internal abb document 5s basics job aid purpose of this job aid is to introduce you to why and how...
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The purpose of this job aid is to introduce you to why and how 5S is used in the workplace.
Internal ABB document
5S Basics Job Aid
Printed copies are uncontrolled copies. This version is current as of March 31, 2016.
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5S Basics BF-QO 9AKK106849D0101 March 31, 2016 1/10
Table of Contents
1. What is 5S? 2 2. Why 5S? 2 2.1. Safety and 5S. 2 3. How to Apply 5S in Your Workplace 2 3.1. S1- Sort 2 3.2. S2- Straighten (or Set in place) 3 3.3. S3- Shine 4 3.4. S4- Standardize 5 3.5. S5- Sustain 8 3.6. 5S and Kaizen 9
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1. What is 5S?
The 5Ss are English equivalents of five Japanese words that describe the five steps of a workplace organization process. 5S contributes to the 4Q methodology by establishing the operational stability required for making and sustaining continuous improvements.
2. Why 5S?
The primary aim of 5S is to create a safe, clean, orderly environment – an environment where there is a place for everything and everything is in its place. 5S helps minimize the Lean waste of excessive movement. 5S can also help make the workplace safer by removing hazards and reducing ergonomic stress by better placement of tools and workpieces. The 5Ss help you to: − Remove items that are no longer needed (sort). − Organize the items to optimize efficiency and flow (straighten). − Clean the area to more easily identify problems (shine). − Standardizing the workplace arrangement with clear documentation and behaviors (standardize). − Making maintaining and improving the optimal workplace organized over the long term (sustain).
2.1. Safety and 5S. Some organizations have 6S – where the 6th S stands for Safety. In ABB we take Safety very seriously and have organizations, standards and audits to support a safe workplace. While conducting 5S, always have safety as a priority in any actions and in the way you standardize your workplaces. 5S is a good way to focus on ergonomics, as mentioned in the following action steps.
3. How to Apply 5S in Your Workplace To understand how to use 5S for a safe, efficient and clutter-free workplace, review each step of the process.
3.1. S1- Sort
S1Sort
S2Straighten
S3Shine
S4Standardize
S5Sustain
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Sort refers to the practice of going through all the tools, materials, etc. in the work area and keeping only essential items. Everything else is either stored offsite or discarded. This leads to less clutter and fewer potential safety hazards. Action steps for S1: − Inspect all items in your workstation. − Identify items critical to the success of the function performed at the workstation. − Remove items not used, such as outdated materials, broken equipment, redundant equipment, etc. − With each item you sort, think about whether it is essential to your job function or if it is an item used only occasionally. − Red tag all non-essential items as either waste or valuable, but not critical. This improves your understanding about need
and use. Dispose or store red tagged equipment outside of the workstations and inside a dedicated storage area. − For computers, archive or delete files and software applications you no longer need or use.
3.2. S2- Straighten (or Set in place) Straighten refers to the practice of orderly storage to enable easy access to the right items when needed. Frequently needed small items and hand tools should be only a low-stress reach away. We want to create an ergonomic environment where there is a place for everything and everything is in its place. Action steps for S2: − Identify the equipment and tools that are needed in the workstation and organize them. − Assign positions for all equipment, tools, work in process (WIP) and raw materials. − Keep in mind the ease of reach, waste of motion identification, and the proximity to the work surface, which will minimize
ergonomic stress and help maximize the efficiency of your workstation layout. − Think about how you perform your job and how adjusting the location of your equipment and tools, or altering the work flow,
could make you more productive with less ergonomic stress.
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3.3. S3- Shine Shining refers to creating a clean worksite without garbage, dirt and dust to enable easy identification of problems such as leaks, spills, excess or lost material, damage, etc. Cleaning should be a part of your daily tasks and should not be postponed until idle time is available. The time for daily 5S activities needs to be subtracted from the available work time per shift. Action steps for S3: − Clean the floors and walls and create a clean worksite. If the ceiling has truss structures, clean these as well as they collect
dust that can fall on workpieces. Same for overhead cranes. − Keep tools and equipment clean and in top condition, ready for use at any time. − Ensure all items are put back in their designated place established in S2 - Straighten. − Ensure your workstation is well lit so it is easy to work as well as to spot dirt, dust and any lost parts.
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3.4. S4- Standardize Standardize refers to setting up standards for a clean and organized workplace. The standardized state of operations is the result of proper Sort, Straighten, and Shine. Action steps for S4: − Define responsible persons in the different work areas to maintain 5S conditions. − Document the desired state of operations with pictures, short instructions of 5S procedures and target Key Performance
Indicators (KPIs). − Review status of 5S conditions regularly. For example, have it as part of your daily Gemba meeting. − Ensure everyone knows their 5S responsibilities.
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3.5. S5- Sustain Sustain refers to making a habit of properly maintaining the correct procedures and the established standards over the long term. New habits take time and effort to develop and maintain. But don’t freeze the new standard. If work changes or better ways of work are found through continual improvement (4Q), by all means, go back and change the standard.
Action steps for S5: − Everyone participates in 5S, maintains the rules, and makes the new process a habit. − Establish and maintain responsibilities:
− Management - Educate, create teams, lead by example − Supervisors - Learn, lead projects, lead by example − Employees - Learn, develop 5S ideas, educate co-workers
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If you do not have your own 5S audit forms there are many available to download from the Internet.
3.6. 5S and Kaizen Conducting the first full 5 step 5S in a workplace is also an excellent way to introduce Kaizen to a team. For more information on how to do this see: 4Q FAST (point Kaizen)