5S made easy: a step-by-step guide to implementing and sustaining your 5S program

104 Pages·2016·18.893 MB·English

by  Visco, David

Business Management / Productivity Improvement
5S Made Easy
A Step-by-Step Guide to
Implementing and Sustaining
Your 5S Program
“ 5S Made Easy is a simple, easy-to-follow guide for 5S in manufacturing. It nicely explains how 5S
has a greater purpose than simple housekeeping. It is about standardizing and improving—often
overlooked points in a 5S deployment.”
—Drew Locher, Change Management Associates, Shingo Prize-Winning Author of
Lean Office and Service Simplified and Value Stream Mapping for Lean Development
“Hurray to Dave Visco for 5S Made Easy .... The stability created through an effective 5S process is
critical to every other best practice, from set-reduction and TPM to kanban and standardized work.
Dave’s book offers a step-by-step primer for any change leader who wants to get this foundational
improvement method right the first time.”
—Bruce Hamilton, President, GBMP
“Anyone can begin a 5S program in their department or business by following this book’s
easy-to-understand steps. In addition, Visco has provided checklists, forms, and resource guides.
Almost everything you need is right here.”
—From the Foreword by Mike McCarthy, Lean Consultant and Author of Sustain
Your Gains: The People Side of Lean-Six Sigma
For decades, 5S practitioners have struggled with exactly how to implement and sustain a 5S
program in their workplaces. While there are many books available on the organization meth-
ods suggested by 5S, few provide easy-to-understand, step-by-step guidance on how to set
up and sustain successful 5S implementations. 5S Made Easy fills this need.
Written by an expert whose focus for the last decade has been nothing but 5S, the book
supplies in-depth guidance on how to implement and sustain each of the 5S pillars—sort, set
in order, shine, standardize, and sustain.
The book uses an easy-to-follow format that was designed for use during 5S events. It
provides color images of real-world 5S solutions, including before and after pictures from the
field. It also supplies readers with online access to all of the forms and documents needed for
an effective 5S program. All the forms and documents are provided in an easily editable format
to fit any operation.
K25513
ISBN: 978-1-4987-1982-7
90000
9 781498 719827

5S Made Easy
A Step-by-Step Guide to Implementing
and Sustaining Your 5S Program

5S Made Easy
A Step-by-Step Guide to Implementing
and Sustaining Your 5S Program
David Visco
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A PRODUCTIV ITY PRESS BOOK
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Version Date: 20150721
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Contents
Foreword ...........................................................................................................ix
Preface ...............................................................................................................xi
1 What Is 5S and Why Do It? ................................................................1
What Is 5S? .........................................................................................................1
Benefits of 5S .................................................................................................1
Summary of Each of the 5 Pillars ..................................................................1
How Is It Implemented? .....................................................................................3
Action Items ...................................................................................................4
Parking Lot Items ...........................................................................................4
2 How to Use This Book .......................................................................5
Action Items ...................................................................................................6
Parking Lot Items ...........................................................................................6
Notes ...............................................................................................................6
3 Develop Your Plan .............................................................................7
Develop Your Plan: Summary of Steps ........................................................11
Action Items ..................................................................................................11
Parking Lot Items ..........................................................................................11
Notes ..............................................................................................................11
4 Train the Team .................................................................................13
Tips for Launch Success ................................................................................15
Train the Team: Summary of Steps ..............................................................16
Action Items ..................................................................................................16
Team Ideas ....................................................................................................16
Parking Lot Items ..........................................................................................16
5 Sort 17
Benefits .............................................................................................................18
Materials Needed ..............................................................................................19
Pre- Event Tasks .................................................................................................19
Red Tag Event Steps ..........................................................................................19
Lessons Learned for Future Red Tag Events ...............................................21
Sort: Summary of Steps ................................................................................21
v
vi ◾ Contents
Action Items .................................................................................................22
Parking Lot Items .........................................................................................22
Notes .............................................................................................................22
6 Set in Order and Shine ....................................................................23
Summary ..........................................................................................................23
Benefits .............................................................................................................23
Materials Needed .............................................................................................24
Pre- Event Tasks ................................................................................................24
Set in Order and Shine Steps ..........................................................................25
Team Ideas ...................................................................................................28
Some Idea Examples ....................................................................................28
Some Shine Idea Examples ..........................................................................38
Some Idea Examples ....................................................................................39
Set in Order: Summary of Steps ..................................................................47
Action Items .................................................................................................47
Team Ideas ...................................................................................................47
Parking Lot Items .........................................................................................48
7 Standardize ......................................................................................49
Benefits .............................................................................................................50
Materials Needed .............................................................................................50
Pre- Event Tasks ................................................................................................50
Standardize Steps .............................................................................................50
Benefits ..........................................................................................................51
Benefits of 5S Audits ........................................................................................52
Standardize: Summary of Steps ...................................................................56
Action Items .................................................................................................56
Parking Lot Items .........................................................................................56
8 Sustain .............................................................................................57
Summary ..........................................................................................................57
Benefits .............................................................................................................58
Materials Needed .............................................................................................58
Pre- Event Tasks ................................................................................................58
Sustain Steps ....................................................................................................59
Sustain: Summary of Steps ..........................................................................64
Action Items .................................................................................................64
Parking Lot Items .........................................................................................65
9 The Ideal Conditions to Implement Lean ........................................ 67
Know What Your End Goal Is ..........................................................................67
Make Sure Leadership Is Onboard ..................................................................68
Prepare Your People ........................................................................................68
Contents ◾ vii
Do Not Lose Momentum .................................................................................68
Action Items .................................................................................................69
Parking Lot Items .........................................................................................69
In Closing ............................................................................................... 71
5S Launch Guide.....................................................................................73
Develop Your Plan: Summary of Steps ...........................................................73
Train the Team: Summary of Steps .................................................................73
Sort: Summary of Steps ...................................................................................73
Set in Order: Summary of Steps .......................................................................74
Standardize: Summary of Steps ........................................................................74
Sustain: Summary of Steps ...............................................................................74
5S Materials Checklist ............................................................................ 75
Forms ......................................................................................................77
Resources ...............................................................................................83
Training and Education ....................................................................................83
Supplies ............................................................................................................83
Acknowledgments ..................................................................................85
About the Author ....................................................................................87