Guide-5S IMPLEMENTAÇÃO DA METODOLOGIA.docx

5S Guide
Learn how a simple organizational strategy can transform
your business

5S
www.creativesafetysupply.com/guides | 1-866-777-
Introduction
If your company is like most organizations, you’re searching for a competitive
edge. Something that will reduce costs, increase sales, and make you more
agile in a changing business environment.
You’ve found it.
Simply put, 5S is a systematic approach to workplace organization.
But it’s also much more than that. 5S is about efficiency, competitiveness, and
survival. It is a deceptively simple system that creates an organized and
productive workplace.
It’s not just about cleaning up and eliminating toolboxes. 5S creates a
workplace environment that can adapt and succeed.
Chaos and unproductivity are your enemies; organization and efficiency are your
allies. If implemented correctly and followed diligently, 5S will lead to:
• Lower costs
• Better quality
• Improved safety
• Increased productivity
• Higher employee satisfaction
From the offices of upper management to the workstations in the factory, the
power of this system will quickly reveal itself in your bottom line.

5S
The Five Pillars
Originally developed by Hiroyuki Hirano for manufacturing companies in
Japan, the principles of 5S translate well to the laboratory, the repair facility,
and even the corporate office. Almost any work environment will benefit from
the structure and efficiency this model provides.
5S is sometimes called the five pillars because just like the physical pillars that
hold up a structure, 5S has five elements that support the effectiveness of the
system.
And just like the pillars of a building, if one was to weaken or fail, the entire
structure would fall.
The five steps/pillars of 5S are:
1 Sort 4 Standardize
2 Set in Order 5 Sustain
3 Shine

5S www.creativesafetysupply.com/guides | 1-866-777-
Sort
Sort is the process of
removing all the items not
needed for current production
from the workspace.
Original Japanese word:
Seiri
5S begins with the Sort step. Sort is the cornerstone of 5S and will help
get rid of problems such as:
• Tools and materials impeding workflow
• Wasted time looking for parts, tools, and products
• Stockpiling unnecessary and expensive inventory
• Safety hazards resulting from clutter
The goal of Sort is to eliminate all the unneeded tools and materials and
create a space free of clutter. This allows for a workflow free from
distraction.
A good rule of thumb is: “If you do not use it on a daily basis, throw it out.”
Leave only the things you absolutely need to get your job done. This
includes tools, materials, and machinery.
When executing the Sort step, you must be vigilant and ruthless. Doing
this first step correctly will lay the groundwork for 5S and ensure a
successful implementation of the 5S model.
Identifying unneeded parts and tools is not always an easy task.
Employees and managers get so used to the chaos that they don’t even
see it anymore.

5S has an effective tool that will help you with your sort process: red tags.

Red Tags
Red tags help you identify objects that need to be
removed from the workplace.
When you see something you think may need
to be removed, you put a red tag on it. This lets
everyone know this item needs to be evaluated.
On the red tag, indicate what action should be taken:
1. Leave the item where it is
2. Relocate the item
3. Dispose of the item
4. Recycle the item
5. Place in “Red Tag Holding Area”
The Red Tag Holding Area is a location where
items are placed until you determine their
value.
For example, say you have a tool you haven’t seen
anyone use in a long time, but you aren’t sure you
should get rid of it. Place it in the red tag holding
area with a date on it, perhaps for a month from
now. If that date passes and no one has used the
tool, you can safely assume it’s not needed and
remove it from the workplace.
On the other hand, if you determine an item is still
needed, remove the red tag and find an
appropriate location to store it.

Shop Red Tags:
www.creativesafetysupply.com/5s-Red-Tags/

Set in Order
Set in Order is the process of
putting everything in a place
that is easy to get to. All items
should be clearly marked so
anyone can easily find its proper
home.
Seiton
Begin the Set in Order phase of 5S only when the Sort phase is complete. This
phase will be useless if there is unnecessary clutter in the workspace.
The goal of Set in Order is to create a standardized and consistent way to store and
retrieve tools and materials. The key here is standardization. The user must develop
this system based on how often the tools and materials are accessed and the
process that uses them.
Some guidelines to consider:
If items are used together, store them
together. Put frequently used items closest
to the user.
If possible, devise a let-go system in which tools are
attached to a retractable cord and automatically go back to
the stored position.
Place items so the user doesn't need to bend or twist much

The Set in Order step utilizes several strategies to accomplish its goals.

