Process Implementation Through 5S: Laying the Foundation for Lean, 1st Edition (Paperback) book cover

Process Implementation Through 5S

Laying the Foundation for Lean, 1st Edition

By Drew Willis

Productivity Press

120 pages | 17 Color Illus. | 4 B/W Illus.

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pub: 2016-04-01
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Process Implementation Through 5S: Laying the Foundation for Lean explains how to implement standardized work and visual controls through Plan–Do–Check–Adjust (PDCA). The author uses PDCA to outline the book and explains how 5S (Sort, Straighten, Shine, Standardize, and Sustain) and Standardization are not only foundational parts of the PDCA for your Lean transformation, but are actually PDCA processes within themselves.

The book provides a road map to implement new processes. In addition, it shows how this same implementation process can be used to shore up existing processes and improve upon them. Once you walk through this process with your team, you not only will have laid the foundation for Lean in your organization, but will have laid the foundation for PDCA and for building an army of problem solvers. This transformation is what ultimately will add value to your customer base and drive the business results you are looking for.

These Lean tools are not an end to a means, but rather a means to an end. The purpose is not to implement these tools, check off the box, and then move on to the next area. Rather, they are tools designed to engage your team and help your team see problems, which you then can solve. This is the continuous improvement culture most organizations and Lean leaders seek.


"Drew Willis, with his hands-on floor experience at Toyota, has captured the essence of ‘getting started’ on your Lean journey in any industry."

Michael Hoseus, Lean practitioner and award-winning author

Table of Contents


Overview of the Process

5S Overview

Standardized Work Overview



Format of This Book



Identify the Area

Reactive Process Implementation

Proactive Process Implementation

Get a Team

Assess Current State and Set the Goal

Determine If You Have Stability

Set the Goal


Document and Analyze the Processes

Watch the Work

Document the Steps of the Process and Ask Questions


Meet with Your Group and Assign Action Items



Implement a Pilot

Implement the Final Process, Share Success, and Begin the Next Process

Visual Controls

Standardized Work

Assess Your Goal



Standardized Work

5S Audits


Training Standardized Work

How to Instruct

MFWC—Multi-Function Worker Chart



About the Author

Drew Willis began his Lean journey through extensive classroom training and hands-on experience as a production team member at Toyota Motor Manufacturing Kentucky. During his tenure at Toyota, he successfully applied the Lean methods he learned from Toyota Production System (TPS) training into multiple processes, which reduced defects and improved upon the standardized work. Since Toyota, Drew has held numerous positions, including having responsibility for implementation of 5S and standardized work, program management, and government relations and contracting. He currently works in food manufacturing as the business manager of various military ration programs. Drew earned a Juris Doctorate degree and has published articles in the area of labor law.

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Industrial Management