9.09.

2017

5S
5S means orderliness, cleanliness and discipline, in
short terms.
It is the starting point to improve the production
system performance.
Behind workplace successes and failures are the 5Ss.

Prepared by Dr. Sule Itir Satoglu 1 Prepared by Dr. Sule Itir Satoglu 2

Things to be Eliminated Things to be Eliminated

Dirt in a plant includes; Tables are in a mess!
Defective parts inventory Tools just thrown or forgotten around the shopfloor.
Unnecessary tools and equipment
Shelves with tools unclassified!
Oil on the ground
Unneeded carts, equipment, tables
Inventory that time forgot!
Dirt in an office includes;
Unneeded reports, documents
5S is washing out these dirt.

Prepared by Dr. Sule Itir Satoglu 3 Prepared by Dr. Sule Itir Satoglu 4

Benefits of 5S
Why Need 5S?
(Hirano,
As taking shower, brushing teeth are daily routines,
1995)
workplace also need routine cleaning!
People look for tools, carts at the factory.
Office people look for files, staplers, documents etc.?
Time lost because these are not in order!
(Hirano, 1995).

Prepared by Dr. Sule Itir Satoglu 5 Prepared by Dr. Sule Itir Satoglu 6

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Benefits of 5S
Product Diversification
Setup time is reduced as time spent for looking for dies,
tools and equipment decreased. Everything is well
organized and in order.
Lower setup times enhances product diversification.
Many types of products in small quantities produced.
(Hirano, 1995)
Prepared by Dr. Sule Itir Satoglu
Benefits of 5S
Zero waste brings lower costs
Eliminated or reduced wastes of
motion (searching etc)
Space occupied due to unordered tools, equipment
Non-value added actions (counting)
Unneeded storage places
Excess inventory and warehouse expenses
Prepared by Dr. Sule Itir Satoglu
Benefits through 5S
Zero injuries promote safety
Injuries expected when
stocks are piled up,
machines/equipments are covered with oil,
items are left into walkways.
Lack of outlined storage areas
Collisions when forklifts turn corner without warning
High inventories fall over unexpectedly etc.
Prepared by Dr. Sule Itir Satoglu
9.09.2017
Benefits of 5S
Higher Quality
Defects harder to notice in an unordered workplace.
Clean and orderly equipment: fewer defects
Makes workers more conscious.
Less tool selection errors and fewer defects.
Feelings of pride will be used for motivation due to high
quality.
7 Prepared by Dr. Sule Itir Satoglu 8
Benefits through 5S
Zero delays bring reliable deliveries
When errors and defects are eliminated, order can go
out on time.
Conveying products after elimination of unnecessary
materials will be easier.
Work is more efficient in waste-free environments.
Absenteeism is lower at 5S shops.
9 Prepared by Dr. Sule Itir Satoglu 10
Benefits through 5S
Zero injuries promote safety
Safety first is a good concept!
Place things in a safe manner.
Maintain well defined places to put things, uncluttered
aisles etc.
Discover mechanical failures and hazards right away, when
machines in good, clean condition.
Clearly mark emergency exits, put warning signs for
hazardous substances & dangers.
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Benefits through 5S 5Ss

Zero breakdowns bring better maintenance Seiri (Organization)
Trash, dirt and dust shortens equipment life. Seiton (Orderliness)
Easier to observe machines while running when they are Seiso (Cleanliness)
clean.
Seiketsu (Standardized Cleanup)
Maintain and check equiment daily.
Shitsuke (Discipline)

Prepared by Dr. Sule Itir Satoglu 13 Prepared by Dr. Sule Itir Satoglu 14

Steps of 5S
1. Organize:
Distinguish (sort) between what is needed and and
what is unneeded (Hirano, 1995).
Involves evaluating the necessity of each item.
Discard the items unneeded.
Unneeded items occupy space and increase the risk of
error.

Prepared by Dr. Sule Itir Satoglu 15 Prepared by Dr. Sule Itir Satoglu 16

Steps of 5S: Organize- Red Tagging

Steps of 5S
1. Organize:
Use visual methods such as red tagging.
It can help gain additional space and eliminate broken
tools and excess material - inventory.

Picture source: www.strategosinc.com/5s_elements.htm

www.gemba.com
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Example (Monden, 1993)

Steps of 5S
2. Orderliness
Organizing required items so that they can
be found and used easily whenever
needed.
It determines location of each item.
No time spent to look for items.

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Example (Hirano, 1995)

Prepared by Dr. Sule Itir Satoglu
Orderliness in the Factory (Hirano, 1995)
Category Orderliness Target
Spaces Floors, walkways,
operation areas, walls,
shelves, warehouses
Products Raw materials, parts for
machining, in-process
inventory, assembly
parts, finished products
Equipment Machines, equipment,
tools, dies, carts,
conveyance tools, work
21 tables, cabinets, chairs. 22
Prepared by Dr. Sule Itir Satoglu

Orderliness: Determine Locations Orderliness: Color Coding

Workers simply look at A visual technique to match the items
each item
more easily.
Estimate the frequency
of use The two items with the same color are
Then select a location. matched.
After a few days, they Probability of mismatch is reduced!
can review and revise
their locations.
www.strategosinc.com/
5s_elements.htm

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Ordrliness: Determine Locations Orderliness: Determine Locations

A typical
workstation
www.strategosi
nc.com/5s_elem
ents.htm

www.dugganinc.com
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Orderliness Orderliness: Painting Strategy

By painting, boundaries for the location and space for
each item identified
They encourage recoil, that is the proper return of an
item, as shown below.
They also tend to prevent people from placing other
(wrong) items in a designated space.

