For a complimentary copy please click here>> “The Very Best of 5S” Benchmarking report

Let’s start off with the Executive Summary

This manuscript is an in-depth report on 5S Workplace Organization and Standardization. It sheds light on how organizations have successfully created a 5S system or the obstacles and solutions they used to overcome them. Of those surveyed, the overall rank of the effectiveness of their 5S system is a 3 on a scale of 1-5 (1=low, 5=high). This is a clear indication that there is much room for improvement. There are many suggestions and comments presented here to help coach and guide organizations as they improve their 5S systems. The level of cooperation for 5S initiatives is initially low but increases with time with the most resistance coming from the supervisor level. Contrary to this is that upper management is generally supportive of a 5S system, but the top reasons for obstacles for implementation are “lack of management support” and “not enough time.” Another finding is that the amount of training spent on 5S training is relatively low (typically two hours or less). It seems that organizations have a hard time quantifying benefits from 5S (other than 5S Audits). Companies that did calculate the financial benefits proved that the return on investment far exceeds the cost of training, supplies and manpower. The lack of reward & recognition and the ability to engrain 5S into the organization’s culture is another impediment that must be overcome. Over 50 “best practices” are shared and many suggestions on how to properly create a 5S system or improve your current one are included.

So check out the report, share it with your colleagues and friends, have discussions and give us feedback on what you see. – Tony

When it comes to documentation, information and inspections I have found that using display stands is a tremendous help with tons of benefits.

For example, let’s just say that one employee spends ten minutes a day searching for paperwork (we all know this is probably on the low side). At ten minutes a day, five days a week and 50 weeks a year that adds up to 2,500 minutes or 41 hours and 40 minutes. Is it worth a week’s pay in a year’s time just to have an employee searching for the correct document? Of course not. Now multiply that times the number of people that use that paperwork. The cost could be staggering.

Now here’s is a simple solution – display stands. 5S Supply carries eight different styles of documentation, information and inspections stands in a variety of sizes to fit most everyone’s needs.

• Kaizen Event Stand – perfect for holding information related to your kaizen event. Comes with Kaizen Planning Charts and has wheels to make it mobile from one kaizen event to another.
• Document Stand – Six models and16 styles to choose from. Wall mount, bench munt, wheels – we have it all covered. From small paperwork to large and from basic models to deluxe.
• Information Stand – These models have a deep 4” 3-ring binder on top and an angled writing surface.
• Inspection Stand – Need the ability to move your inspections stands to where you need them? This is your answer. Four different models to choose from.
• Blueprint Display Stand – Finding it difficult to have a convenient place to put your blueprints or other large documents that’s not in your way? Our Blueprint Stands go from Basic to Deluxe and have wheels to get them where you need them.
• Message Board – Not only a great document stand, but this model includes an 18” x 24” dry erase message board so that you can keep the communication flowing.
• Catalog Display Stand – need a lot of room for binders? This stand can hold up to 12 one inch binders for convenient access. No binders disappearing form the work area.
• Mobile Parts Caddy – Need an easy way to move light parts from one area to another? Consider this Mobile Parts Caddy.

The return on investment for these stands is great. Reducing the amount of time searching for documentation, not having to search for documents to get them updated, making sure the correct revision is available at point-of-use are all benefits of using these stands. From the example above, you would probably recoup your investment in less than a year with just one employee and definitely a shorter period of time if you have more than one employee using these stands.

There a many ways to make sure the information you need is visual, convenient and at point-of-use; these stands are the perfect solution. For more information, please visit us at www.5Ssupply.com.

Fast forward six months – this time we were going to do a quick 5S training event in a production area. The operations director was doing the training (his first time and he did a great job!) and he had the team go look at the office areas that we did six months earlier because they were close to the training room. I tagged along and couldn’t believe my eyes. The areas were not just as good as six months ago they were even better!

Before Visuals

End of Kaizen Event

Six months after

I asked a couple of the office workers how they did it. This is what they said:

• “There are about only six people that use this area so it’s easy to keep an eye on it.”
• “Once we got it organized and labeled, it just maintains itself.”
• “You just make sure you don’t leave anything in the area.”
• “It’s easier because we know where everything is and where it belongs.”
• “We hold each other accountable if anything is out of place.”

One of the customer service reps mentioned that she needed to laminate something and she never used the laminator before. She said it was simple and easy because they posted a “One-Point Lesson” right on the wall by the laminator.

There was some resistance when we first did the labeling – “Everyone knows what that is.” But now, it is self-evident when things are in their right place or not. This has helped tremendously to sustaining and improving the gains achieved!

So see, there may be hope for your 5S system after all!

Recently I had an epiphany while working on a kaizen event in an area to help introduce 5S. For this group we needed to mention that 5S is not just about cleaning; we wanted to emphasize that 5S is about unleashing teamwork and discipline. Of course, when I say “discipline” I’m not referring to the mean or evil type of discipline like punishment. People may take the wrong connotation with the word ‘discipline’. So let’s ‘shine’ it up (pun intended). I am talking about the discipline we have to put something back in its correct location after we use it. If we can’t instill the discipline of following simple standards for 5S, then how can we master more complex systems like kanban or total productive maintenance?

