1st Edition
5S Made Easy A Step-by-Step Guide to Implementing and Sustaining Your 5S Program
For decades, 5S practitioners have struggled with exactly how to implement and sustain a 5S program in their workplaces. While there are many books available on the organization methods suggested by 5S, few provide easy-to-understand, step-by-step guidance on how to set up and sustain successful 5S implementations. 5S Made Easy fills this need.
Written by an expert whose focus for the last decade has been nothing but 5S, the book supplies in-depth guidance on how to implement and sustain each of the 5S pillars—sort, set in order, shine, standardize, and sustain.
The book uses an easy-to-follow format that was designed for use during 5S events. It provides color images of real-world 5S solutions, including before and after pictures from the field. It also supplies readers with online access to all of the forms and documents needed for an effective 5S program. All the forms and documents are provided in an easily editable format to fit any operation.
What Is 5S and Why Do It?
What Is 5S?
Benefits of 5S
Summary of Each of the 5 Pillars
How Is It Implemented?
Action Items
Parking Lot Items
How to Use This Book
Action Items
Parking Lot Items
Notes
Develop Your Plan
Develop Your Plan: Summary of Steps
Action Items
Parking Lot Items
Notes
Train the Team
Tips for Launch Success
Train the Team: Summary of Steps
Action Items
Team Ideas
Parking Lot Items
Sort
Benefits
Materials Needed
Pre-Event Tasks
Red Tag Event Steps
Lessons Learned for Future Red Tag Events
Sort: Summary of Steps
Action Items
Parking Lot Items
Notes
Set in Order and Shine
Summary
Benefits
Materials Needed
Pre-Event Tasks
Set in Order and Shine Steps
Team Ideas
Some Idea Examples
Some Shine Idea Examples
Some Ideas Examples
Set in Order: Summary of Steps
Action Items
Team Ideas
Parking Lot Items
Standardize
Benefits
Materials Needed
Pre-Event Tasks
Standardize Steps
Benefits
Benefits of 5S Audits
Standardize: Summary of Steps
Action Items
Parking Lot Items
Sustain
Summary
Benefits
Materials Needed
Pre-Event Tasks
Sustain Steps
Sustain: Summary of Steps
Action Items
Parking Lot Items
The Ideal Conditions to Implement Lean
Know What Your End Goal Is
Make Sure Leadership Is on Board
Prepare Your People
Do Not Lose Momentum
Action Items
Parking Lot Items
In Closing
5S Launch Guide
Develop Your Plan: Summary of Steps
Train the Team: Summary of Steps
Sort: Summary of Steps
Set in Order: Summary of Steps
Standardize: Summary of Steps
Sustain: Summary of Steps
5S Materials Checklist
Forms
Resources
Training and Education
Supplies
Acknowledgments
Index
Biography
David Visco is an experienced 5S Coach and 5S Event Leader. He has 30 years of operations, warehousing, inventory management, and manufacturing experience in the distribution, medical device, biopharmaceutical, and the electronics industries. Visco has a master’s degree from Babson College in Wellesley, Massachusetts.
In 2006, after implementing 5S with his current employer, Visco had an idea to make 5S easier: one stop shopping for 5S supplies and materials. He and his wife Barbara started the5Sstore.com, where you can get everything you need to implement 5S. Visco offers 5S advice to major corporations as well as small- and medium-sized companies. He also researches and finds visual solutions for applying 5S in difficult situations.
"5S Made Easy is a simple, easy-to-follow guide for 5S in manufacturing. It nicely explains how 5S has a greater purpose than simple housekeeping. It is about standardizing and improving—often overlooked points in a 5S deployment."
—Drew Locher, Change Management Associates; Shingo Prize-Winning Author of Lean Office and Service Simplified and Value Stream Mapping for Lean Development"Hurray to Dave Visco for 5S Made Easy. When I ask customers ‘How much time do you spend each day searching for material, information or tools?’ the typical response is ‘about an hour.’ Regardless of the venue – office, healthcare or factory – the answer is almost always the same. A workplace that is not well organized generates an incredible amount of confusion, frustration, and delay every day! But every so often, I encounter a facility where employees declare proudly, ‘We never search for anything.’ These are workplaces transformed by 5S, where employees and managers make workplace organization a regular part of their work and their continuous improvement. The stability created through an effective 5S process is critical to every other best practice, from set-reduction and TPM to kanban and standardized work. Dave’s book offers a step-by-step primer for any change leader who wants to get this foundational improvement method right the first time.
—Bruce Hamilton, President, GBMP
"5S has become one of the most popular improvement activities in factories, offices, and small shops across America. 5S is straightforward and effective in improving any operation. Despite its popularity, there are only a handful of books that explain how to do 5S. Veteran 5S coach and consultant, David Visco, has stepped in to help fill that gap with his ‘how-to’ workbook, 5S Made Easy. Anyone can begin a 5S program in their department or business by following this book’s easy-to-understand steps. In addition, Visco has provided checklists, forms, and resource guides. Almost everything you need is right here."
—From the Foreword by Mike McCarthy, Lean Consultant and Author of Sustain Your Gains: The People Side of Lean-Six Sigma
