5S Concept

DESIGN

SORT SET IN ORDER SHINE STANDARDIZE SYSTEMATIZE

Keep only Arrange items to Clean the work area Set standards for a Maintain and
necessary items in promote efficient so that it is neat consistently organized review standards
and tidy
the workplace workflow workplace

DESIGN EXAMPLES

Sort  Obsolete / expired procedures
 Damaged / expired inventory
PRINCIPLES  Outdated / old equipment
…
 Review tools, parts and
instructions

 Keep only necessary items
in the workplace

 Eliminate anything that
is non-essential

…

DESIGN EXAMPLES

Set in Order  Excess movement
 Excess transportation
PRINCIPLES  Over processing
 Over production
 Arrange items in logical order  Excess inventory
to promote efficient work flow  Excess delays
 Defects
 Indicate places for each item …
clearly

 Keep each item close to where
it will be used

 Clear marking with terms
and colors

…

DESIGN EXAMPLES

Shine  Dirty tools and equipment
 Spills and leaks
PRINCIPLES  Clutter and mess
…
 Make cleaning part of
daily work

 Assign areas of responsibility
 Return all items or files to their

assigned place
 Basic cleaning of work station,

tools and machines
 Eliminate sources of impurities

and contamination
…

DESIGN EXAMPLES

Standardize  Work instructions
 Hazard warnings
PRINZIPALS  Equipment / tool labels
 Process diagrams
 Create standards for “Sort”, …
“Set in Order” and “Shine” for a
consistently organized workplace

 Make standards easy to
understand with Visual Controls

 Assign and educate on individual
responsibilities

 Plans for cleaning, maintenance
and work procedures

…

DESIGN EXAMPLES

Systematize  Emphasize cooperation
 Communicate clearly
PRINCIPLES  Support innovation and

 Maintain and review standards new ideas
 Measure and monitor process …
 Address root causes and avoid

reversion to the “old ways”
 Promote individual feedback

and response for improvements
 With daily practice 5S

becomes routine
 Consequent compliance

with the first four “S”
 Encourage feedback and

proposals for improvement

DESIGN

1 2
4
SUSTAIN

5

3

DESIGN

DESIGN SHINE SYSTEMATIZE
3 4
Gear Wheel Diagram
5
SORT

2
1

SET IN ORDER STANDARDIZE

DESIGN

Stairway Chart

STANDARDIZE SUSTAIN

Visualization of Maintain with
new standards self-discipline

SET IN ORDER SHINE

Put items in Initial cleaning of
logical order the work place

SORT

Sort out
unneeded items

IMPLEMENTATION PLANS Sort Set in Order

Pentagram to Visualize 35
the Average Number of Points 30
25
Self Discipline 20
15
10

5
0

Standardization Shine

IMPLEMENTATION PLANS

Implementation Plan for One Work Area

LEVEL SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN
Original State
0 Points     
Rudimental Implementation   
1 Point    
Visible Implementation   
2 Points    
Good Implementation   
3 Points 
Perfect Implementation
4 Points 
Points per Phase

Maximum possible points: 20
Current points:

IMPLEMENTATION PLANS Section:
Date:
Implementation Plan for One Phase in One Work Area Examiner:

“S“ Examined Area Explanation Points
Notes
Working materials and items Is there any idle working, cleaning
Machines and equipment or measuring material? 0 1 2 345
Tools and spare parts X
Papers and documents Are there any unused or defect
Work place machines or production facilities? X

SEIRI (Sort) Are there any unneeded tools X Exp.: Papers are from last year and
or spare parts? X must be revised urgently

Are there any unessential or obsolete X
papers, information or documents?
14
Are there personal things at the work
place? (e.g. lunch box, thermos jug,
magazines, radios etc.

Total points (phase 1)

Average points (Exp.) 2,8 Target: 5,0

0 Points = worst implementation, 5 Points = best implementation – Repeat inspection for all 5S phases and figure out total points!

AREA VERY POOR QUITE POOR DATE OF INSPECTION GOOD EXCELLENT
SORT SATISFYING
1. Action: … 1 2 4 5
2. Action: … 1 2 3 4 5
3. Action: … 1 2 3 4 5
4. Action: … 1 2 3 4 5
5. Action: … 1 2 3 4 5
3
SET IN ORDER TOTAL SORT:
1. Action: … 3
2. Action: … 12 3 4 5
3. Action: … 12 3 4 5
4. Action: … 12 3 4 5
5. Action: … 12 3 4 5
12 4 5
SHINE 3
1. Action: … 3 TOTAL SET IN ORDER:
2. Action: … 3
3. Action: … 12 3 4 5
4. Action: … 12 3 4 5
5. Action: … 12 4 5
12 3 4 5
STANDARDIZE 12 3 4 5
1. Action: … 3
2. Action: … 3 TOTAL SHINE:
3. Action: … 3
4. Action: … 12 4 5
5. Action: … 12 3 4 5
12 3 4 5
SUSTAIN 12 3 4 5
1. Action: … 12 3 4 5
2. Action: … 3
3. Action: … TOTAL STANDARDIZE:
4. Action: …
5. Action: … 12 4 5
12 4 5
TOTAL RESULT OF ALL 5 CATEGORIES: 12 4 5
100-125 POINTS: WELL IMPLEMENTED 12 4 5
12 4 5

TOTAL SUSTAIN:

75-99 POINTS: IMPROVABLE < 75 POINTS: BADLY IMPLEMENTED