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Topic Title: 5s Audit Training
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Created On: 03/20/2008 09:30 AM
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   5s Audit Training   - JBAND - 03/20/2008 10:14 AM  
   5s Audit Training   - duecesevenOS - 03/20/2008 10:59 AM  
   5s Audit Training   - MarkRosenthal - 03/24/2008 03:47 PM  
   5s Audit Training   - duecesevenOS - 03/26/2008 11:54 AM  
   5s Audit Training   - 69317D2 - 04/01/2008 09:37 AM  
   5s Audit Training   - 135754 - 12/18/2009 10:20 AM  
   5s Audit Training   - jbarrett1967 - 05/24/2010 01:41 PM  
   5s Audit Training   - tb68 - 05/25/2010 11:10 PM  
   5s Audit Training   - DennisReiland - 08/24/2011 04:22 PM  
   5s Audit Training   - SandeepMohan - 04/10/2012 02:35 PM  
   5s Audit Training   - 111923 - 08/26/2016 04:49 PM  
   5s Audit Training   - ChamanK - 11/05/2009 09:52 AM  
   5s Audit Training   - fabiofurlan - 11/06/2009 03:34 PM  
   5s Audit Training   - Arthur_S - 11/09/2009 11:05 AM  
   5s Audit Training   - GTJones - 11/10/2009 09:24 AM  
   5s Audit Training   - RonG - 11/11/2009 12:59 PM  
   5s Audit Training   - 23704 - 11/12/2009 01:23 PM  
   5s Audit Training   - CANTULA - 11/13/2009 01:42 PM  
   5s Audit Training   - marcuuuuuuadca - 08/30/2011 10:26 AM  
   5s Audit Training   - 173290 - 11/13/2009 01:43 PM  
   5s Audit Training   - oluAdekoya - 09/16/2011 12:15 PM  
   5s Audit Training   - 92044 - 09/16/2011 01:50 PM  
   5s Audit Training   - cagatay - 09/19/2011 10:09 AM  
   5s Audit Training   - 191702 - 11/13/2009 01:41 PM  
   5s Audit Training   - 190940 - 11/13/2009 01:41 PM  
   5s Audit Training   - MaheshKumar - 05/07/2010 01:08 AM  
   5s Audit Training   - ViorelFLupu - 11/13/2009 01:42 PM  
   5s Audit Training   - DN - 11/13/2009 01:42 PM  
   5s Audit Training   - Bren06 - 11/13/2009 01:43 PM  
   5s Audit Training   - ScottScudder - 11/13/2009 01:45 PM  
   5s Audit Training   - GTJones - 11/16/2009 11:19 AM  
   5s Audit Training   - John_Benning - 05/06/2010 03:30 PM  
   5s Audit Training   - SteveMilner - 05/07/2010 06:02 AM  
   5s Audit Training   - TheLeanLeader - 05/07/2010 01:52 AM  
   5s Audit Training   - krishna74 - 05/14/2010 09:26 AM  
   5s Audit Training   - 216808 - 09/10/2010 11:05 AM  
   5s Audit Training   - ChrisDavies - 09/02/2011 10:36 AM  
   5s Audit Training   - GTJones - 11/16/2009 11:19 AM  
   5s Audit Training   - terrymrowley - 11/16/2009 11:20 AM  
   5s Audit Training   - jlmoen - 12/14/2009 04:06 PM  
   5s Audit Training   - Ilona - 02/16/2010 06:01 PM  
   5s Audit Training   - oscarvaq - 04/26/2010 10:30 AM  
   5s Audit Training   - cogypsy - 10/14/2010 03:54 PM  
   5s Audit Training   - leanpassion - 09/16/2011 12:15 PM  
   5s Audit Training   - MattPasteris - 09/23/2011 02:34 PM  
   5s Audit Training   - fabbronip - 04/09/2012 11:04 AM  
   5s Audit Training   - NancyRogerson - 06/26/2019 08:58 AM  
   5s Audit Training   - - 11/16/2009 10:40 AM  
   5s Audit Training   - 5256 - 11/16/2009 11:19 AM  
   5s Audit Training   - thomasmcs - 11/16/2009 11:20 AM  
   5s Audit Training   - laxsan - 11/16/2009 11:21 AM  
   5s Audit Training   - martinoneill - 11/16/2009 11:21 AM  
   5s Audit Training   - HP - 11/17/2009 12:49 PM  
   5s Audit Training   - GTJones - 11/18/2009 09:24 AM  
   5s Audit Training   - icpdude - 11/18/2009 09:25 AM  
   5s Audit Training   - GTJones - 12/02/2009 09:14 AM  
   5s Audit Training   - 164948 - 05/07/2010 04:30 AM  
   5s Audit Training   - chewy - 05/17/2010 09:07 AM  
   5s Audit Training   - MRC - 01/27/2010 10:39 AM  
   5s Audit Training   - bologa - 02/01/2010 10:35 AM  
   5s Audit Training   - Laxman - 02/15/2010 03:08 PM  
   5s Audit Training   - Laxman - 02/15/2010 03:09 PM  
   5s Audit Training   - rmilliken - 02/16/2010 06:01 PM  
   5s Audit Training   - - 04/19/2010 09:00 AM  
   5s Audit Training   - taskhirnoori - 04/28/2010 09:28 AM  
   5s Audit Training   - KhaledAli - 04/23/2010 09:35 AM  
   5s Audit Training   - 191702 - 04/30/2010 09:01 AM  
   5s Audit Training   - iartis - 05/10/2010 09:53 AM  
   5s Audit Training   - 211948 - 05/10/2010 09:54 AM  
   5s Audit Training   - sonde330 - 05/14/2010 04:11 PM  
   5s Audit Training   - 1985FLHT - 05/18/2010 04:58 PM  
   5s Audit Training   - RonD - 05/24/2010 01:41 PM  
   5s Audit Training   - ksmathews - 06/01/2010 12:11 PM  
   5s Audit Training   - 234826 - 05/27/2010 12:11 AM  
   5s Audit Training   - WilliamF - 09/13/2010 04:38 PM  
   5s Audit Training   - Alex_Campbell - 09/17/2010 02:13 PM  
   5s Audit Training   - 240689 - 09/17/2010 02:14 PM  
   5s Audit Training   - 243265 - 09/20/2010 08:53 AM  
   5s Audit Training   - 92027 - 09/17/2010 02:13 PM  
   5s Audit Training   - tuanman - 10/13/2010 11:26 AM  
   5s Audit Training   - 241620 - 04/05/2011 10:00 AM  
   5s Audit Training   - badapple - 06/03/2011 09:40 AM  
   5s Audit Training   - oscarvaq - 06/13/2011 09:59 AM  
   5s Audit Training   - tpmcell - 06/16/2011 03:08 PM  
   5s Audit Training   - ballas - 06/20/2011 09:33 AM  
   5s Audit Training   - dileep_mor - 06/20/2011 09:33 AM  
   5s Audit Training   - Edward-Hutcheon - 08/08/2011 05:18 PM  
   5s Audit Training   - KaushikB - 08/15/2011 01:50 PM  
   5s Audit Training   - truongson - 08/18/2011 10:34 AM  
   5s Audit Training   - oliverdemus - 08/19/2011 05:33 PM  
   5s Audit Training   - CEM - 08/22/2011 03:22 PM  
   5s Audit Training   - kennycrosbie - 08/19/2011 05:32 PM  
   5s Audit Training   - 262693 - 08/22/2011 03:22 PM  
   5s Audit Training   - sunilpantoji - 08/23/2011 05:38 PM  
   5s Audit Training   - 262693 - 08/22/2011 03:22 PM  
   5s Audit Training   - 262693 - 08/22/2011 03:22 PM  
   5s Audit Training   - MICHELLEWALTERS - 08/30/2011 10:26 AM  
   5s Audit Training   - catherinejin - 09/02/2011 10:36 AM  
   5s Audit Training   - Ojas - 09/15/2011 04:03 PM  
   5s Audit Training   - keremcoban - 09/16/2011 12:15 PM  
   5s Audit Training   - AustinZhai - 09/19/2011 10:09 AM  
   5s Audit Training   - Dave_Brace - 09/16/2011 12:15 PM  
   5s Audit Training   - RickMartin - 09/20/2011 03:04 PM  
   5s Audit Training   - 112221 - 09/23/2011 11:06 AM  
   5s Audit Training   - 188604 - 09/23/2011 11:06 AM  
   5s Audit Training   - JRobC - 09/23/2011 11:06 AM  
   5s Audit Training   - AntonioDeCarlo - 09/28/2011 09:45 AM  
   5s Audit Training   - episfil - 09/30/2011 10:54 AM  
   5s Audit Training   - Steve24 - 01/13/2012 03:06 PM  
   5s Audit Training   - turntabalist - 03/09/2012 10:34 AM  
   5s Audit Training   - Pablomartin - 03/16/2012 12:58 PM  
   5s Audit Training   - JasonWoods - 03/28/2012 05:40 PM  
   5s Audit Training   - lenmcdonald - 04/10/2012 02:35 PM  
   5s Audit Training   - 273364 - 04/13/2012 07:45 PM  
   5s Audit Training   - Gonorenzou - 07/18/2012 10:42 AM  
   5s Audit Training   - ShurekaGantt - 08/26/2016 04:51 PM  
   5s Audit Training   - oberkele - 09/07/2016 10:06 PM  
   5s Audit Training   - 333825 - 08/19/2016 02:35 PM  
   5s Audit Training   - duecesevenOS - 11/09/2009 11:05 AM  
   5s Audit Training   - 235259 - 04/29/2010 09:30 AM  
   5s Audit Training   - RuiRodrigues - 05/03/2010 04:03 PM  
   5s Audit Training   - Max13 - 05/06/2010 02:16 PM  
   5s Audit Training   - TheLeanLeader - 05/07/2010 01:45 AM  
   5s Audit Training   - Cplatt21 - 09/21/2010 01:07 PM  
   5s Audit Training   - Kwok-wo_Bong - 06/14/2011 02:59 PM  
   5s Audit Training   - mele - 06/15/2011 09:41 AM  
   5s Audit Training   - Skyhigh07 - 06/16/2011 10:12 AM  
   5s Audit Training   - M_Norton - 06/23/2011 06:09 PM  
   5s Audit Training   - Dashamimi - 07/29/2011 03:51 PM  
   5s Audit Training   - JMVIVES - 09/28/2011 09:45 AM  
   5s Audit Training   - SL - 09/29/2011 01:25 PM  
   5s Audit Training   - MarcosPoffo - 04/05/2012 12:44 PM  
   5s Audit Training   - MarcosPoffo - 06/15/2012 12:05 PM  
   5s Audit Training   - 37318 - 04/20/2012 11:49 AM  
   5s Audit Training   - CinthyaKuramoto - 06/15/2012 12:05 PM  
   5s Audit Training   - 256003 - 06/25/2012 12:38 PM  
   5s Audit Training   - BertAnneveldt - 08/24/2016 10:35 AM  
   5s Audit Training   - AdamStorms - 08/26/2016 10:37 AM  
   5s Audit Training   - Soundfreq - 08/26/2016 04:50 PM  
   5s Audit Training   - Moderator_Lory - 08/26/2016 04:50 PM  
   5s Audit Training   - DanKyes - 08/26/2016 04:51 PM  
   5s Audit Training   - djackson - 06/26/2019 08:58 AM  
   5s Audit Training   - BenSherman - 07/19/2019 10:29 AM  
   5s Audit Training   - 360968 - 07/24/2019 11:52 AM  
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03/20/2008 10:14 AM
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JBAND
John Hale



Hi All

I have been asked to put together a training package for team leaders who are going to carryout 5s audits in their area of responsibility.

All of the team leaders have been through the 5s training, so I need to tailor the training specifically to the auditing of the areas and not just repeat the 5s training. I'm struggling for ways to do this, and wondered if anyone has experience of training in the auditing process that they could share with me.

Thanks
03/20/2008 10:59 AM
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duecesevenOS
Kris Hallan



Do you have audit criteria? If your going to train on audits, the only requirement is a good audit sheet that covers the key points in 5S your trying to address. A good audit sheet is fairly difficult to put together but there are quite a few things that you want to look for in a well maintained 5S area. Make the audit difficult and set a high standard. We do our audit out of 50 points and an area that hasn't applied any 5S might get a score of 5 out of 50. A perfect score should be almost impossible to attain.

I think the best way to train auditing is to actually go out and do a bunch of audits. A 5S audit is inherently subjective so the only way to really "calibrate" your auditors is to go threw a few different areas and audit them. Then when you disagree on different scores you can justify why you might score one way as opposed to another. This is also an opertunity improve your audit criteria. Your going to realize real quickly that some of the questions don't apply to all areas.

After a few audits, the scores for each auditor should be fairly close to the same for the same area. Then they are trained. Like any other gage (and an auditor is a gage of 5S) auditors need to be periodically calibrated. We try to do a "calibration" where auditors get together and audit a couple areas every 3-6 months. This gives us an opertunity to improve and update the audit sheets as well.
03/24/2008 03:47 PM
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MarkRosenthal
Mark Rosenthal



An audit is a "CHECK" in PDCA.
An audit should be checking the PROCESS of 5S, not 5S itself, though you are going to be looking at the state of the 5S in a large measure to do it.

A few things to consider:
The local team leaders should be doing the primary checking. It is up to them, not the audit, to maintain the process.

The audit process should be a teaching process, not a scoring process.
You are teaching the local team leaders what to look for, and how to check themselves.

To paraphrase Drew Cary, "The points don't matter." They don't. Please don't get hung up on the 1-5 scale because EVERYBODY IS A TWO. About the time most people think they are a three, they also understand just how much further "perfection" is than they thought. Since this is a pursuit of perfection, THERE IS NO FIVE.

What your auditors should be emphasizing is to examine what forces are in place to continuously spot two things:
- Ambiguity. Places where it is not perfectly clear what is needed and where it belongs. Anything that does not clearly belong where it is is suspect.
The first phases of 5S are about removing this ambiguity. That is why you sort, and why you find and identify places for everything. But extra things creep into the work area, and the check process is about determining why and how that happens.

In this context a "problem" is anything that is not clear. Most times that ambiguity goes unnoticed because it is accepted as always there. Your pursuit of perfection is a pursuit of no ambiguity at all. EVERYTHING clearly belongs where it is. The audit should be about teaching your local leaders to see this ambiguity and respond to it.

- Problem solving. Once you have a standard or specification for what belongs, and where they go, then a "Problem" is "any departure from that specification."

If something is not ambiguous, then it is either obviously where it should be, or it is NOT. If it is not, then your audit is about checking the process to: Return it to its "should-be" condition, and challenge the process itself. Usually something ends up wandering because someone somewhere else didn't have it and needed it; or it was used in a way that departs from the process as it was designed.

Seeing either of these conditions is a great opportunity because it points you to the next small "quick and easy" kaizen step which, in turn, will help your 5S.

This last point is critical: 5S CANNOT stand alone. It must be combined with kaizen to constantly reinforce the process and examine the standard. Otherwise it becomes a Dilbert exercise of outlining the vending machine with a label that says "VENDING MACHINE."
03/26/2008 11:54 AM
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duecesevenOS
Kris Hallan



I agree with Mark that 1-5 scoring is pointless. We use all binary questions that they either get right, or they don't. You get 1 point for a yes answer and 0 points for a no. We give different ratings (bronze, silver, or gold) based upon two criteria.

1) They get a certain number of points across the board.
2) They meet "must have" criteria.

We have ten points in each S category and a few must haves for each. As an example we will ask the question in the Sort category, "Have all supplies been removed from boxes and shipping containers?" It's a simple answer, yes they have or no they haven't. If they have, they get a point for it. To go with Mark's kaizen point, if they don't get a point, we let them know what they need to do in order to fix what took the point away. In this case pull supplies out of the box as they come in so that all supplies can be visible on shelves and they don't take up extra space. The leaders in that area can then assign actions to improve the area from that knowledge. If an auditor is able to answer yes to enough questions, then they can meet the first criteria.

When we started doing audits, that is all we did...above 30 is bronze and so forth. What we realized was that there were a few questions that were absolutely vital to the success of 5S in the area. If they didn't have those questions answered right, they didn't have anything. As an example in the Sustain category we ask, "Is there an active checklist (or substitute) that assigns daily responsibility to the first 3S's?" In our reckoning, if you don't have that, your not bronze. It doesn't matter if you have 49 of 50 points, if you don't have some form of daily checklist, you won't see sustainment and all you have done is clean up the area. Down the road, those types of checklists might not be necessary. For now, we insist on them.

The ratings are, of course, pointless. They don't mean anything, in and of themselves, but they do allow you to set goals for an areas progress in 5S and they help to emphasize key points. It also sets standards for progress. If you want to change the direction of emphasis for progress, you simply change the audit sheet. The key to being successful in these audits is to make sure that everybody realizes that this is a tool to get better. The whole goal of auditing is to improve your way out of a job.
04/01/2008 09:37 AM
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69317D2
Brent Jorgenson



I have some sample audits I can send you and there are some forms available on my website. E-mail me if you are interested at:

brentjorgenson@leansupermarket.com
12/18/2009 10:20 AM
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135754
Tracy Guderian



I am looking for some sample audit forms for 5S and plant audits, also looking for vendor Quality verification forms that i can work with to qualify my vendors to meet our company standards.

Can one help with this?
05/24/2010 01:41 PM
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jbarrett1967
John Barrett



Hi Brent, I am interested in reviewing your 5S forms. Can you please send copies to me? Thank you in advance.
05/25/2010 11:10 PM
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tb68
Todd Bille



Brent,

I am interested in your 5S packet as well. I work in a manufacturing plant that is in the infancy of formal 5S, and would love to see what you have. My email is tbille@live.com.

Thanks.
Todd B.
08/24/2011 04:22 PM
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DennisReiland
Dennis Reiland



Could pls send me a copy of a sample audit? Thx
04/10/2012 02:35 PM
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SandeepMohan
Sandeep Mohan



Dear Brent:

Pl. send me a copy at sandeep.mohan@sify.com

Thanks
08/26/2016 04:49 PM
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111923
David Wierzbicki Wierzbicki



Keep it simple. The 5th S is Sustain and the audit process is just to make sure you maintain full 5S.
You dont have to conduct full 5S with your audits.
Just make sure that the area stays in standard. I also think daily simple audits keep the area from slipping.
11/05/2009 09:52 AM
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ChamanK
Chamandeep Kaur Khehra



Were you able to deliver a successful training to your 5S auditors? I am in the same situation now? We have done two audits, and there are complains from the floor that the results are not consistent, so I have to train my auditors to ensure consistent results and streamline their thinking. Any ideas?
11/06/2009 03:34 PM
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fabiofurlan
Fabio Furlan



A successfull training to the 5Ss auditors is the one that provides you results. First, check if the content of the audit encompass everything. Use the binary checks (yes/no) for each item to be checked. For each no, take a problem resolution process, and then an action plan. Last, check the effectiveness of the plan.
In my recent audits I noticed that the area auditors turned a blind eye in some items (they put green in some red items). So, the tool lost its functionality.
I hope this helps. Fabio
11/09/2009 11:05 AM
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Arthur_S
Arthur Sutherland



For what ever its worth. Ambigus responses are the result of ambigus questions.

Couple of suggestions;

1. Score base on specific tasks (yes / no)
a) Are Productivity, Downtime, Quality, and Safety goals posted?
b) Do tracking charts show meeting or beating goals? If no, are appropriate actions shown to be in process?
This suggestion should hold a base line to a given standard that is either met or not met. The problem here though is that unless it is improved, you only end up with a new "status quo". Its either done or not done to recieve a lollie pop.

Productivity
2. 1-point. Goals posted and tracked
2-points Trend shows meeting or beating goals
3-points Goals that are not met have countermeasure responses.
4-points Countermeasure response is in place and effective.
5-points Process improvement plans posted to improve productivity above goal.
This suggestion tries to define where we really want to be, and what needs to be done to get there.

Hope this holds some value for you. :)
11/10/2009 09:24 AM
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GTJones
Gary Jones



This is where Audits differ from Assessments, Audits should be clear and identify where there are any non-conformities.

The Audit should also allow the recipients to have an understanding of "What do i have to do" to achieve improvement in my Audit Score so a mix of Yes & No "I do it and can demonstrate it?" along with how well the process is deployed is necessary.

We find that when an area embarks upon 5S it is worth conducting a pre-activity Audit this normally results in a low score - this is then used as a reference point to measure where we were to where we are now and underlines the improvements made in an area (along with lots of photographs and story boards)

We use both Audits and Assessments (Sustainability) to support our 5S programme and as you can see from the examples the audit gives an indication of performance in each of the 5 stages of 5S the Sustainability looks at the Approach used to sustain the improvements and has it become Business as Usual?

I have a Full Project pack including the Planning Tool - Area Maps - Red Tag Registers - Story Boards etc if anyone is interested just send me your email address.

As with all examples please do not distribute as they carry our company details and i would not like these in general circulation but to help our community i think an example is worth a thousand words.

Gary


11/11/2009 12:59 PM
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RonG
Ron Green



Gary,

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to: rgreen_19520@yahoo.com

Thanks in advance.

Ron
11/12/2009 01:23 PM
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23704
Mike Phillips



Gary,

I would like to have your 5S Full Project pack. I aslo will remove any identifying information.

Please send to: chandlerpop@netzero.net

Thanks,

Mike
11/13/2009 01:42 PM
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CANTULA
Luis Cantu



Dear Gary,

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to: cantula@yahoo.com

Thanks in advance.

Luis Cantu
08/30/2011 10:26 AM
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marcuuuuuuadca
marc u u u u u u adcasd



hi gary ,

Were you able to deliver a successful training to your 5S auditors? I am in the same situation now? We have done two audits, and there are complains from the floor that the results are not consistent, so I have to train my auditors to ensure consistent results and streamline their thinking. Any ideas?

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to: 95783@myrp.edu.sg
Thanks in advance.
11/13/2009 01:43 PM
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173290
Steve Magirias



Gary,

Please send me your 5S Full Project pack and I will also remove any identifying information.

Please send to: steve_magirias@indaltech.com

Thank you,
Steve
09/16/2011 12:15 PM
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oluAdekoya
olu Adekoya



Gary,

I would like to have your 5S Full Project pack. I aslo will remove any identifying information.

Please send to: olusegunadekoya@gmail.com


Thank you.
09/16/2011 01:50 PM
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92044
Jonathan Frund



Gary,

I'd appreciate receiving a copy of your 5S Full Project pack, also.

Please send it to: jonathan.frund@almatis.com

Thanks!
Jonathan Frund
09/19/2011 10:09 AM
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cagatay
Ça?atay Ba?do?an



Gary,



I'd appreciate receiving a copy of your 5S Full Project pack, also.



Please send it to: cagatayb@valf.com.tr

Thanks!
11/13/2009 01:41 PM
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191702
Hal Davis



My e-mail is hdavis@collisionsolution.com
Thanks You!
11/13/2009 01:41 PM
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190940
Aoife Beirne



Hi Gary,

It would be great to have access to the 5S Full Project pack.
My contact details are aoifebeirne@yahoo.co.uk. I will ensure not to circulate them.

Kind Regards,
Aoife
05/07/2010 01:08 AM
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MaheshKumar
Mahesh Kumar Velayutham



Hi Gary,

I would like to have this 5S full package to implement in my work area. So please send me 5S full package to (maheshkumar_ie@yahoo.com.)

Thanks,
Mahesh
11/13/2009 01:42 PM
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ViorelFLupu
Viorel Lupu



Gary,

I would also like to have your 5S Full Project pack. I aslo will remove any identifying information.
We struggle in my company with 5S even after 18 months since implementing it. I hope your package can give me some ideas.

Please send to: viorelf_lupu@yahoo.com

Thanks in advance

Viorel L.
11/13/2009 01:42 PM
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DN
David Nikolic



Gary,

could you send me the project pack as well.
David.Nikolic@web.de

Thanks in advance
11/13/2009 01:43 PM
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Bren06
Brendan Conway



Gary,
I would be interested in getting the presentation package.
Please forward to brendan.c.conway@us.army.mil
Thanks
Brendan C
11/13/2009 01:45 PM
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ScottScudder
Scott Scudder



Gary,

Thanks for those examples. I would love to have the 5S Project pack that you mentioned. I have included examples of what we are using as well. Maybe these can help others out there.

scott.m.scudder@usmc.mil

Thanks
Scott


11/16/2009 11:19 AM
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GTJones
Gary Jones



Hi Everyone

I have sent out copies of the Example Pack and the Excel templates - please let me know what you think as we are always looking to improve

Regards

Gary
05/06/2010 03:30 PM
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John_Benning
John Benning



Hi Gary,
May I get a copy as well. Thanks for sharing.

john.benning@ejgallo.com
05/07/2010 06:02 AM
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SteveMilner
Steve Milner



There's loads of good stuff already flagged up here John, so you'll hopefully have lots of key points to include or avoid when you start the practical stuff. Here's my two penn'orth, derived from implementing this in a wide variety of workplaces.

1.Be clear on what 5S is and what the words mean. The Japanese is variously translated (about 2 dozen versions at my last count) and they don't all mean the same in English. There are also different rationales. Why organise dirty things? Surely configuring is standardising? It's helpful to have the rules clear to start with, rather than have people score high and then appear to reduce their scores later.

2.The logic I subscribe to (which I believe is the most common) is:
i. Clear out the unnecessary
ii.Configure the necessary
iii. Clean (and check) the necessary; assure condition
iv.Set standards: assure conformity to ensure the first 3 don't slip
v.Make it Custom & Practice to keep things moving. E.g. On a first pass, clearing out
more than a day's stock might have been the goal. Next time round, maybe 4 hours?

3.Binary scoring is unambiguous: red or green, no amber - BUT would you want to give points for spotlessly-maintained equipment or well-organised stock that really shouldn't have been there in the first place? Having a well-written standard that's not observed? Therefore proceed step-by-step in each area: ensure people start at the beginning and progress methodically. If stuff is clean but not well configured, sorry, but they've not achieved the second step - however, once they've done that, they'll move rapidly through step 3, so there is some potential benefit to their efforts.

4.Keep it to five levels of overall condition. Make it more and time gets wasted deliberating on whether it's a 6 or a 7. No halves either. If an area is not-quite-a-four it's a 3!

5.Keep it all objective - no poor / fair / average / good / excellent etc. Objectivity involves using a scale / standard / comparator use words and pictures which exemplify the condition you're seeking.

6.Some might be disheartened by low scores, others spurred on to greater efforts. When I started doing this (and similar) audits 20-odd years ago it was based on what I'd experienced in Japan. UK factories were upset at their scores. "A ONE?!! You should have seen how bad we were 18 months ago ...and we're still only 1?!!' They said they were pursuing 'World Class Manufacturing', so what yardstick should have been used? They would have been less taken aback with better up-front education, nevertheless, be prepared to be generous in your words and recognise achievements, even if the numbers are low.

7.Excellence isn't achieved overnight, and those close to the area might be disheartened at slow progress. Taking plenty of photographs and annotating them to illustrate points not only helps to 'see the area as others see it', but also ensures that:
i.The lasting record is not 'what someone thought they remembered the auditors said',
but of positive comments. 'Nice example of XXX' etc. 'This rack would benefit by being
labelled like YYY' etc. rather than 'Unconfigured rack'
ii.Leaves a record to show how far they've come when progress seems slow.
iii. If audit team includes people from the area, they can use photos to compile a quick 'to do' list

8.There are a couple of audit forms. The sort (I believe) we're talking about here is a 'one size fits all' for use within an organisation, and which can be applied anywhere - factory, warehouse, offices etc. There's another, the local audit form, which is really part of the 4th step and mentions specifics or uses photos to illustrate the way things should be. I find the latter necessary to avoid ambiguity, and people buy into and understand that because it's locally-made.

I hope this helps. Drop me a line if you'd like any elaboration.
05/07/2010 01:52 AM
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TheLeanLeader
Jerome Martinez



Gary,

Hi! I would like to have copy of the full package as well. Thanks a lot.


My e-mail add is jjmartin@lexmark.com

Jerome Martinez
05/14/2010 09:26 AM
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krishna74
Shrikrishna Tiwari



Hi Gary

We are aiming at 5S implementation to drive cultural change rather than a tool. i would be grately thankful to you if you could send me your 5S package .

My email id is

shrikrishna.tiwari@alfalaval.com
09/10/2010 11:05 AM
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216808
Swati Bhardwaj



Gary,
If it's not too late, I would appreicate a copy of your 5 S presntation as well as the 5 S Full projet packet.

Thank you for your help!
Swati
sbhardwaj@sahalliance.org
09/02/2011 10:36 AM
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ChrisDavies
Chris Davies



Hi Gary,
Are you still able to send out a copy of your Five S pack to chris.davies@pepsico.com
11/16/2009 11:19 AM
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GTJones
Gary Jones



Hi Scott

Thanks for the Templates - These will help i am sure during our review - we will use them as a Benchmark Std.

Thanks again

Gary

"Supporting the British & American Military"



Originally posted by: ScottScudder

Gary,



Thanks for those examples. I would love to have the 5S Project pack that you mentioned. I have included examples of what we are using as well. Maybe these can help others out there.



scott.m.scudder@usmc.mil



Thanks

Scott
11/16/2009 11:20 AM
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terrymrowley
Terry Rowley



Gary,

Please email the 5S Project Pack to me, terrymrowley 'at' yahoo.com.

Thanks for sharing!

Terry
12/14/2009 04:06 PM
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jlmoen
Jason Moen



Gary, Scott,

Thanks for the examples. We have been using a detailed 5S audit form for the last few years and are working on revising it to include more of the Lean tools. Attached is a draft of what we may be going with. I welcome any feedback or suggestions.


