.3 Top management declare that company start 5S programme and 5S team. Inform the date of BIG Sorting and Cleaning date (2 to 4 weeks laters)
4/ Sell the 5S idea to staff (leaflet, notice board, meeting)
5/ Start the Big Cleaning Date
5.1 Taking pictures (before)
5.2 Everybody including top guys sorting things out and doing the cleaning
5.3 Taking pictures (after status)
6/ Summarise the result including benifit in $, post the pictures for people to compare.
7/ Define regular cleaning interval (for the whole company and/or department)
8/ It become much more harder from now to make it regular and become habit for everybody, but i hope those initial steps would help to start up the program. But the good thing is 5S can produce good short term result very quickly so that people really like it .

It is much more harder to implement 5S in service sector as it is very difficult for me to maintain my own desk.

Cheers,
Tuan

5S Implementation

Steps indicated by Tuan are quite similar with those performed by us, 3 years ago.
Some additional comments are indicated bellow.

Training to create awareness, Aug'00:
We customized 2 days training sessions for management and direct force, with the following structure:
1. Japan-Cultural & Managerial Impact; 2. 5S; 3. 7 QC Tools; 4. From 7 QC tools to Action Plan.
5S module was based on 5 videotapes, one per step. After each presentation, the team discussed about the subject, and performed on floor audit. Trainer prepared special checklists for S1…S5. At the end of 5S module, all observations written on the checklist there were discussed one by one and put on the board. Collected ideas for improvement:95. (32% S1, 28% S3, 23% S2, 17% S4)
During 7 QC Tools module, after general introduction and small exercises, trainees used Affinity techniques and Cause Effect Diagram to group and find the 3 major causes.
During the fourth module, the exercises were focused to create Action Plan, (Steps, responsibilities-names and signature, implementing date).

Small group activity:
Faced with this improvement perspective, it was decided to empower the working team (machine/shift) for 5S. Standard working map was created for them, (Oct’01)

5S Campaign:
Long-term strategy for 5S implementation, Dec’01, with 2 major steps:
I. AIDA (Awareness, to obtain Interest, noting the need for 5S training in order to create Desire, with a next step, creating the conditions for Actions)
II. SOCSA, based on local acronym of 5S meanings

5S team:
Cross-functional team (PROD-5 persons, QC 1 person, ENG 1 person, LOG 1 person) was created to manage 5S activities per department, (Feb’02).

5S Implementation:
Jan’01, S1 routine
Dec’01, S2 routine
Dec’02, S3 routine
Dec’03, S4, S5 routine

Note: Before "Sx" implementation: Refreshment sessions, periodical audit, planed or not (based on check list, images of critical aspects followed by analyses sessions), improvement suggestions.


5S Suggestion Program:
Started in Feb’01, considered to be the motivating driver to ensure 5S continuity.

Standard Improvement Suggestion Program:
Started in May’01, considered to empower direct force to propose suggestions for standard improvements


vio

qpainter said that 5S is mentioned in ISO 9004:2000 and told us to look at qpainter's the one hundredth post.

First of all I can not find the posting.

Second in ISO 9004:2000, the 5S is not directly stated.

In clause 6.4 Work environment they said that 'Management should ensure that the work environment has a positive influence on motivation, satisfaction and performance of people in order to enhance the performance of the organization. Creation of a suitable work environment, as a combination of human and physical factors, should include consideration of
---crative work methods and opportunities for greater involvement to realize the potential of people in the organization,
---safety rules and quidance, including the use of protect equipment,
---ergonomics,
---workplace location,
---social interaction,
---facilities for people in the organization,
---heat, humidity, light, airflow and
---hygiene, cleanliness, noise, vibration and pollution.

The essentials of 5S is said indirectly in this clause.


:vfunny:

In our company we decided to integrate 5S inside “Audit Process”.
5S Audit can be seen as process oriented (work place) activity.
In this forum you can find lots of 5S audit checklists, covering different issues.

vio

I am looking for an audit checklist (5s) for a mnaufacturing plant? Does anyone have one they might be willign to share?

I am looking for an audit checklist (5s) for a mnaufacturing plant? Does anyone have one they might be willign to share?

Here's on we use

See bellow some examples of 5S audit check lists we used for shop floor.

Vio

I am going to go out on the production floor right now and take some before pictures and use this material to help me with 5's in my own dept.
Thank you so much
I am going to get the other members of the management team to buy in. :applause:

lday38,
Go to 5S Audit - Seiri, Seiton, Seiso, Seiketsu, Shitsuke (http://elsmar.com/Forums/showthread.php?t=5368).

The 5S visual may of some use to you in your endeavour. The visual is attached to post #6.
Wallace.

I don't know how good it is, but a free booklet about the 5s system is available here:

http://www.graphicproducts.com/free-gifts/five-s-booklet.php

They also have other free stuff such as a pipe marking guide, arc flash book (it's excellent) and a NFPA guide.

I don't know how good it is, but a free booklet about the 5s system is available

Thanks for the link, Homecraft, and welcome on board! :bigwave:

Thanks for the link, Homecraft, and welcome on board! Ditto. Welcome to the Cove http://elsmar.com/Forums/images/smilies/bigwave-d2.gif

/Claes

i need a logo or posters for 5s

i need a logo or posters for 5s

Welcome to the Cove.
Try this site (http://www.enna.com/Merchant2/merchant.mvc?page=E/CTGY/5P&gclid=CLG39p-JuJICFQUilwodAA0lQg) for starters. Not an endorsement, just an example. Google has lots of them. :D