The 5S’s: Workplace Organization Course Outline
Purpose of the programs
This program focuses on getting managers, maintenance personnel and equipment users all working together to prevent equipment problems and reduce expenditures. By giving ownership and responsibility of equipment and processes to the right employees, equipment breakdowns are reduced. 5S provides a systematic approach to setting standards and visual guides for preventing breakdowns and making your equipment run smoothly.
By the end of this seminar, students will be able to go back to their facility and immediately apply what they learned to help keep their equipment up an running. Training like this never costs – it pays!
Who should take this course?
This seminar is a must for anyone who is involved with maintenance at industrial plants, utilities or commercial and private building facilities. Attendees come from a wide variety of industries, skill-levels, company sizes, and job titles, so if you’re not sure you’ll fit in or will benefit from the class, don’t worry – you will – as long as your job involves maintenance!
Training Outcomes
Upon completion of this course, students will receive a training certificate and 1.6 Continuing Education, indicating that the student has learned to:
• Understand How and Why Equipment Fails
• Identify Causes and Types of Equipment Failures
• Use Root Cause Identification Tools
• Measure Overall Equipment Effectiveness (OEE)
• Implement 5S
• Build an Effective Maintenance Team
• Create a Tracking and Checklist Program
• Utilize Visual Guides
• How to Communicate TPM through the whole Facility
The 5S Version Training Package will help you develop and conduct a world-class 5S program. This package is structured around the Sort, Set In Order, Shine, Standardize, and Sustain terminologies. If you are conducting a Lean workshop, a Kaizen Blitz, or other process improvement programs 5S needs to be apart of your improvement initiative. Talent's 5S Version Training Package is a full solution for your company.
This package will empower your staff by allowing them to take ownership and maintaining 5S in their work area. The 5S is action oriented using a mixture of training room learning and shop floor implementation. In the training room, the team will learn the fundamentals of 5S including definitions, benefits, and how to eliminate waste. The session on the shop floor, the team performs an initial 5S evaluation and documentation to establish a base line. Then the 5S project team applies 5S in the team’s work area solidifying their understanding of the 5S principles while making positive, visible changes to their area.
Unit One:
Lesson 1 • An overview of the 5S’s is presented.
What is 5S All About? • The benefits and operational impact of implementing the 5S’s are discussed.
Lesson 2 • How to organize the work area for efficiency & effectiveness and use the “48-Hour Rule.”
Sort: Clearing the Work Area • A stepwise approach to clear the work area is presented.
Lesson 3 • How to designate “a place for everything & ensure everything is in its place.”
Set in Order: Designated Locations • 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 • The three aspects of Shine (getting the workplace clean, maintaining its appearance, and Shine: Cleanliness & Workplace Appearance using preventive measures to keep it clean) are explored.
Lesson 5 • The three aspects of Shine (getting the workplace clean, maintaining its appearance, and Standardize: Everyone Doing Things the Same Way using preventive measures to keep it clean) are explored.
Lesson 6 • Sustain is perhaps the toughest of the 5S’s. Techniques to prevent backsliding are Sustain: Ingrain It in the Culture presented.
The 5S Challenge • An assessment of the learner’s progress in this unit.
Unit 2 - 5S Implementation
Lesson 1 • How to plan and implement a 5S initiative.
An Organization-Wide 5S Effort • 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 • How to implement the 5S’s in a work area if an organization-wide initiative is not supported.
Tackling 5S’s on Your Own
Lesson 3 • Examples of “Sort Successes” showing both the before state and the after state with the impact Success Stories: Sorts (savings) explained.
• Checklist to help achieve successful Sorts.
Lesson 4 • Examples of “Set in Order Successes” showing both the before state and the after state complete with Success Stories: Set in Order the impact on the organization.
• Set in Order Checklists.
Lesson 5 • Examples of successful approaches for the Shine, Standardize, & Sustain phases of a 5S program.
Success Stories: Shine, Standardize,
& Sustain
The 5S Challenge • An assessment of the learner’s progress in this unit.
Course Outline / Agenda
I. WORKPLACE ORGANIZATION USING 5S
• Sort
• Set in Order
• Shine
• Standardize
• Sustain
II. CREATING A MAINTENANCE TEAM
• Operator involvement
• Maintenance Personnel Involvement
• Management involvement
III.“FIVE WHY” TOOL TO FERRET OUT ROOT CAUSES
IV. TYPES OF EQUIPMENT FAILURES
V.CAUSES OF EQUIPMENT FAILURES
VI.WHEN AND HOW TO REPORT PROBLEMS
VII.CLEANING AND INSPECTION
VIII.CONTINUOUS IMPROVEMENT OF EQUIPMENT
• Measuring Overall Equipment Effectiveness (OEE)
• How measurement develops proper focus for maintenance
• Six big losses resulting from inadequate maintenance
• Calculating OEE
IX.KEY ELEMENTS OF PREVENTIVE MAINTENANCE
X.TRACKING PREVENTIVE MAINTENANCE
XI.BUILDING EFFECTIVE CHECKLISTS
XII. KEY ELEMENTS OF PREDICTIVE MAINTENANCE
XIII, TEAM WORK
• Operator’s Role
• Maintainer’s Role
• Management’s Role
XIV.HOW VISUAL CONTROLS ASSIST TOTAL PRODUCTIVE MAINTENANCE
XV.COMMUNICATING THE TPM MENTALITY TO EVERYONE IN THE FACILITY