Edited: 12/14/2009 at 04:06 PM by Lean Moderator


02/16/2010 06:01 PM
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Ilona
Ilona Kurach



Hi,
Please send me your 5S Full Project pack.
my e-mail ilona.kurach@wp.pl

Thank you

Best regards
Ilona Kurach
04/26/2010 10:30 AM
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oscarvaq
Oscar Vaquerano



Gary,

I'll appreciate receiving your 5S Full Project package. I will make sure any source identifying information is removed, should we decide to adopt them.

Please send to: ovaquerano@tesa.hn

Sincerely grateful for your generosity in sharing.
10/14/2010 03:54 PM
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cogypsy
William Pickens



Gary,

Thanks for those examples. I would love to have the 5S Project pack that you mentioned.

V/r,

W. Gary
william.pickens@va.gov
09/16/2011 12:15 PM
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leanpassion
Vikas Narkar



Hi Gary

I would love to get 5S project pack. My email id is

vnarkar@baumer-waaree.com

VN
09/23/2011 02:34 PM
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MattPasteris
Matt Pasteris



Gary, I could use the help by getting your presentation package,

Sincere Thank-you for your offering,

Matt P. mpasteris@flambeau.com
04/09/2012 11:04 AM
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fabbronip
Pier Luigi Fabbroni



Gary,

Thanks for those examples. I would love to have the 5S Project pack that you mentioned.

fabbroni@meta-partner.de

Thanks
Pier Luigi
06/26/2019 08:58 AM
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NancyRogerson
Nancy Rogerson



Originally posted by: ScottScudder

Gary,



Thanks for those examples. I would love to have the 5S Project pack that you mentioned. I have included examples of what we are using as well. Maybe these can help others out there.



scott.m.scudder@usmc.mil



Thanks

Scott


Thanks for sharing the files. Really appreciated your hard work.
11/16/2009 10:40 AM
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Greg MacKenzie



Hi Gary,

I would appreciate you sending me your 5S Full Project Pack. Will be used for internal reference so will not distribute your comapny details.

Can send to:
mackenzie.greg@irvingpaper.com

Thanks,
Greg
11/16/2009 11:19 AM
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5256
William Gilbert



Gary,

I would also like a copy of your Full Project Pack. Please send to wgilbert@bellsouth.net.
This information will not be distributed.

Thanks,
Bill
11/16/2009 11:20 AM
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thomasmcs
Thomasmcs Mcs



Gary,

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to: soam116@yahoo.com

Thanks in advance

Thomas
11/16/2009 11:21 AM
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laxsan
Sankaran Ramesh



Gary,

Last three months before i gave 5S trainnng to my team members. Everbody appreciateed that concept. But till date i am not able to implement that in my work

I would appreciate receiving your 5S Full Project pack to use for new ideas.

Please send to: mathu.rameshs@gmail.com

Thanks in advance.

Ramesh S
11/16/2009 11:21 AM
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martinoneill
Martin O'Neill



Gary,
a copy of your service pack would be appreciated. Please send to seadante@yahoo.co.uk I will ensure that it is not circulated.
thanks and regards,
Martin
11/17/2009 12:49 PM
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HP
Haresh Patel



Gary,
It would be highly appreciated , if you can send a copy of 5S full pack to me at
haresh_patel73@yahoo.com

That will remain completely confidential.

Thanking you in advance.

Haresh
11/18/2009 09:24 AM
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GTJones
Gary Jones



Hi Guys

I see there are many requests for the 5S audit packs - if you have not received a copy as yet please PM me on:

GaryThomasJones@aol.com

and i will then send you a copy, as always please remove any identifying logo's etc if you intend to use them.

Gary
11/18/2009 09:25 AM
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icpdude
Pedro Condessa



Gary,
It would be highly appreciated , if you can send a copy of 5S full pack to me at pedro.condessa@sapo.pt.

Thanks and best regards.

PC
12/02/2009 09:14 AM
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GTJones
Gary Jones



Hi Guys

Sent out all the packs now it's payback time :-)

Would be great to hear if the information was of use and Added Value to what you are doing within your organisations, the example pack was from one of our manufacturing areas and as you would have seen falls into the category of Heavy Engineering (Steel Works) so the old chestnut of "5S can only work in Production Line scenario" isn't true here.

Hope to hear from you soon

Gary
05/07/2010 04:30 AM
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164948
Keith Jones



Gary, could you send out a pack to myself at the following email address

keith.a.jones@baesystems.com
05/17/2010 09:07 AM
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chewy
Stephen Chew



hi Gary,
please could you send your 5s audit pack
stephen.chew@ntlworld.com

kind regards

Stephen
01/27/2010 10:39 AM
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MRC
Mark Clayton



Gary,

I've just come across your post and if possible I would like to have your 5S Full Project pack. I will remove any identifying information.

Please send to: mark.clayton@newsint.co.uk

Many thanks,

Mark..
02/01/2010 10:35 AM
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bologa
Marius Bologa



Gary,

I would appreciate receiving your 5S Full Project.

Please send to: mbologa@yahoo.com

Thanks in advance.

Marius
02/15/2010 03:08 PM
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Laxman
Laxman Subramanian



Gary,

This is Laxman from Ovation Cabinetry. I came across your posting in Lean.org. I was interested in getting your 5S Full Project pack. I will also remove any identifying information. I would really appreciate if you could send it over to me.

--
Thanks
Laxman Subramanian
Manufacturing / Process Engineer
Ovation Cabinetry Inc.
02/15/2010 03:09 PM
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Laxman
Laxman Subramanian



my Email is lsubramanian@ovationcabinetry.com
02/16/2010 06:01 PM
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rmilliken
Roseann Milliken



Hello Gary,

I would like the project pack - thanks kindly for sharing!

Roseann
rmilliken@appletonideas.com
04/19/2010 09:00 AM
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Gary Logan



Hi Gary,

Gary,

I would also like to have your 5S Full Project pack. I will remove any identifying information.

We struggle in my company with 5S, although attempts have been made no audits hasve taken place even after 12 months since implementing it. I hope your package can give me some ideas.

Please send to: glogan@sims-systems.com


Thanks in advance

Gary L
04/28/2010 09:28 AM
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taskhirnoori
Taskhir Noori



Hi Gary
Greetings from Taskhir!!!

I would also like to have your 5S full project pack. as i am working as 5s consultant.Definitely i will get a new idea from your work. if any one received that stuffs from Gary plz share with me.

plz share it to- taskhirnoori@gmail.com

Thanks in advance
Taskhir Noori
04/23/2010 09:35 AM
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KhaledAli
Khaled Ali



Hi Gary
Iam very interesting to getting you 5S presentation and 5S event package
i will remove any identifications from it
my email is
khaledismail@hotmail.com

i also have a lot of lean resources for you if you need

thank you very much
Khaled
04/30/2010 09:01 AM
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191702
Hal Davis



Gary,
Could I obtain a copy?
Thanks!
Hal

hdavis@collisionsolution.com
05/10/2010 09:53 AM
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iartis
Isaac Artis



Gary I would also like a 5s Packet

isaac.artis@covidien.com
05/10/2010 09:54 AM
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211948
Barry Roberts



Gary
I would be interested in receiving your 5S Full project package to use for possible ideas. I will remove any identifying information.

Please send to bdr54@verizon.net

Thanks

Barry
05/14/2010 04:11 PM
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sonde330
Matt Sonderen



Gary,

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Thanks so much for sharing your expertise.

Please send to matts@sonderen.com
05/18/2010 04:58 PM
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1985FLHT
George McKinnon



Hi Gary,
I too would be very interested in obtaining your Full Project pack including the Planning Tool - Area Maps - Red Tag Registers - Story Boards etc

Thanks
George McKinnon
email: mckinng@chesterton.com
05/24/2010 01:41 PM
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RonD
Ron Desourdie



Hi Gary,
Could you please send me the Full Project pack as well.

