The 5S Playbook: A Step-by-Step Guideline for the Lean Practitioner, 1st Edition (Paperback) book cover

The 5S Playbook

A Step-by-Step Guideline for the Lean Practitioner, 1st Edition

By Chris A. Ortiz

Productivity Press

79 pages | 77 Color Illus.

Purchasing Options:$ = USD
Paperback: 9781498730358
pub: 2015-09-08
eBook (VitalSource) : 9780429258015
pub: 2015-09-08
from $20.98

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A powerful and effective Lean tool, 5S can help prevent company failure and launch an organization into world-class operational excellence. Until now, however, there has been a need for a book with detailed step-by-step guidelines on how to properly implement 5S (Sort, Set in Order, Scrub, Standardize, Sustain) and the visual workplace. Complete with color images, The 5S Playbook: A Step-by-Step Guideline for the Lean Practitioner fills this need.

This new book in The LEAN Playbook Series is your guide to proper 5S and visual workplace implementation. It is ideal for Lean practitioners and facilitators looking for a training tool and a guideline that can be used in the work area while improvements are being made.

Like a football coach, you can use this playbook for quick reference to convey what’s needed to facilitate effective 5S kaizen events. If for some reason you forget a "play" during the 5S implementation, you can easily reference the playbook. You can follow page by page and use the playbook to facilitate a 5S implementation, or you can go directly to certain topics and use it to help you implement that particular "play."

The playbook includes color images from actual 5S implementations. In addition to the images, a combination of short paragraphs and bulleted descriptions walk you through each step of an effective 5S implementation.

Looking for supplemental information or Lean coaching from Chris Ortiz? Go to to receive ongoing support and advice on how to use The LEAN Playbook Series for training and implementation.

Table of Contents


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


About the Author

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:

About the Series

The LEAN Playbook Series

Learn more…

Subject Categories

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