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Lean Manufacturing
Welcome to 5S

5S5S is a system to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results. Implementation of this method "cleans up" and organizes the workplace basically in its existing configuration, and it is typically the first lean method which organizations implement.

The 5S pillars, Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardize (Seiketsu), and Sustain (Shitsuke), provide a methodology for organizing, cleaning, developing, and sustaining a productive work environment. In the daily work of a company, routines that maintain organization and orderliness are essential to a smooth and efficient flow of activities. This lean method encourages workers to improve their working conditions and helps them to learn to reduce waste, unplanned downtime, and in-process inventory.

A typical 5S implementation would result in significant reductions in the square footage of space needed for existing operations. It also would result in the organization of tools and materials into labeled and color coded storage locations, as well as "kits" that contain just what is needed to perform a task. 5S provides the foundation on which other lean methods, such as TPM, cellular manufacturing, just-in-time production, and six sigma can be introduced.

Method and Implementation Approach

5S is a cyclical methodology: sort, set in order, shine, standardize, sustain the cycle. This results in continuous improvement.

The 5S Pillars

Sort. Sort, the first S, focuses on eliminating unnecessary items from the workplace that are not needed for current production operations. An effective visual method to identify these unneeded items is called "red tagging", which involves evaluating the necessity of each item in a work area and dealing with it appropriately. A red tag is placed on all items that are not important for operations or that are not in the proper location or quantity. Once the red tag items are identified, these items are then moved to a central holding area for subsequent disposal, recycling, or reassignment. Organizations often find that sorting enables them to reclaim valuable floor space and eliminate such things as broken tools, scrap, and excess raw material.

Set In Order. Set In Order focuses on creating efficient and effective storage methods to arrange items so that they are easy to use and to label them so that they are easy to find and put away. Set in Order can only be implemented once the first pillar, Sort, has cleared the work area of unneeded items. Strategies for effective Set In Order include painting floors, affixing labels and placards to designate proper storage locations and methods, outlining work areas and locations, and installing modular shelving and cabinets.

Shine. Once the clutter that has been clogging the work areas is eliminated and remaining items are organized, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary to sustain this improvement. Working in a clean environment enables workers to notice malfunctions in equipment such as leaks, vibrations, breakages, and misalignments. These changes, if left unattended, could lead to equipment failure and loss of production. Organizations often establish Shine targets, assignments, methods, and tools before beginning the shine pillar.

Standardize. Once the first three 5S's have been implemented, the next pillar is to standardize the best practices in the work area. Standardize, the method to maintain the first three pillars, creates a consistent approach with which tasks and procedures are done. The three steps in this process are assigning 5S (Sort, Set in Order, Shine) job responsibilities, integrating 5S duties into regular work duties, and checking on the maintenance of 5S. Some of the tools used in standardizing the 5S procedures are: job cycle charts, visual cues (e.g., signs, placards, display scoreboards), scheduling of "five-minute" 5S periods, and check lists. The second part of Standardize is prevention - preventing accumulation of unneeded items, preventing procedures from breaking down, and preventing equipment and materials from getting dirty.

Sustain. Sustain, making a habit of properly maintaining correct procedures, is often the most difficult S to implement and achieve. Changing entrenched behaviors can be difficult, and the tendency is often to return to the status quo and the comfort zone of the "old way" of doing things. Sustain focuses on defining a new status quo and standard of work place organization. Without the Sustain pillar the achievements of the other pillars will not last long. Tools for sustaining 5S include signs and posters, newsletters, pocket manuals, team and management check-ins, performance reviews, and department tours. Organizations typically seek to reinforce 5S messages in multiple formats until it becomes "the way things are done."

Proper discipline keeps the 5S circle in motion.