Thanks,
Ron Desourdie
rond@brodaseating.com
06/01/2010 12:11 PM
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ksmathews
Scott Mathews



Gary

I would like to receive the 5S Full Project pack if it is still available. My email is below.

Thanks,

Scott
scott@midwestcaststone.com
05/27/2010 12:11 AM
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234826
Jean-Francois Pelka



Hello Gary,

I do not know if it is still available but Would you please send me the 5S Full Project pack ? I will be in the process to use them pretty soon.

This is my e-mail for any correspondance: fpelka@aol.com

Thanks in advance.

Francois
09/13/2010 04:38 PM
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WilliamF
William Fan



Gary,

Would you please also send the 5S full Project pack to me? My email address is williamfan@rocketmail.com. Thank you.

William
09/17/2010 02:13 PM
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Alex_Campbell
Alex Campbell



Gary,
I would also like to see your full 5S project packet. I will remove any identifying information contained within. Thank you for your addition to the forums.

Alex
alex.campbell@rexam.com
09/17/2010 02:14 PM
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240689
Evan Miller



Gary,
I am a entry level engineer, attempting to implement Lean Manufacturing starting with a 5S program, if you still have the material I would appreciate a copy of the 5S Full Project Pack

Thank you for your help!
Evan
emiller@anhrefractories.com
09/20/2010 08:53 AM
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243265
Roman Prantl



Hi Gary,

I'll appreciate receiving your 5S Full Project package. I will make sure any source identifying information is removed.

Please send to: romanprantl@gmail.com


Thank you!!
09/17/2010 02:13 PM
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92027
Andrew Bryce



Hi Gary,

I know its a long time since you posted, would it be possible to send me the 5S project pack.

andi.bryce@btinternet.com

Thanks in advance
Andy
10/13/2010 11:26 AM
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tuanman
Tuan Newlin



Gary,
Can I get the Project pack.
I want to change direction in how our current 5S is going.
Thanks,

Tuanman
tnewlin@verabradley.com
04/05/2011 10:00 AM
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241620
Joyce Yii



Hi Gary,
Appreciate if you can send me your 5S pack as well at tohbin@yahoo.com.

Thanks a lot.

Toh
06/03/2011 09:40 AM
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badapple
Avid Ribchester



Gary,

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to:skitz_daring@yahoo.co.uk

Thanks in advance.

Dave
06/13/2011 09:59 AM
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oscarvaq
Oscar Vaquerano



Dear Gary;

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to: oscarvaq@hotmail.com
Regards
Oscar Vaquerano
06/16/2011 03:08 PM
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tpmcell
Tpmcell Tpmcell



Hi Gary,
Good morning!!! Can you please share the Full Project pack of 5S.

Thanks in advance!!!

My email id is mpj@lmwindpower.com

have a great day ahead!!!

rgds
Madhu
06/20/2011 09:33 AM
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ballas
Andrew Ball



Office 5S

Hi all,

as we are the subject of 5S I was wondering if I could have some views on the way in which I am currently rolling out 5S across my site.

The shopfloor has been using 5S for many years and is at a good level (always room for improvment) so the main focus for this roll out is the office areas (50xshop, 230x office), all of whom have never experienced anything to do with Lean.

I have taking the approach of using a softer approach than normal iin the office - the audit is not a binary style yes or no affair. Instead it is a series of statements which the teams auditing themselves have to judge whether they are going in the right direction or not (do they have the right intent). If they are making good progress and are most of the way there they get the point if they are struggling over cetain parts for too long they don't.

Some senior managers feel uneasy about this method as the scores can vary depending on the person carrying out the audit resulting in some areas being too harsh or two easy. Each team is walked through the audit for the 1st month (audits weekly).

The reason I have taken this approach is for the following reasons:-
1.The scores for me mean absolutly nothing - as long as the audit drives the right behaviour in people I am not concerned.
2.Many of these people have never had their daily tasks set or reviewed so I am using this soft approach to get them acustomed to aduits before ramping up the criteria to a binary style.
3.Many office staff see 5S as a manufacturing activity and not something we all must do
4.To get the initial buy in and momentum needed to sustain 5s before we move further ahead in our lean journey.

Any views and opinions welcome

Many thanks

Andy
06/20/2011 09:33 AM
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dileep_mor
Dileep More



Dear Gary

Please send a full project pack to dileep.more@gmail.com
I would appreciate your time.

Regards

Dileep
08/08/2011 05:18 PM
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Edward-Hutcheon
Edward Hutcheon



Gary,

I realise this a bit late but i would appreciate it if you could email me your full Project Pack on 5's

Thanks

Eddie.
08/15/2011 01:50 PM
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KaushikB
Kaushik Bhattacharya



Gary,
Can you please send me the full project pack on kdb2442@rit.edu. It will be a good example to analyse and learn from.

Thanks,
Kaushik
kdb2442@rit.edu
08/18/2011 10:34 AM
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truongson
Son Truong



Hi Gary,

Could you please send the Full Project pack to me as the email below:

email: truongsonbk75@yahoo.com

Thank you very much and best regards
08/19/2011 05:33 PM
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oliverdemus
Oliver Demus



Hi Gary,
could you please send me the project documents as well?

Thanks,
Oliver

oliverdemus@me.com
08/22/2011 03:22 PM
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CEM
Carlos Moretti



Hi Gary,
could you please send me the project documents as well?

Thanks in advance
Carlos

carlosemoretti@terra.com.br
08/19/2011 05:32 PM
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kennycrosbie
Kenny Crosbie



Gary,

I would also like to have your 5S Full Project pack. I will remove any identifying information.

Please send to: crozzers@live.co.uk
08/22/2011 03:22 PM
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262693
Marc Uuu



Hi gary ,
Can send me the 5sfull project pack
Thank you
Marc
08/23/2011 05:38 PM
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sunilpantoji
Sunil Pantoji



Hi gary ,

Can you send me the 5sfull project pack ?

my mail id is sunil.pantoji@gmail.com

Thank you

Sunil Pantoji
08/22/2011 03:22 PM
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262693
Marc Uuu



Hi gary ,

I am marc need ur 5s full project pack to refer as a guide for my campus project.
My email is 95783@myrp.edu.sg
Thank you
Marc
08/22/2011 03:22 PM
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262693
Marc Uuu



Hi gary ,

I am marc need ur 5s full project pack to refer as a guide for my campus project.
My email is 95783@myrp.edu.sg
Thank you
Marc
08/30/2011 10:26 AM
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MICHELLEWALTERS
MICHELLE WALTERS



Please send to: Michelle.Walters@averydennison.com
09/02/2011 10:36 AM
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catherinejin
Catherine Jin



Hi Gary,

Reviewing all the post, I have the clear thinking about 5S audit and 5S audit assessment.
The yes/no is much better than 1-5 scores.
The management teams have gemba walk and make sort-set by theirselves. This is a practice method to cultivate 5S culture in the infancy stage.
I am also interested in the Full Project pack, would you mail to me? my e-mail address: jinyue7302@163.com.

Thanks a lot.

BR/Catherine
09/15/2011 04:03 PM
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Ojas
Ojas Gokhale



I would also appreciate receiving your 5S Project Pack.
My email address -

ojasgokhale@gmail.com

Thank You!

Ojas
09/16/2011 12:15 PM
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keremcoban
Kerem Coban



Gary,
I would be interested in getting the presentation package.