Then it dawned on me, maybe I should look up other words for discipline. So here’s a list I compiled that may be helpful when trying to describe the traits we are trying to instill with 5S.

Since the concepts of 5S are easy, but getting people to follow the system may be hard try using some of these synonyms for discipline to effectively communicate what we are trying to accomplish with 5S.

If you need help with your 5S System, visit us at www.5Ssupply.com.

Brady BMP21- If you need labels from 3/8” to 3/4” then this is your answer

Brady BMP21 Label Maker

Simple to operate and quick to print, the BMP™21 label printer is the economical, must-have labeling tool for Lean. With this hand-held thermal transfer printer, you can create your labels just once – knowing they’ll stay stuck and stay legible for years ahead.

Perfect for creating a visual workplace – Lean & 5S Labeling, Healthcare Identification, Facility, Safety & Maintenance Identification, General & Industrial Labeling, Barcode Labeling, Circuit Board Labeling, Data Communications Labeling, Panel Identification, Wire & Cable Marking and more.

BMP21 price: $145.95

Printer Accessories:

• AC Adapter for BMP21 Printer
• Hard Carrying Case for BMP21 Printer
• Magnet Only Accessory
• Multi-Functional Tool

Label types (3/8”, 1/2”, and 3/4”):

• Indoor/Outdoor Vinyl Film
• Self-Laminating Vinyl
• Permasleeve Wire Marker Sleeves
• Nylon Cloth Labels
• Polyester Labels

Cobra VnM2- This thermal printer can create labels from 1” to 4”

Cobra VnM2 Label Maker

The VnM Label and Sign Maker is your ideal solution for all your labeling needs. The VnM2 can print any label you want from 6 standard templates. The VnM SignMaker is the most mobile industrial labeling solution available. The VnM2 works with the VnM keyboard so no PC connection is needed. Save time and money by printing custom labels on demand at a fraction the cost.

VnM2 price: $1,295.00

Options:

• Battery pack
• Travel Case
• Cleaning kit
• External roll holder
• Ink rolls
• Several media types, sizes and colors to choose from: vinyl, reflective, fluorescent, glow-in-the-dark, and magnetic

Mobile In-house Sign Shop- Make any sign you want, any size and any color

Mobile In-house Sign Shop

This is your answer for creating a Visual Workplace!  This Mobile In-house Sign Shop (MIHSS) has everything you need to make professional looking signs, labels and more at point-of-use to reduce waste in your workplace and create visual standards for everything!

MIHSS price: $3,595.00

The MIHSS system consists of:

• Heavy-duty 5S Crash Cart
• Laptop computer pre-loaded with Gemini CP sign making software
• Hundreds of editable sign templates and thousands of clipart
• Vinyl cutting plotter
• Sign making tools
• Supplies to make 64 signs
• Also included is free, unlimited technical support and training to get you up and running immediately

Make your workplace a visual workplace with these systems!

I would also like to thank the many people and groups that helped us develop and communicate the survey including:

• Chris Abrey, Northstar Aerospace
• John Calabrese, Arizona MEP
• Gwendolyn Galsworth, QMI:Visual-Lean Institute
• Lela Glikes, GBMP
• Jim Godfrey, Arizona MEP
• Bob Hatfield, S&C Electric
• Carla Konzel, Saint Vincent Health System
• Rhonda Kovera, Visual Workplace, Inc.
• Karen Martin, Karen Martin & Associates
• Tim McMahon,  A Lean Journey
• Mark Sattler, ProMedica Laboratories
• Bonnie Rashleigh, ProMedica Laboratories
• Beth Reid, Northrop-Grumman
• Dave Visco, The 5S Store

Without the help of these people and their organizations, we would have never been able to make this 5S Benchmarking Survey a success.

If you didn’t get a chance to participate this time, stay tuned because we may do this again in the future!

- Tony

Our versatile Mobile Tool Works makes it easy to find, use and put away tools when and where needed. This accessible unit goes where you go and will enhance maintenance, production, 5S, operations and aid in overall standardization. Unlike toolboxes or chests, you will always be able to visually locate what you need quickly and have full access to it at all times. This fully visible cart promotes proper tool accountability and usage among shifts. Efficiently store, manage and organize equipment and small parts without clutter. Plenty of secure, flexible and convenient options for storing your tools and gear including the front, sides and even the back if you need to. Casters allow cart for maneuverability over most surfaces. Made of 14 gauge steel, this can stand up to most any environment and is finished with a red color powder coat.

Dimensions: 41 5/4″ W x 31″ D x 67 1/2″ H

Includes: 16” D open shelf

Price: $649

Some assembly required

Phone Orders ONLY – Please call us toll-free at 888 4 LEAN 5S (888-453-2657) to place your order. Freight shipping only

Each set comes with two 36” x 18” boards and mounting hardware. We have 12 different styles of hooks and accessories so you can customize your workspace and have your important tools at point-of-use.

