v
Contents
How to Use This Playbook ............................................................................ vii
Introduction ..................................................................................................... ix
8 Wastes ............................................................................................................ xi
Lean Metrics ...................................................................................................xiii
5S Supply List ................................................................................................ xvii
5S Supply Cart ................................................................................................ xix
1 Sort .................................................................................................... 1
Step 1 .................................................................................................................. 1
Red Tagging ....................................................................................................... 2
Why Sort? ........................................................................................................... 3
Red-Tag Areas ..................................................................................................... 4
Production ...................................................................................................... 4
Boxes .............................................................................................................. 4
Rented Container ............................................................................................ 5
Ofce .............................................................................................................. 5
Sorting Hardware ........................................................................................... 6
Body Shop ...................................................................................................... 6
Removal Procedure ............................................................................................ 7
Removal Ideas ................................................................................................ 7
2 Set in Order ....................................................................................... 9
Stage 2 ................................................................................................................ 9
Painted Work Areas and Aisleways ................................................................. 10
Floor Tape Work Areas and Aisleways ............................................................11
Machine Shop ................................................................................................... 12
Tools ................................................................................................................. 18
Tool Check Cards ............................................................................................. 21
Examples .......................................................................................................... 24
Tool Placement ................................................................................................. 24
3 Scrub ................................................................................................ 27
Stage 3 .............................................................................................................. 27
vi ◾ Contents
4 Standardize ...................................................................................... 29
5 Sustain ............................................................................................. 31
End-of-Day Cleanup Procedure ........................................................................31
Daily Walkthrough ........................................................................................... 32
5S Audit Form/Criteria ..................................................................................... 32
Sample 5S Audit Form: Form 5-1 ..................................................................... 33
Assigning Auditors and Rotation ..................................................................... 34
Sample Auditor Rotation .................................................................................. 34
5S Tracking Sheet ............................................................................................. 34
Sample 5S Tracking Sheet ............................................................................ 35
Incentive Program ............................................................................................ 35
6 5S Shadow Board: How-toReference Guide .................................... 37
Introduction ...................................................................................................... 38
Why Use a 5S Shadow Board? ......................................................................... 39
How to Build a 5S Shadow Board .................................................................. 39
Steps 1 and 2 .................................................................................................... 40
Step 1: Paint Peg Board ............................................................................... 40
Step 2: Begin to Place the Boards on a FlatSurface
toVerifySpaceRequirements ...................................................................... 40
Steps 3 and 4 .................................................................................................... 41
Step 3: Hang Board in Desired Location .................................................... 41
Step 4: Place Tools on Board ....................................................................... 41
Steps 5, 6, and 7 ............................................................................................... 42
Step 5: Leave Enough Room for the Shadow or Outline............................ 42
Step 6: Finalize All Tool Locations .............................................................. 42
Step 7: Use a Paint Pen to Outline Tool ...................................................... 42
Steps 8 and 9 .................................................................................................... 43
Step 8: Make and Place Labels Near Tool ................................................... 43
Step 9: Place Color Tape Around Tool for Designation .............................. 43
Steps 10 and 11 ................................................................................................ 44
Step 10: Designate the Board with a Location ............................................ 44
Step 11: Place a Designation Label on Tool ................................................ 44
Completion ....................................................................................................... 45
Examples .......................................................................................................... 46
Conclusion .............................................................................................. 49
Denition of Terms ................................................................................ 51
About the Author .................................................................................... 59
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