Could you please forward to coban-consulting@coban-consulting.com ?

Many Thanks
Kerem Coban
09/19/2011 10:09 AM
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AustinZhai
Weidong Zhai



Hi Gary:

Could you please send me the 5S project pack, Thank you.

My email is weidong.zhai@gmail.com
09/16/2011 12:15 PM
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Dave_Brace
David Brace



Hi Gary,
I'd be most grateful if you could send me a copy of the 5S project pack that you mention. Thankyou.

Dave Brace

davidbrace@payne-worldwide.com
09/20/2011 03:04 PM
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RickMartin
Rick Martin



Gary,

Please e-mail the 5S pack to agrmarti@nmhg.com.

Thanks,
Rick
09/23/2011 11:06 AM
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112221
Fred Tossick



Please forward your 5S Full Project Pack to me: fgtossick@lmcindustries.com
09/23/2011 11:06 AM
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188604
Rick Tuckerman



Gary,

I would appreciate receiving your 5s Full Project pack.

Please send to: rick.tuckerman@hardinge.com

Thanks so much

Rick
09/23/2011 11:06 AM
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JRobC
John Coleman



Hello Gary,
I'd be grateful to receive your 5S Audit pack.

Regards
Rob Coleman

e-mail: robcoleman@eaton.com
09/28/2011 09:45 AM
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AntonioDeCarlo
Antonio DeCarlo



Gary,

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to antonio.decarlo@materion.com

Thanks, Tony
09/30/2011 10:54 AM
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episfil
Elmer Pisfil



Gary,

I would appreciate receiving your 5S Full Project pack.

Please send to: episfil@asesume.com

Thanks.

Elmer
01/13/2012 03:06 PM
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Steve24
Steve Howell



Hi Gary,

I know it has been a while since you posted, would it be possible to send me the 5S project pack?

howelsm@jmusa.com

Thanks a million!
Steve

Also, on this thread I have noticed many people using a yes/no in their scoring of audit line items. One thing I previously used for many (not all) line items on a 5S audit was to score based on # of occurances. For example: for the audit line item: "Items are not in their correct place" - if there were five or more occurances of items not in their correct place, the score is zero (0); three to four occurances, score = 1; two occurances, score = 2; if one occurance, score = 3; if no occurances, score = 4. To get no points in an entire area because a single hammer was not put back seemed unfair to people. And, because they viewed a "# of occurances" scoring as being a fair assesment, they seemed to be more receptive to the audit findings. Not saying this is "the right way" to score, but just wanted to share another perspective. Very interested in hearing thoughts on this....
03/09/2012 10:34 AM
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turntabalist
Amjed Hussain



Hi Gary, I am in the process of implementing 5s in our production area and would welcome your help. I would be very grateful if you could e-mail me your complete 5s pack that you have done.My e-mail address is Amjed.Hussain@Terumo-Europe.com
03/16/2012 12:58 PM
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Pablomartin
Pablo Casacuberta



Hi Gary,
I am the current Lean Coach of the factory, and I have just loggin into this Lean Inst.
I am relly very interested in getting your complete 5s pack.
My mail is: pmartin@cafosa.com
Thanks in advance

Pablo Martin
03/28/2012 05:40 PM
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JasonWoods
Jason Woods



Hi Gary,

We are just embarking on our 5S journey in a Ductile Iron plant...I would love to review your full project pack for ideas.

My email is jwoods@metal-technologies.com

Thank you.
04/10/2012 02:35 PM
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lenmcdonald
Len McDonald



Gary,
Please send me a packet. WALCMD42@gmail.com
04/13/2012 07:45 PM
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273364
Ossama Ismail



Gary,

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to: qaqctqm6sigmalean@gmail.com

Thanks in advance.
Ossama Ismail
07/18/2012 10:42 AM
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Gonorenzou
Peter Chitauro



Hi Gary

Could you please send me the Full Project 5S pack. My email address is
peter.chitauro@yahoo.co.uk
08/26/2016 04:51 PM
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ShurekaGantt
Shureka Gantt



Hi Gary,

I would like to receive a full project pack.

shurekab@gmail.com
09/07/2016 10:06 PM
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oberkele
Owen Berkeley-Hill



Having been an auditor (not 5S) in a previous life, I squirm when 5S and "audit" are mentioned in the same sentence. Yes, my post may be descending into the realms of semantics but words, as Humpty Dumpty once suggested, are very powerful and can send the wrong meaning.

"Audit" suggests to me getting the teams' compliance rather than their commitment. It assumes that there is a higher authority that knows how to organise a workplace better than the people who work there. It also suggests a management culture of Command & Control rather than a culture where the leadership is in the vanguard of the Lean journey and are very good at mentoring and coaching their people to appreciate why Lean needs to be embraced. If your leadership is not thinking, believing, acting and behaving in a Lean way then the organisation is just tinkering with the methodology and all the efforts to get to 1S will fade by lunchtime tomorrow. At the heart of Lean are continuous Improvement and respect for people (i.e. encouraging them to learn and develop all through their working lives). 5S should be based on this thinking.

I can also imagine the CEO, fuelled by an overdose of testosterone, insisting on all his or her managers hitting 4S by Christmas. I'll leave it to your imaginations as to what happens further down the line.

The fundamental purpose of 5S is not so that the CEO will see a tidy workplace fashioned along military lines with not a hair our of place. It is about getting the workplace to work for the people there rather than the other way round. Will an auditor who is looking for "consistency" as many of you have demanded see this if she/he has not spent a lot of time in the area being audited? Err... doing the work? I doubt it.

One of the biggest grumbles when any change is suggested (even Lean) is the "What's in it for me" factor. If you can you show the teams that 5S is in their best interest and then encourage them to come up with thier improvement opprtunities based on the death by a thousand cuts they experience every day with no one taking notice.

Mark Rosenthal's post hit the nail on the head (in 2008) but it seemed to have flown over at 30,000 ft judging by the demand for audit documentation.

Remember, Lean is about commitment, not compliance. Good luck!
08/19/2016 02:35 PM
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333825
Kathy Johnson



I would like the Full Project pack. My e-mail is kajohnson@airmar.com

Thank you,

Kathy
11/09/2009 11:05 AM
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duecesevenOS
Kris Hallan



Were you able to deliver a successful training to your 5S auditors? I am in the same situation now? We have done two audits, and there are complains from the floor that the results are not consistent, so I have to train my auditors to ensure consistent results and streamline their thinking. Any ideas?


Go to the Gemba.

Do audits together and calibrate your auditors to yourself. Build this up organically and have your auditors do audits with others. By using tiered accountability we have actually gotten to the point where managers honestly audit their own areas. Upper managerment does periodic "auditing of the audit" to ensure continuous calibration. Our lean group does periodic auditing of the upper management team (plus occasional spot audits in areas we think might be slipping). Now that management can honestly see the gap between where we want to be and where we are, the audits are a short distance from being unnecessary...2 years later. It's not quite a way of life for everyone yet but it's pretty close.

A classroom teaching of this will NOT work.

Also: Don't plan on ever being done with this training. Auditing standards are in a continous state of RAPID decay. Without continuous reinforcement and training, it will cease...just like anything else (only even faster in this case).
04/29/2010 09:30 AM
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235259
David Kruckas



John, if your team leaders have been thru 5S training then my questions is are their standards established? If the standards are established then I suggest you take pictures of the ok condition and use them as Audit sheets.

So for example - what should the break area look like in ideal condition, take a picture, attach the picture to some excel audit sheet and use that as an audit.

For more information check out my blog
www.informationyoucanuseguy.blogspot.com
05/03/2010 04:03 PM
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RuiRodrigues
Rui Rodrigues



Dear Gary,

I would appreciate receiving your 5S Full Project pack.
I will remove any identifying information.