Hooks and Accessories

• Stainless Steel Shelf 18″ L x 6 1/2″ W
• 1″ Stainless Steel Single Rod 30⁰ Bend 3-Pack
• 3″ Stainless Steel Single Rod 30⁰ Bend 3-Pack
• 6″ Stainless Steel Single Rod 90⁰ Bend 3-Pack
• 4″ Stainless Steel Double Rod with 90⁰ Bend 3-Pack
• Stainless Steel Extended Spring Clip 3/4″-1-1/4″ 3-Pack
• Stainless Steel Extended Spring Clip 1″-2-1/4″ 3-Pack
• Stainless Steel Extended Spring Clip 1/2″ to 3/4″ 3-Pack
• Stainless Steel Curved Hook 2-1/4″ I.D. 3-Pack
• Stainless Steel Multi-Prong Tool Holder 8-1/2″L QTY 1
• Stainless Steel Multi-Ring Tool Holder 8-1/2″ L QTY 1
• Stainless Steel LocBoard BinClip3/8″ to Mount Bins QTY 1

Need help configuring your stainless steel or work area solution? Give us a call 888 4 LEAN 5S or email info@5Ssupply.com.

To kick off the summer, we are offering them at an introductory price of $12 (regularly $15, save 20%!). Proudly display your 5S pride and get yours today!

Features:

• Short sleeve
• Navy blue with 5S logo
• Pre-shrunk
• 100% cotton

"Old" location

I had a lot of fun working with a great team performing a 5S in a manufacturing area last week. This was the company’s first official 5S event so we treated it as a “learn-do” occasion. We did all the usual things associated with 5S – red tagging, setting items in order, cleaning & inspection, creating standards, etc. But, my favorite part was the team working on tool shadow boards (as part of “Set-in-order”).

Some of the team members that have been part of companies that have applied 5S before came up to me to let me know that their tool shadow boards don’t work. In fact, they even went as far as to say that they have never seen tool shadow boards work effectively.

Of course, I had to ask why tools shadow boards don’t work and the reply was “Because people don’t put the tools back!” I wanted to use the 5 Whys technique (asking why five times) to help to get to the root cause of the situation. Because of the amount of resistance I felt was underlying the situation I decided to take another approach. As a good lean student should I performed genchi genbutsu (actual place, actual thing or go see and get facts).

Here is what I first discovered – yes, indeed the tools where not put back on the tool shadow board. Many of the tools were missing. Next, I saw that the tool shadow board was located on the side operator’s desk. At first this may seem to be a good location for the operator, but it also had a garbage can directly in front of it. The tools had lines traced around the outside but were not labeled as to what goes where. As you can see from this picture that 5S has not been applied to this area.

Sorting Tools

As part of “Sort” we went through and Red Tagged items that weren’t needed in the immediate work area. We found many tools in different locations. A couple of team members went through all the tools that were gathered up to see what they needed and did not need, and what was missing. The amazing thing was that the team found over 50 tools lying around the production area, yet they still didn’t have everything they needed!

A couple of the operators got together to decide which tools they actually needed. At this point I asked questions of why their tool shadow board wasn’t working before in the past. To my

"New" location at point-of-use

surprise they decided to create a new tool shadow board, but this time it was smaller, had only the exact tools they needed, they mounted at point-of-use, they used Tool Tracer Vinyl to outline the tools and labeled each of the tools.

Two of the operators that told me that tool shadow boards never worked before told me that this time they think they have a chance. I asked why and the two reasons they gave me were 1) that locating it at point-of-use would make it much easier for the operator to put it back and 2) now they have a standard that all operators can follow.

One more observation of improvement – the team mounted the board inside a clear Plexiglas covering on one of the machines. This seemed to be a great point-of-use location. When they came in the next morning, they noticed the board was taken down. They asked the operator running the line that day why he took it down; he said he couldn’t see the machine running when he was standing by the computer. Instead of the team getting frustrated that he didn;t like the board where it was originally located, they brainstormed other locations where it wouldn’t be in the way and conferred with the operator to make sure the new location was o.k. Now that’s continuous improvement.

So here are ten quick questions you can use as a checklist of things to think about when making a tool shadow board:

1. Does it have the right tools on it?

2. Are there extra tools on the board that are not needed or used (remove these)?

3. Is the board conveniently located so that people can easily get the tool they want and put it back when they are done?

4. Do all the tools have shadows around them?

5. Are all tools labeled?

6. Did you consider using color-coding to identify tools?

7. Did you create a Standard for the tool shadow board?

8. Did you use immediate correction if a tool is not put back when it is supposed to?

9. Do you use daily audits to make sure all tools are put back?

10. Are all people in the area trained on the proper use of the toolshadow board?

As the “Check” part of Plan-Do-Check-Act (PDCA) I’ll follow up in a couple of weeks to see if the tools are still there.