RAYAN ADVANCED
INDUSTRIAL COMPANY
IMPLEMENTING 5S METHODOLOGY TRAINING
PREPARED BY :MUNTHER SHARAB
AGENDA
• WHAT IS 5S
• OBJECTIVE OF 5S
• WHAT ARE THE BENEFITS OF A 5S SYSTEM
• THE FIVE PRACTICES OF 5S
• REQUIREMENT OF SUCCESS
WHAT IS 5S
• 5S is one of lean manufacturing tools
• 5S is a Japanese methodology for organizing and improving work
environments.
• The 5S methodology is a system for improving productivity and
efficiency in the workplace. If you follow the best 5s practices, including
5S implementation in office environments or within a manufacturing
process, you can quickly improve productivity, employee and
engagement.
• In fact, we are all aware of these concepts from our grandfathers that had
tools lined up perfectly in the shed using Shadow Boards, through to
proper cleaning procedures for critical equipment across various sectors.
The continuous improvement plan 5s, can unlock incremental
improvements and build the discipline needed with the culture to always
strive to improve.
BENEFITS OF A 5S SYSTEM :
• WHEN YOU DON’T DO 5S
i. Waste Time
ii. Waste space
iii. Waste money
iv. Poor Quality
v. Compromise the equipment
vi. Unsafe Work environment Safety
vii. Hide propblems
WHEN WE DO 5S :
i. Waste Time Save Time
ii. Waste space Conserve Space
iii. Waste money Increase profits
iv. Poor Quality Improve Quality
v. Compromise the equipment Preserve equipment
vi. Unsafe Work environment Safety Promote Safety
vii. Hide problems Reveal Problems
THE FIVE
PRACTICES OF
5S :
S1-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.
SOME EXAMPLES OF SORT
• Remove waste 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.
S2- SET IN ORDER :
• is the second step in the 5S methodology.
It relates to orderliness, sequence, and
placement of objects in a logical position.
• proper arrangement, All materials,
including equipment, tools and supplies,
and as well as all work-related objects
should be placed at optimal locations for
ease of access by workers in a production
environment.
S3- 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.
• 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
HOW DO YOU IMPLEMENT SHINE?
1. 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.
2. 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.
3. 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.
NOTE : One of the most important benefits of Shine is catching problems early and
preventing unexpected breakdowns.
S4-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.
• Standardize makes 5S repeatable. It
transforms 5S from a one-off project to a
reproducible set of activities
HOW DO YOU IMPLEMENT STANDARDIZE ?
1. Make sure each employee know their responsibilities
2. Make it a part of their daily routine
3. Evaluate periodically
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.
5S – SUSTAIN
• The Sustain step ensures that 5S is applied
on an ongoing basis. It transforms your
standardized 5S processes into regularly
completed tasks.
• Iterative 5S processes lock in your gains
and ensure further and continued progress
HOW DO YOU IMPLEMENT SUSTAIN?
• Create a schedule. Ensure 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.
NOTE : Continuous improvement is driven by continuous feedback. Solicit ideas to
improve your 5S processes and approach each suggestion with genuine curiosity and
a desire to learn.
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.
REQUIREMENT FOR SUCCESS
1. You have got to create discipline and daily participation
2. It has to be daily habit !
END OF TRAINING
THANKS !