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Orderliness: Painting Strategy

Orderliness: Painting Strategy

www.strategosinc.com/5s_elements.htm

(Hirano, 1995)
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Orderliness: Painting Strategy

Orderliness: Painting Strategy

(Hirano, 1995)
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www.dugganinc.com
Prepared by Dr. Sule Itir Satoglu 32

Orderliness: Painting Strategy

Prepared by Dr. Sule Itir Satoglu www.dugganinc.com 33 Prepared by Dr. Sule Itir Satoglu 34

Steps of 5S Steps of 5S
3. Cleanliness:
4. Standardized Cleanup
Sweeping the floor
The three activities explained above will become a
Cleaning the tools and
routine and continue.
equipment .
The shopfloor will be kept clean by these activities.
No dust, oil, water and rust.
Standardize normal work acitivities
Eliminating sources of dirt.
Develop work instructions.

www.strategosinc.co
m/5s_elements.htm

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Steps of 5S Steps of 5S
4. Standardized Cleanup 5. Discipline
Develop schedules: which acitivites are to be done The decisive attitude to maintain (keep) the
weekly, daily, continuously. shopfloor cleanliness and orderliness conditions.
machine clean,inspection daily The hardest step is sustaining 5S activities.
tool check, inventory check daily So that they are institutionalized.
degrease work area weekly.
red tagging continuously.

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Eight Tools to Sustain 5S

www.strategosinc.com/5s_elements.htm www.gembapantarei.com
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Example (Monden, 1993)

Before 5S

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After 5S
Before 5S

Kaynak: Wyeth Pharmaceuticals Kaynak: Wyeth Pharmaceuticals

After 5S Before 5S

Kaynak: Wyeth Pharmaceuticals Kaynak: Wyeth Pharmaceuticals

After 5S Before 5S

Kaynak: Wyeth Pharmaceuticals Kaynak: The Lean Enterprise

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After 5S Before 5S

Kaynak: The Lean Kaynak: The Lean

Enterprise Enterprise

After 5S

Messy workstation Ordered Workstation

Kaynak: The Lean

Enterprise

Drawer manuf. Table (Before 5S)

5S for the Office Environments
Step 1: Organize Sort
Messy Office: Transform the cluttered and disorganized
office into an efficient workstation!
First sort needed and unneeded items.
Red tag unneeded big items, eg: furnitures, broken
monitors, PCs, etc.
Dispose unneeded office supplies, papers, reports etc.

Drawer manuf. Table (After 5S)

Source: http://www.lean.state.mn.us/photos.htm

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5S for the Office Environments 5S for the Office Environments

Step-3: Clean
Step-2: Set in order (orderliness)
Clean office vs. Cluttered Office: compare!
Organized drawer
Point of use
Office supply station

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Source: Prepared
http://www.lean.state.mn.us/photos.htm
by Dr. Sule Itir Satoglu 56

5S for the Office Environments

Step-4: Standardize
Labeled cabinets: Labels tell exactly what is inside.
Color coded files: Visual system for placing files quickly
Before into the cabinet.
Map of files: Anyone can easily find files.

After
Source: www.sigmacenter.com.tr
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5S for the Office Environments Office 5S Video

Step-5: Sustain (Discipline) Cluttered Cubicles Go Lean With 5S Rules
Commitment required to sustain 5S conditions, in the http://www.youtube.com/watch?v=AUaJ9roHj2s
office.
Maintain established procedures.
5S Circle

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Characteristics of a Visual
Workplace
clearly communicates needed
information
clearly reflects established standards
clearly identifies behavior or process
targets
clearly is low cost and easy to use
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Visual Management :Andon
Andon refers to a signal used to call for help
when an abnormal condition is recognized.
The most common andon lights are used to
request assistance on an assembly line.
Opels new production facility in Rsselsheim
for the new Vectra autos.
Andon systems installed at every station to help
prevent defective parts being produced, or
passed on down the line.
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9.09.2017
Visual Workplace
Distinguishing value versus waste &
communicating process outcomes are all
important elements of visual
management.
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Visual Management Scoreboard
A simple scoreboard provides the foundation for visual
management. Process metrics, descriptions, historical
data, improvement communicated!
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Visual Management :Andon
Two cords are positioned at each work station .
If an employee pulls the yellow cord, a light and an
acoustic signal are triggered, requesting help from
other members of the team.
Pulling the red cord stops the assembly line until the
problem has been solved.
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Visual Control
http://www.youtube.com/watch?v=7TBSr8LHm1I

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Easy access to the Alarm Button for 5S in Offices & Working by Standing
Assembly by using
white gloves tools Problems Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs

5S in Meeting Rooms
Kaynak:
http://www.youtube.com/watch?v=nHutkkfUpDs Kaynak:
http://www.youtube.com/watch?v=nHutkkfUpDs

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Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs Kaynak:

http://www.youtube.com/watch?v=nHutkkfUpDs

Poka Yoke

Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs Prepared by Dr. Sule Itir Satoglu 76

Poka Yoke Poka Yoke

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