1st Edition

The 5S Playbook A Step-by-Step Guideline for the Lean Practitioner

By Chris A. Ortiz Copyright 2016
    80 Pages 77 Color Illustrations
    by Productivity Press

    80 Pages
    by Productivity Press

    This book provides detailed step-by-step guidelines on how to properly implement 5S (Sort, Set in Order, Scrub, Standardize, Sustain) and the visual workplace. It is ideal for Lean practitioners and facilitators looking for a training tool and a guideline that can be used in the work area.


    8 Wastes

    Lean Metrics

    5S Supply List

    5S Supply Cart


    Step 1
    Red Tagging
    Why Sort?
    Red-Tag Areas
    Rented Container
    Sorting Hardware
    Body Shop
    Removal Procedure
    Removal Ideas

    Set in Order
    Stage 2
    Painted Work Areas and Aisleways
    Floor Tape Work Areas and Aisleways
    Machine Shop
    Tool Check Cards
    Tool Placement

    Stage 3


    End-of-Day Cleanup Procedure
    Daily Walkthrough
    5S Audit Form/Criteria
    Sample 5S Audit Form: Form 5-1
    Assigning Auditors and Rotation
    Sample Auditor Rotation
    5S Tracking Sheet
    Sample 5S Tracking Sheet
    Incentive Program

    5S Shadow Board: How-to Reference Guide
    Why Use a 5S Shadow Board?
    How to Build a 5S Shadow Board
    Steps 1 and 2
    Step 1: Paint Peg Board
    Step 2: Begin to Place the Boards on a Flat Surface to Verify Space Requirements
    Steps 3 and 4
    Step 3: Hang Board in Desired Location
    Step 4: Place Tools on Board
    Steps 5, 6, and 7
    Step 5: Leave Enough Room for the Shadow or Outline
    Step 6: Finalize All Tool Locations
    Step 7: Use a Paint Pen to Outline Tool
    Steps 8 and 9
    Step 8: Make and Place Labels Near Tool
    Step 9: Place Color Tape Around Tool for Designation
    Steps 10 and 11
    Step 10: Designate the Board with a Location
    Step 11: Place a Designation Label on Tool


    Definition of Terms



    Chris Ortiz is the founder and president of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Chris has been featured on CNN Headline News on the show "Inside Business with Fred Thompson." He is the author of six books on Lean manufacturing.

    Chris is a frequent presenter and keynote speaker at conferences around North America. He has also been interviewed on KGMI radio and the American Innovator and has written numerous articles on Lean manufacturing and business improvement for various regional and national publications.

    Kaizen Assembly’s clients include industry leaders in aerospace, composites, processing, automotive, rope-manufacturing, restoration equipment, food processing, and fish-processing industries.

    Chris is considered to be an expert in the field in Lean manufacturing implementation and has over 15 years of experience in Lean manufacturing and business improvement.

    Watch Fred Thompson talk about Kaizen Assembly and Chris Ortiz on "Inside Business with Fred Thompson" at: