5-S Implementation

5-S Implementation
What is 5-S

5 S SORT
SET IN ORDER
SHINE
STANDARDIZE
SUSTAIN

and. COMMITMENT

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
Why 5-S

5-S Drives CULTURE!

Safety
Ergonomics
Promote Flow
Reduce searching
Reduce unplanned downtime
Increase Quality
Eliminate distractions
Reduce inventory and space

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
Why 5-S

5-S is the foundation of all other activities

Discipline to follow standard work
One piece flow
Expose problems
Safe working areas
Space reduction

Productivity

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
Getting Started

Workplace Scan (Documentation of

Reality)
Meet with area workers
Sort, Set in Order, Shine

Mark the area

Create a material spaghetti diagram
Conduct a 5-S & Safety Audit
Photograph the existing condition
Create a Scan Display
Review Reality Documentation
Copyright NN, Inc. 2004 Company Confidential
 5-S Implementation
SORT

Determine red tagging Talk to area workers

criteria Perform red tagging
Designate red tag and record tagged
items in log book
holding area
Move tagged items to
Identify person holding area
responsible for holding Update Workplace
area Scan display
Obtain red tags Disposition tagged
items.

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SORT

Category
Item name & number
Quantity
Reason
Disposal by
Disposal method
Posting date
Disposal date

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SET IN ORDER

Analyze the current situation

Target improvement issues
Get items off the floor and out from under
benches
Decide where to put needed items
Make it visually obvious where things
belong
Make it obvious when items are out of
place

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SET IN ORDER

Guidelines for deciding where to put

items
The more frequently used, the closer it should
be
Every item should have a designated location
and be labeled, shadowed, or color coded
Make everything easy to get and to properly put
away
Get items off the floor

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SET IN ORDER
Results
No Searching, Bending, or Stretching
A place for everything, and everything is in its
place

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SET IN ORDER

Spare parts for assembly machine at NN Delta Rubber Company

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SET IN ORDER

Maintenance workshop at Rockwell in Marion

Tooling carts for setters at NN in Veenendaal

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SHINE

Clean everything
Inspect through cleaning
Prevent dirt, grime &
contamination from
occurring

Cleaning a flasher machine in

Pinerolo

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SHINE

Determine targets
Stored items
Equipment
Space

Determine methods

Conduct initial cleaning and

painting
Painting a Boulton vibro
cleaning machine in Kysuck
Replace worn wires, hoses, and Nov Mesto

tubes
Copyright NN, Inc. 2004 Company Confidential
 5-S Implementation
SHINE
Prevent breakdowns & increase
safety
Look for:
Dirt
Corrosion
Lubrication
Wear
Leaks

This is
what we do
not want !!!
Copyright NN, Inc. 2004 Company Confidential
 5-S Implementation
STANDARDIZE
There is a place for everything and
everything is in its place
Establish standards for 1st three Ss
Attain the 3-S conditions
Make the standards visual
Assign responsibilities, determine
Who, What, Where, When, and How
Make labels & signs that are easy to see from a distance
Put them on or near what they relate to
Make them easily understandable
Ensure they make the work place brighter and orderly

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
STANDARDIZE

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
STANDARDIZE
Who is responsible for what area

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation
SUSTAIN

Conditions for Sustaining

Development of new awareness skills
Management support
Ongoing communication
Make 5-S a part of daily work
5 minute 5-S
30 minute weekly 5-S meeting with
targets
Total Employee Involvement

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation

Copyright NN, Inc. 2004 Company Confidential

 5-S Implementation

5-S
KAIZEN EVENT
FORMS

Copyright NN, Inc. 2004 Company Confidential

 5-S Workplace Scan
To identify workers, processes, and functions of the area. To plan the Workplace Scan.

Target Area Name:

Directions:
Define the boundaries of the target area and tape it off.

State the primary purpose of the target area.

Record the functions of the target area.