Labels and Signs
A key component of any organizational
program, labeling is the easiest way to
quickly and visually identify proper placement
of tools, materials, and equipment.
For example, drawers of tool chests can be
labeled with their contents so employees can
easily find what they need. The floor can even be
labeled indicating where trash cans, machinery,
and other equipment should be placed so these
things always find their way back to where they
belong.
This type of labeling makes it easy for even people
unfamiliar with your system to locate items and
return them to the right places. It also helps with
sustaining organizational processes because once
everything
is properly labeled, it’s easier for employees to
keep 5S in focus on a daily basis. If they ever
forget the location of something, the answer is
right in front of them.
In addition, larger signs, banners, and posters can
be used to convey messages of organization or
safety, including reminders of the 5S process.
Large signs can be posted above storage areas, for
example, to facilitate clean-up at the end of shifts.
Together, these tools create a great backbone for
any visual organization program.

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Line Marking
Painted or taped lines are often associated with
safety (pedestrian paths, forklift and equipment
paths, etc.), but they are also very useful for
marking work areas, as well as locations for
pallets, raw materials, finished goods, shipping,
and other static locations.
By marking the boundaries of these areas, you’ll
make it easier for employees and visitors to make
sense of space.
Industrial floor tapes are preferred to painted
lines as they are more resistant to foot and
forklift traffic and don’t require long dry times.
They are also easy to clean and require little
upkeep. These tapes come
in many colors and sizes so you can create a
marking system that makes sense for your facility.
Often, companies also use thinner vinyl tapes
(0.25” to 2” width) of different colors to mark
workbenches and work cells. These tapes can
create visual cues or
indicate the locations of tools/equipment that
shouldn’t move. This helps keep work areas clear of
clutter and keeps these static items in their optimal
positions.
These techniques can be used for work cells of any
kind. They will improve workflow and result in
improved productivity. Additionally, misplaced
items and equipment are easy to spot.

Shop Floor Marking:
www.creativesafetysupply.com/floor-marking-tapes

5S
Floor Marking Color Guidelines
Yellow Aisleways & Traffic Lanes; Paths of Egress; Work Cells
White
Production; Racks, Machines, Carts,
Benches, & Other Equipment
Red Defect/Scrap Area; Red Tag Area
Orange Material or Product Inspection; Energized Equipment
Green Materials & Manufacturing: Finished Goods
Blue Materials & Manufacturing: Raw Materials
Black Materials & Manufacturing: Works in Progress
Black & Yellow
Areas which present physical or health
risks to employees
Red & White Areas to be kept clear for safety reasons
Black & White Areas to be kept clear for operational purposes
These color code recommendations are widely accepted and comply with
any interpretation of OSHA or American National Standards Institute
(ANSI) codes.
This scheme isn’t set by any specific law, so it can be modified to fit the needs of
specific facilities. It is a useful starting point for most applications.
If modified, post a color guide in a conspicuous location.

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Tool Foam
For tool drawers, you can use customizable foam
to create a tool organization system to prevent
tools from going missing. This foam can also help
protect your toolbox and tools from damage.
This customizable foam is usually available as
part of a kit, which means you will receive two
pieces of foam in contrasting colors. The
brighter color foam is placed in the bottom of
the drawer. You trace
the outlines of your tools on the second piece of
foam and cut them out using a foam-cutting
knife. Then when you place that layer of foam into
your drawer, the brighter color beneath will show
through, highlighting any missing tools.

Shop Foam Products:
www.creativesafetysupply.com/foam-organizers

Shadow Board / Tool Outlining
Tool outlining means creating a visual
outline of your tool so you can quickly
return it to its proper home.
For pegboards and other hanging tool
systems, this is done by placing painted or
vinyl cutouts of your tools behind those tools.
Vinyl tool outlines work well since they are
easy to apply and require no maintenance.
This method is called shadow boarding.
These methods of organizing tools are simple
but effective. They make organization more
visual, which makes it easier for people to
follow your organizational protocols without
too much thought.