Best Regards

Miguel Rodrigues
rodrigues.rmiguel@gmail.com
05/06/2010 02:16 PM
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Max13
Maksym Bykhovtsov



Dear Gary,

is it still possible to receive the copy of Full Project pack?

Thank you in advance,

Max

mb@pc-zorya.com.ua
05/07/2010 01:45 AM
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TheLeanLeader
Jerome Martinez



John,

5S Auditing is something that we have tried to do in years but on my personal observation it has not been a very effective way of achieving a strong 5S culture.

People always has a level of resistance once an audit is conducted on their area. Most often it is one of the trigger in developing of certain culture in 5S where employees react and prepare specially if audits are scheduled. And if its a surprise audit, most employees tends to be more indifferent and embarassed during the audit. In our culture (Asian), a certain percentage of the workforce find ways to get out of the area during the audit.

Recently, we have adopted the Lean Management System or Standard Work for Leaders to ensure that all in the organization is given the responsibility in conducting Gemba Walks. Frequency differs from different job level, the higher the position the less frequent it is.

The major difference of doing the Gemba Walk compared to the audit is that we ourselves from the management team and the supervisors are the ones conducting the actual 5S 'Sort and Set" and talks to the entire team after each gemba walk. The impact on behavior changes from avoiding auditors and audits but instead people engages themselves when the entire management team is down on the floor with wipes, scrapers, cleaning and other cleaning tools. We do this daily as a manufacturing manager and people have shown appreciation on the changes. They have started to be conscious on the cleanliness of the area in a more positive way and is appreciative of the daily presence of managers on the production floor. We find it effective and on one of the consultative meetings with operators, they appreciate the efforts of management and it gives them more inspiration to adopt a stronger culture in 5S.

One of the critical things that is needed though is to get the management commitment to ensure the activity is done daily and considered as a priority.

My one-cent contribution

Jerome Martinez
09/21/2010 01:07 PM
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Cplatt21
Chuck Platt



What i do with my guys is make a checklist that is to be performed at the end of each shift. Then once a week athey do a self audit and then once a week i do an audit. As they do what the checklist asks them to do, when they do the audit, it gives them better scores.
06/14/2011 02:59 PM
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Kwok-wo_Bong
Kwok-wo Bong



Dear Gary

I would appreciate receiving your 5S Full Project pack to use for new ideas. I will remove any identifying information if we adopt them.

Please send to: desmond_418@live.co.uk
Regards
Desmond
06/15/2011 09:41 AM
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mele
Federico Luján



Gary,

I would like to have the 5S Full Project pack.
Please send it to: familia_lujan@arnet.com.ar
Thanks in advance,

Federico
06/16/2011 10:12 AM
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Skyhigh07
Garry Gentry



Sir,

I would also like to review the 5S Full Project Pack? Thanks. garryL44@aol.com
06/23/2011 06:09 PM
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M_Norton
Michael Norton



Gary,

If you're willing to share you Full Project pack, I would be interested in obtaining it. Thank you for making it available.

mike.norton@fimcoindustries.com

Mike
07/29/2011 03:51 PM
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Dashamimi
Jackie Musgrave



I would like the full project pack if you are still sharing. Please send to jmusgave1966@hotmail.com
09/28/2011 09:45 AM
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JMVIVES
Jose Vives



Hello:

I agree with Steve Milner's reasons. Be clear on what 5S is in order to have the rules very clear from the very beginning, rather than have people score. And, in case, the red/green system I think is more useful than the 1-5 points.

Regards,

JM Vives
09/29/2011 01:25 PM
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SL
S Kho



Hi Gary,

I'm new to 5S, and would appreciate it if you could forward to me your 5S full package at sioklian@yahoo.com


Thanks

Regards,
SL
04/05/2012 12:44 PM
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MarcosPoffo
Marcos Poffo



Hi,

Please, send me the 5S Full Project.
For: poffom@yahoo.com.br

Thanks

Marcos Poffo
06/15/2012 12:05 PM
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MarcosPoffo
Marcos Poffo



Originally posted by: MarcosPoffo

Hi,

Please, send me the 5S Full Project.

For: poffom@yahoo.com.br

Thanks

Marcos Poffo


Gaby,

You can send me again the 5S full project? I think lost its email!

Sorry,

Marcos
04/20/2012 11:49 AM
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37318
Anthony Manos



A long time ago we had difficulties in a hospital lab calibrating the 5S Auditors to give consistent results from person to person, area-to-area and even audit-to-audit. We held a 5S Auditor training session that covered the elements of what makes a good audit and what makes a good auditor. We used a model based on internal auditor training a la ISO 9001. We did several group audits scoring individually and comparing results together. A key element was to teach the auditors and supervisors of the area that the actual score was not the desired outcome, but improvement was what we were looking for. We also tracked the audits over the next few cycles to see that the results were much more standardized. This seemed to get everyone on the same track. Good ols PDCA. I hope this helps. If you want more information about 5S, we created a free ebook ""The Very Best of 5S - Benchmarking Report".
06/15/2012 12:05 PM
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CinthyaKuramoto
Cinthya Kuramoto



Hello There,
I saw that there are many posts to Gary asking for the audit training. I´m also very interested in it. Please It would be possible to send to cinthya@psitech.com.br

´m training the 5S Audit Team beacuse the assessment they were doing was kind of superficial and they claim that they don´t know how to carry it out in the shoop floor. As we are now in a Lean Journey we also want to evaluate whether the 5S is really contributing to it, e.g Continuous Flow and.

Is there any different check list to assess administrative areas and shop floor? Hope receive suggestions.

Thank you very much

Cinthya
skype: cinthyakuramoto
email: cinthya@psitech.com.br
06/25/2012 12:38 PM
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256003
Jozef Gavel



Gary.
Please send 5S full project pack to my email address
jovoga@seznam.cz
08/24/2016 10:35 AM
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BertAnneveldt
Bert Anneveldt



Gary,

I would highly appreciate receiving your 5S Full Project pack to use for new ideas.
I will remove any identifying information if we adopt them.

Please send to: bert.anneveldt@hotmail.com

Many thanks in advance,
Bert
08/26/2016 10:37 AM
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AdamStorms
Adam Storms



Gary,
I would also greatly appreciate receiving your 5S Full Project pack to see if there is anything that I can use to make our process more lean and effective. I am always looking for new ideas on how to improve our process. I will definitely remove any identifying information before anything gets distributed.
Please send it to : adam.storms@kautex.textron.com

I appreciate your assistance.
Thank you
Adam Storms
08/26/2016 04:50 PM
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Soundfreq
Keeley Moore



Gary. I would also appreciate receiving your 5S Full Project Pack. I will remove any identifying information prior to using it in any way.
Thank you.
Keeley
08/26/2016 04:50 PM
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Moderator_Lory
Lory Moniz



Hi All,
When requesting materials from a person please you Private Messages instead.

Thank you!
Lory
08/26/2016 04:51 PM
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DanKyes
Dan Kyes



Hi Gary

I would like to look at your 5S packet
dan.kyes@terex.com

thanks
Dan
06/26/2019 08:58 AM
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djackson
Daniel Jackson



Hi Gary,
My company is in the process of overhauling our 5S program. Would you email me your 5S project pack? It sounds very interesting! My email is danjackson2012@yahoo.com
07/19/2019 10:29 AM
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BenSherman
Ben Sherman



Thanks, cool
07/24/2019 11:52 AM
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360968
Gator Packaging



Nice Post. Thanks For Sharing Knowledge
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