5S Made Easy: A Step-by-Step Guide to Implementing and Sustaining Your 5S Program, 1st Edition (Paperback) book cover

5S Made Easy

A Step-by-Step Guide to Implementing and Sustaining Your 5S Program, 1st Edition

By David Visco

Productivity Press

92 pages | 60 Color Illus.

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Description

For decades, 5S practitioners have struggled with exactly how to implement and sustain a 5S program in their workplaces. While there are many books available on the organization methods suggested by 5S, few provide easy-to-understand, step-by-step guidance on how to set up and sustain successful 5S implementations. 5S Made Easy fills this need.

Written by an expert whose focus for the last decade has been nothing but 5S, the book supplies in-depth guidance on how to implement and sustain each of the 5S pillars—sort, set in order, shine, standardize, and sustain.

The book uses an easy-to-follow format that was designed for use during 5S events. It provides color images of real-world 5S solutions, including before and after pictures from the field. It also supplies readers with online access to all of the forms and documents needed for an effective 5S program. All the forms and documents are provided in an easily editable format to fit any operation.

Reviews

"5S Made Easy is a simple, easy-to-follow guide for 5S in manufacturing. It nicely explains how 5S has a greater purpose than simple housekeeping. It is about standardizing and improving—often overlooked points in a 5S deployment."

—Drew Locher, Change Management Associates; Shingo Prize-Winning Author of Lean Office and Service Simplified and Value Stream Mapping for Lean Development

"Hurray to Dave Visco for 5S Made Easy. When I ask customers ‘How much time do you spend each day searching for material, information or tools?’ the typical response is ‘about an hour.’ Regardless of the venue – office, healthcare or factory – the answer is almost always the same. A workplace that is not well organized generates an incredible amount of confusion, frustration, and delay every day! But every so often, I encounter a facility where employees declare proudly, ‘We never search for anything.’ These are workplaces transformed by 5S, where employees and managers make workplace organization a regular part of their work and their continuous improvement. The stability created through an effective 5S process is critical to every other best practice, from set-reduction and TPM to kanban and standardized work. Dave’s book offers a step-by-step primer for any change leader who wants to get this foundational improvement method right the first time.

—Bruce Hamilton, President, GBMP

"5S has become one of the most popular improvement activities in factories, offices, and small shops across America. 5S is straightforward and effective in improving any operation. Despite its popularity, there are only a handful of books that explain how to do 5S. Veteran 5S coach and consultant, David Visco, has stepped in to help fill that gap with his ‘how-to’ workbook, 5S Made Easy. Anyone can begin a 5S program in their department or business by following this book’s easy-to-understand steps. In addition, Visco has provided checklists, forms, and resource guides. Almost everything you need is right here."

—From the Foreword by Mike McCarthy, Lean Consultant and Author of Sustain Your Gains: The People Side of Lean-Six Sigma

Table of Contents

What Is 5S and Why Do It?

What Is 5S?

Benefits of 5S

Summary of Each of the 5 Pillars

How Is It Implemented?

Action Items

Parking Lot Items

How to Use This Book

Action Items

Parking Lot Items

Notes

Develop Your Plan

Develop Your Plan: Summary of Steps

Action Items

Parking Lot Items

Notes

Train the Team

Tips for Launch Success

Train the Team: Summary of Steps

Action Items

Team Ideas

Parking Lot Items

Sort

Benefits

Materials Needed

Pre-Event Tasks

Red Tag Event Steps

Lessons Learned for Future Red Tag Events

Sort: Summary of Steps

Action Items

Parking Lot Items

Notes

Set in Order and Shine

Summary

Benefits

Materials Needed

Pre-Event Tasks

Set in Order and Shine Steps

Team Ideas

Some Idea Examples

Some Shine Idea Examples

Some Ideas Examples

Set in Order: Summary of Steps

Action Items

Team Ideas

Parking Lot Items

Standardize

Benefits

Materials Needed

Pre-Event Tasks

Standardize Steps

Benefits

Benefits of 5S Audits

Standardize: Summary of Steps

Action Items

Parking Lot Items

Sustain

Summary

Benefits

Materials Needed

Pre-Event Tasks

Sustain Steps

Sustain: Summary of Steps

Action Items

Parking Lot Items

The Ideal Conditions to Implement Lean

Know What Your End Goal Is

Make Sure Leadership Is on Board

Prepare Your People

Do Not Lose Momentum

Action Items

Parking Lot Items

In Closing

5S Launch Guide

Develop Your Plan: Summary of Steps

Train the Team: Summary of Steps

Sort: Summary of Steps

Set in Order: Summary of Steps

Standardize: Summary of Steps

Sustain: Summary of Steps

5S Materials Checklist

Forms

Resources

Training and Education

Supplies

Acknowledgments

Index

About the Author

David Visco is an experienced 5S Coach and 5S Event Leader. He has 30 years of operations, warehousing, inventory management, and manufacturing experience in the distribution, medical device, biopharmaceutical, and the electronics industries. Visco has a master’s degree from Babson College in Wellesley, Massachusetts.

In 2006, after implementing 5S with his current employer, Visco had an idea to make 5S easier: one stop shopping for 5S supplies and materials. He and his wife Barbara started the5Sstore.com, where you can get everything you need to implement 5S. Visco offers 5S advice to major corporations as well as small- and medium-sized companies. He also researches and finds visual solutions for applying 5S in difficult situations.

Subject Categories

BISAC Subject Codes/Headings:
BUS053000
BUSINESS & ECONOMICS / Quality Control
BUS070050
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
BUS082000
BUSINESS & ECONOMICS / Industrial Management