Shop Tool Outline Vinyl:
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Shine
Shine means removing all the
dirt and grime and keeping the
workplace
clean on daily basis. You want to
get it clean and keep it clean.
Seiso
You eliminated clutter with Sort and you organized with Set in Order. Now it’s
time to sanitize with Shine.
When you implement this step, two things will happen. First, your employees
will like coming to work in a clean environment. Second, because you are
keeping the equipment and your surroundings in great shape, you will have
fewer injuries and fewer equipment breakdowns. That means greater
productivity and fewer costs.
In the 5S system, cleaning is everyone’s responsibility. Although you may still
use a janitorial staff to tackle large jobs, the detailed cleaning will be done
by your
employees. You must train your staff to view dirt and chaos as an intolerable
situation. This must be a culture that is followed from the CEO down to the
apprentice.
Standardize your cleaning program for best results. Train your employees to do
it correctly. Make sure they know what they are responsible for and give them
the tools to do the job. Utilize checklists and diagrams for consistency.

The goal for Shine is to keep everything in great
working order so it lasts as long as possible and doesn’t
break down.
Inspection and Maintenance
Cleaning is not the only facet of Shine. The daily Shine ritual should also include
inspection and routine maintenance.
As your employees are doing their daily cleaning routine, they should be
inspecting tools and machinery for damage as well. Include this in the daily
checklist to make sure it gets done.
Periodic routine maintenance should also be done at this time. Some examples
are checking the oil level in machinery, tightening up belts, hoses, nuts, and
bolts, or checking if tools need sharpening.
Clean and properly maintained tools and machines also increase safety in the
workplace. Fewer injuries and less downtime equate to higher morale and higher
productivity.
What if an employee sees a pool of oil that wasn’t there before or notices a
safety hazard?
If it’s a quick fix, put a maintenance tag on it and notify your supervisor. If
something needs further evaluation, there should be a maintenance log you can
fill out that will ensure further action.
And don’t forget your computers and other office equipment! They need to be
defragmented (PCs) and air-dusted periodically to keep them in good condition.
Everything is coming together. The groundwork has been set for a successful 5S
implementation. Now we move on to the pillar that will be the glue that keeps it
all together: Standardize.

Standardize
Standardize creates a system of
tasks and procedures that will
ensure the principles of 5S are
performed on a daily basis.
Seiketsu
We all have our own way of doing things. This kind of individuality is great in our
personal lives because it makes life more interesting.
But non-conformity can be unproductive in the workplace. If your employees
start doing things their own way, then things will start to get missed and
conditions will slowly begin to deteriorate.
The Standardize pillar utilizes a set of schedules and checklists that can be
easily followed so each step of 5S is performed exactly the same way every
day.
This way, each employee knows what he needs to do, when he needs to do
it, and exactly how to do it.
There is no room for uncertainty.
Standardize uses three steps to make sure that the 5S pillars are getting
done consistently and correctly:

1) Make sure each employee knows their responsibilities.
If employees don’t know exactly what is expected of them, then how can they do it?
They should have a clear understanding of their daily and weekly Sort, Set to
Order, and Shine tasks. Their responsibilities should be clearly written out on a
checklist or a chart so they can be easily accessed throughout the day.
2) Make it a part of their daily routine.
If you train your employees correctly, they will execute the steps of 5S
without even thinking about it.
"That wrench is out of place. Its home is here." -or- "I know the next tool I need
is the screwdriver because my tools are stored in the order that I use them."
No extra thought is needed; employees flow through their daily routine
because they can see that it makes sense.
3) Periodic evaluation.
Once the steps are in place, you can evaluate performance at regular intervals.
You can either form a committee made up of employees from different
departments or assign evaluation to department supervisors. Either way, you
will need a system to ensure tasks are consistently getting done.

Standardize is essential to the success of your 5S implementation. If your staff
has procedures to follow to complete the steps, you will ensure long-term
success and reap all of the rewards of 5S.

Whiteboards for 5S and other Lean Methods
Whiteboards are the perfect choice for projects that involve standardizing new or
existing processes. With a whiteboard, all the necessary information employees
need can be contained in one place. This eliminates the risk of conflicting
information, therefore keeping everyone on track for success.
These tools are excellent for:
• Scheduling
• Maintenance work
• Basic organization
• Kanban
• Lean manufacturing
• 5S
The above are only a handful of examples where whiteboards can be used.
Not only are these visual tools flexible in terms of what they can be used for,
but whiteboards can be easily changed or repurposed for another type of
organizational effort.

