Lecture 7: 5S the Foundation of Visual Management

Question 1

Who developed the 5S system?

Answer 1

Sakichi Toyoda, Kiichiro Toyoda and Toyota engineer Taiichi Ohno

Question 2

What does 5S stand for?

Answer 2

Sort
Set
Shine
Standardize
Sustain

Question 3

What does 5S do?

Answer 3

Remove waste and improve workplace safety

Question 4

How does 5S improve quality?

Answer 4

Abnormalities are immediately identified

Question 5

What is Step 1 of 5S?

Answer 5

Sort

Question 6

What do you do during the sort step?

Answer 6

Distinguish between what is and what is not needed

Question 7

Which questions do you ask about the items in an area in the Sort step? (6)

Answer 7

• Why is this quantity required?
• Where is this item used?
• When is this item used?
• What is the purpose of this item?
• Why is it stored here?
• How is this controlled?

Question 8

Red tag or not?

When an item has a defined purpose and it is used regularly

Answer 8

No red tag

Question 9

Red tag or not?

When an item has no definite purpose or is not needed

Answer 9

Red tag

Question 10

Red tag or not?

When an item is unsafe but needed

Answer 10

Red tag to be repaired or replaced

Question 11

Red tag or not?

When an item is unsafe and not needed

Answer 11

Red tag for disposal

Question 12

Red tag or not?

When you are unsure about an item’s purpose?

Answer 12

Red tag for a discussion

Question 13

What is step 2 of 5S?

Answer 13

Set

Question 14

What do you do during the Set phase of 5S?

Answer 14

Arrange all items where they are needed

Question 15

What do you identify during the Set step of 5S?

Answer 15

The ‘home’ for all items

Question 16

What are the benefits of the Set step? (2)

Answer 16

• Clear visual standards and abnormalities become clear

* Workplace optimised to eliminate time searching for items

Question 17

What is step 3 of 5S?

Answer 17

Shine

Question 18

What does the Shine step include?

Answer 18

Making sure that everything is kept in this orderly way and there is routine cleaning

Question 19

What is the benefit of the shine step?

Answer 19

a safe working environment that is maintained to a standard

Question 20

What is step 4 of 5S?

Answer 20

Standardize

Question 21

What does the standardize step include?

Answer 21

Adherence to the known standard. Use visual controls to make deviations from the standard obvious.

Question 22

What is the benefit of the standardize step?

Answer 22

ongoing consistency within the workplace area

Question 23

What is step 5 of 5S?

Answer 23

Sustain

Question 24

What does the sustain step include?

Answer 24

Maintaining the standard through the organization culture

Question 25

Why are waste walks necessary in the sustain step?

Answer 25

Because by looking and seeing you can identify waste more easily

Question 26

What are the benefits of the sustain step?

Answer 26

an organizational culture of continuous improvement

Question 27

What are the 5 implementation guidelines for 5S?

Answer 27

1. Identify project area 2. Train your people 3 Take photos of the project area 4. Identify the teams 5. Make the time available

Question 28

What is important when starting a 5S project?

Answer 28

Being prepared to maintain the standard

Question 29

What is visual management?

Answer 29

a system to recognize deviations from the standard

Question 30

What are visual displays?

Answer 30

communicate important information but do not control the process

Question 31

What are visual controls?

Answer 31

build visual control into the process to ensure that activities are performed according to standard

Question 32

If the problem is about quality do you use Lean or Six Sigma?

Answer 32

Six Sigma

Question 33

If the problem is about efficiency do you use Lean or Six Sigma?

Answer 33

Lean

Question 34

What is Six Sigma centered around?

Answer 34

understanding where variation is coming from

Question 35

What is Lean centered around?

Answer 35

reducing waste