The 5S Methodology–
Each “S” represents a key step in the process:

Eliminate unnecessary items from the workplace. “When in doubt, throw it out!”

Ask yourself:

• Is this item essential for the job?
• Do we really need these items?

Examples:

• Excess or defective items
• Outdated or broken tools, jigs, and dies
• Worn-out parts, inserts, and inspection equipment
• Obsolete signs, memos, or posters
• Broken electrical equipment

Red Tag Method: A visual approach to identifying and removing unnecessary items:

• Attach red tags to unneeded or misplaced items.
• Document each tagged item.
• Maintain a “5S Tag Log” for reference.
• Discard obvious trash immediately.

Organize necessary items for easy access and return. Everything should have a designated place.

Ask yourself: Would a newcomer immediately know where each item belongs?

Benefits:

• Items are found quickly and easily.
• Time spent searching is minimized.
• Mistakes in retrieving the wrong parts are reduced.
• Walkways and workspaces remain clutter-free.

Implementation:

• Store frequently used items together in sequence.
• Create dedicated storage for tools.
• Keep infrequently used items away from the immediate workspace.

Think of a NASCAR pit crew: Every tool is positioned for maximum efficiency, eliminating wasted motion and errors.

Maintain cleanliness to ensure a safe and efficient workspace.

Ask yourself: Are there areas that need cleaning?

Benefits:

• Easier detection of defects and safety hazards.
• A tidy work area reduces tripping risks.
• Well-maintained machines function efficiently and last longer.
• A clean environment boosts team morale and pride.

Implementation:

• Identify cleaning targets.
• Set a cleaning schedule and assign responsibilities.
• Establish procedures for regular maintenance and inspection.

A clean work area is like a freshly washed car—imperfections become more visible, allowing for proactive maintenance.

Create a structured, consistent approach to maintaining Sort, Set in Order, and Shine.

Ask yourself:

• Are the first three Ss consistently followed?
• Is 5S embedded in daily routines?

Benefits:

• Faster and easier training for new employees.
• Reduced errors and material waste.
• A safer, more organized workspace.

Implementation:

• Integrate 5S into daily operations.
• Establish clear documentation for procedures.
• Ensure visual cues indicate when items are out of place.

Consistency is key—when processes are clearly outlined and signed off, they are more likely to be followed.

Make 5S a long-term habit rather than a temporary initiative.

Ask yourself: Are we slipping back into old, disorganized habits?

Benefits:

• A continuously clean and safe environment.
• Standardized, efficient workflows.
• Easier access to tools and materials.
• Higher employee morale.

Implementation:

• Keep 5S principles top of mind.
• Schedule daily maintenance tasks.
• Recognize and reward compliance.
• Conduct regular 5S audits.

Sustaining 5S requires commitment—practicing it daily ensures lasting benefits.

---

5S Summary
5S is a structured approach to maintaining an organized, efficient, and high-performing workplace. It allows employees to easily identify normal vs. abnormal conditions, supports continuous improvement, and enhances safety and productivity.

Key benefits of 5S include:

• A cleaner, safer workspace
• Increased efficiency
• Higher employee morale
• Standardized processes

By following all five steps—without skipping any—5S becomes a shared responsibility and a fundamental part of workplace culture.