Plan the Workplace Scan by identifying who is responsible for each step and when completion
is expected.
Scan Step Who When
Draw an area layout
Draw a material spaghetti chart
Complete 5-S & Safety audits
Take photos
Create a workplace scan display

Copyright NN, Inc. 2004 Company Confidential

 5-S Audit Checklist

Copyright NN, Inc. 2004 Company Confidential

 5-S Red Tag Checklist
Examine all items in each category.
Directions
Red tag every item that may not be needed.
Enter a when a category is inspected.
Search these spaces. Search these storage places.
Floors Shelves
Aisles Racks
Operation areas Closets
Work Stations Sheds
Corners, behind/under equipment Other storage areas
Stairs
Small rooms
Offices Search the walls, boards, etc.
Loading docks Items hung on walls
Inside cabinets and drawers Bulletin boards
Signboards
Other
Look for unneeded equipment.
Machines
Small tools
Dies Look for unneeded material / supplies.
Jigs Raw materials
Bits Supplies
Conveyance equipment Parts
Work in process
Plumbing, pipes, etc.
Finished products
Electrical equipment
Shipping materials
Wire, fixtures, junction boxes

Look for unneeded furniture. Look for other unneeded items.

Cabinets Work clothes
Benches and tables Helmets
Chairs Work shoes
Carts Trash cans
Other Other

Copyright NN, Inc. 2004 Company Confidential

 5-S Unneeded Items Log
Unneeded Item # Date Reason for Tagging Notes / Disposition

Copyright NN, Inc. 2004 Company Confidential

 5-S Item Disposition Guidance
Determine the category in which each tagged item belongs.
Directions Determine required action. Record on tag and Unneeded Items Log.
Take action.
Category Action
Obsolete Sell
Hold for depreciation
Give away
Throw away

Return to supplier
Defective
Throw away
Repair

Scrap Remove to proper location

Throw away
Trash / garbage
Recycle

Unneeded in this area Remove to proper location

Used at least once per day Carry with you

Keep at place of use
Store in area
Used about once per week
Store where accessible in plant
Used less than once per month
Store in distant place
Seldom used
Sell
Give away
Throw away

Use unknown Find out use

Remove to proper location

Copyright NN, Inc. 2004 Company Confidential

 5-S Set in Order Inspection Sheet
Inspect all items in entire area.
Directions Move items to proper place.
Enter a when a category is inspected.

Equipment Materials / supplies / inventory

Machines Raw material
Small tools Supplies
Dies Parts
Jigs Work in process
Bits Finished product
Conveyance equipment Shipping materials
Cleaning equipment Cleaning supplies
Electrical equipment
Fixtures, junction boxes, etc.
Computer equipment
Other items
Charts, graphs, etc.
Books, checklists, etc.
Furniture Bulletin boards
Signboards
Cabinets Pens, pencils, rulers, etc.
Benches and tables Work clothes
Chairs
Helmets
Carts
Work shoes
Shelves
Trash cans
Racks
Personal items

Copyright NN, Inc. 2004 Company Confidential

 5-S Shine Inspection Sheet

Search all items in the area for cleaning needs.

Directions Use this with the Initial Cleaning Plan.
Enter a when a category is completed.
Large Surfaces Carts
Shelves
Ceilings
Aisles Racks
Work Stations
Corners, behind/under equipment Inside equipment / furniture
Stairs
Loading docks Machines
Walls Conveyance equipment
Doors Closets
Pillars and posts Drawers
Floors Cabinets
Other Sheds
Tool boxes
Storage bins

Surfaces of equipment and furniture Other items

Machines Materials and supplies
Conveyance equipment Trash cans
Plumbing, pipes, sinks Bulletin boards
Electrical equipment Labels and signs
Fixtures, junction boxes Small tools
Chairs Hoses, cords, tubing, etc.
Other

Copyright NN, Inc. 2004 Company Confidential

 5-S Initial Cleaning Plan

Directions List tasks and complete the columns below.

Target Area
Task Location Who When Materials and Tools Needed

Copyright NN, Inc. 2004 Company Confidential

 5-S Daily Checklist

Copyright NN, Inc. 2004 Company Confidential