The Advantages of 5S are:

  • decreased lighting, energy needs when windows are cleaned and equipment is painted light colors
  • spills and leaks noticed quickly
  • decreased potential for accidents and spills with clearly-marked and obstacle-free thoroughfares
  • reduced contamination of products results in fewer product defects (which reduces energy and resource needs; avoids waste)
  • reduced floor space needed for operations and storage; potential decrease in energy needs
  • less unneeded consumption of materials and chemicals when equipment, parts, and materials are organized, easy to find; less need for disposal of expired chemicals
  • visual cues can raise awareness of waste handling/management procedures, workplace hazards, and emergency response procedures
Endorsed Presentation:
5S ChartitNOW Presentation Chartitnow

5S PowerPoint Training Presentation
This professionally-developed presentation is designed as a 40-60 minute overview of the topic. Many customers use the presentation as part of a group learning event, individual training at a computer, or as foundation slides for a more detailed or customized training presentation.

The presentation is delivered in native Microsoft PowerPoint format for easy customization. All slides may be changed to accommodate your desired use. The only restriction is that the presentation cannot be resold without permission of Superfactory.
  • Number of slides: 43
Table of Contents:
  • Introduction
  • Background & History
  • 5S and Lean Manufacturing
  • Sort
  • Straighten
  • Shine
  • Standardize
  • Sustain
  • Safety
  • Visual Factory
  • Implementation
  • Knowledge Check

5S Package

5S efforts almost always improve workplace safety, operator morale, quality, and throughput. The ChartitNOW package contains the following:
  • 5S Comprehensive Instructions (107 pages)
  • 5S Plus Safety Audit Check Sheet Template
  • 5S Operator Checksheet Template
  • 5S Schedule Template
  • 5S Red Tag Template
  • 5S Red Tag Disposition Log Template

The 5S's: Workplace Organization Course Outline -- 2 Units

Unit 1 - 5S's Step-by-Step Lesson 1: What is 5S All About? · An overview of the 5S's is presented. · The benefits and operational impact of implementing the 5S's are discussed. Lesson 2: Sort: Clearing the Work Area · How to organize the work area for efficiency & effectiveness and use the "48-Hour Rule." · A stepwise approach to clear the work area is presented. Lesson 3: Set in Order: Designated Locations · How to designate "a place for everything & ensure everything is in its place." · Considerations for establishing locations for storing items including: storage rational, storage options, location-specific tips, storage don'ts, using signs & labels, & documenting the plan are all covered. Lesson 4: Shine: Cleanliness & Workplace Appearance · The three aspects of Shine (getting the workplace clean, maintaining its appearance, and using preventive measures to keep it clean) are explored. Lesson 5: Standardize: Everyone Doing Things the Same Way · The three aspects of Shine (getting the workplace clean, maintaining its appearance, and using preventive measures to keep it clean) are explored. Lesson 6: Sustain: Ingrain It in the Culture · Sustain is perhaps the toughest of the 5S's. Techniques to prevent backsliding are presented. Challenge: An assessment of the learner's progress in this unit.

Unit 2 - 5S Implementation Lesson 1: An Organization-Wide 5S Effort · How to plan and implement a 5S initiative. · An 8-point roadmap for the 5S's: 1: Leadership Team; 2: Infrastructure, 3: Communications; 4: Training; 5: 5S Pilots; 6: Best Practices; 7: Full Roll-Out Plan; 8: Evaluate & Adjust. Lesson 2: Tackling 5S's on Your Own · How to implement the 5S's in a work area if an organization-wide initiative is not supported. Lesson 3: Success Stories: Sorts · Examples of "Sort Successes" showing both the before state and the after state with the impact (savings) explained. · Checklist to help achieve successful Sorts. Lesson 4: Success Stories: Set in Order · Examples of "Set in Order Successes" showing both the before state and the after state complete with the impact on the organization. · Set in Order Checklists. Lesson 5: Success Stories: Shine, Standardize, & Sustain · Examples of successful approaches for the Shine, Standardize, & Sustain phases of a 5S program. Challenge: An assessment of the learner's progress in this unit.

Introduction to the 5S's

Explore each of the 5S's, learning techniques to organize your work area and overview an 8-point roadmap to launch a 5S effort. Time: 1.7 hours.

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