s
t iv a e
e n t o f
ow h , o
Shitsuke
Once you start the 5S method at your business, you will see improvements
very quickly. But the key to long-term success is simple: diligence.
Have you ever gone on a diet to lose a few pounds? In the beginning, you really
keep at it. You stay away from those French fries, eat more fruits and veggies,
and may even go for a jog a couple days a week. You lose six pounds in two
weeks.
But inevitably, you start to slip. You’re out with friends and you indulge in
dessert. Or you hit your favorite fried chicken joint. It’s only this one time, you
say. Before you know it, you’re back to your old bad habits and have gained all
of your weight back.
That’s just human nature. If there is nothing to keep you motivated, you will start
to cut corners and slip. The fifth pillar, Sustain, is designed to keep your staff
motivated and on track.
Take concrete steps to make sure 5S doesn't fall by the wayside. The five
suggestions on the next page can help Sustain 5S and keep your program
functioning well. Assign the time to do it.
Give your staff the time to do the steps correctly. For example, designate the
fifteen minutes before lunch and shift end as Shine time. During this time, their
main focus is cleaning and organizing according to their checklists.

Start from the top.
Your whole organization must be on board if 5S is going to work in the long run.
If your employees see that management is not following the steps, do you think
they will continue to do it?
Create a reward system.
Have friendly competitions between departments each month and reward the
winner. Buy them lunch, let them go early one day, or give them priority parking.
It doesn’t have to break the bank; you just want to show them your appreciation
for a job well done.
Get everyone involved.
Form a committee made up of employees and supervisors of different
departments. Their job will be to oversee the implementation of 5S for a fixed
period, maybe six months. Then you can rotate in new members.
Let them see it.
Posters, banners, and newsletters can be
a constant reminder of the importance of 5S.

Shop 5S posters:
www.creativesafetysupply.com/5S-Posters/

Traditionally there are only 5 pillars or steps in the 5S system, but many
companies and organizations opt to add a sixth pillar: Safety. This system is then
usually referred to as “6S”.
Safety plays a critical role in any company and goes hand in hand with proper
organization, so it makes sense to highlight it at the same time as 5S. In fact,
implementing the 5S model is a huge first step to creating a safe environment
for you and your staff.
What are some other things you can do?
• Make sure your employees have the correct equipment for their jobs.
Hardhats, coveralls, gloves, and steel toe shoes are some typical items
required in a warehouse or manufacturing complex.
• Train your staff to use the equipment correctly. Heavy equipment,
electronics, forklifts, and power tools are all dangerous to those who use
them incorrectly.
• Easy-to-understand labels, signs, and other markings contribute to creating a
safe, visual workplace.
• Train your staff on exactly what to do in an emergency. From small
incidents like cuts and bruises to larger ones like injuries and fire, each
Safety
Safety is an ongoing process supported by nearly all pillars
of the 5S system. It is often considered a “6th S”. Companies
that include this step refer to the system as 6S.

employee should know what they need to do or who they need to notify.

Summary
5S is a system, a philosophy, and a culture.
The true power of 5S reveals itself when your whole organization embraces its
ideals and your employees see that your business is transforming itself.
The 5S model for workplace efficiency and organization is both powerful and
simple. It has the potential to transform your company into a safe and
productive warehouse, manufacturing facility, or office.
One of 5S’s most powerful attributes is that it’s a visual model. Each tool has an
outlined home and each pathway is marked with lines. Vision is our dominant
sense, and because 5S uses colors, lines, and labels to organize, following the
steps becomes second nature very easily.
Remove the clutter with Sort, organize with Set to Order, clean with Shine, set your
routine with Standardize, and motivate with Sustain.
It’s that easy.
Questions about 5S or Lean?
Call us at 1-866-777-1360

Additional Resources
Creative Safety Supply carries a wide selection tools that will help create a
successful and sustainable 5S program. Visual communication is our specialty, and
it also happens to be a large part of any 5S program for improving safety and
efficiency within the workplace. For example, red tags are a staple for sorting items
in an area. Floor marking materials, labels, foam tool organizers, and tool
outline vinyl are all useful when thinking about the Set in Order step of 5S.
All of these items have the capability to give you a much tidier and more organized
workspace, which is a core value in the 5S method. To make things even easier in
getting started with your 5S program, you may want to think about obtaining your
own industrial label printer. You will save on costs by choosing to print your own
signs and labels rather than suffering long lead times and cost of labor for another
company to print out the labels you need. Check out this 5S Revealed training DVD
to get your employees on board with this fantastic Lean method. We are here to
help you with your 5S journey!
5S sample labels just a click away.
Ready to start a 5S program where you work? Click the link
below to get LabelTac®
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What’s included:
- A selection of LabelTac® printed 5S labels

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