This curriculum spans the equivalent of a multi-workshop operational readiness and implementation program, covering the same scope of activities as an internal process improvement team’s end-to-end 5S deployment across pilot workcells, integration with maintenance and quality systems, and alignment with enterprise audit and compliance frameworks.
Module 1: Assessing Organizational Readiness for 5S Implementation
- Conducting cross-functional walkthroughs to identify existing workflow inefficiencies and physical workspace constraints.
- Evaluating leadership alignment by mapping stakeholder influence and resistance to visual management systems.
- Reviewing current safety audit records to determine compliance gaps that 5S can directly address.
- Assessing union or workforce representation policies that may impact workspace reorganization timelines.
- Determining the availability of internal champions with operational credibility to lead pilot areas.
- Establishing baseline productivity metrics in targeted departments to measure pre-implementation performance.
Module 2: Strategic Planning and Scope Definition
- Selecting pilot workcells based on high-touch processes with recurring material handling delays.
- Defining clear boundaries for 5S application—production floor, warehouse, or administrative offices—based on value stream impact.
- Developing a phased rollout schedule that aligns with maintenance shutdowns or low-production periods.
- Allocating budget for shadow boards, labeling systems, and storage modifications without capital project approval delays.
- Integrating 5S milestones into existing operational review calendars to ensure executive visibility.
- Creating escalation paths for resolving conflicts between departmental space ownership and shared tool access.
Module 3: Sort (Seiri) – Eliminating Non-Essential Items
- Executing red-tagging campaigns with standardized criteria for tagging tools, materials, and documents.
- Establishing quarantine zones for red-tagged items with defined review and disposition timelines.
- Coordinating with procurement to verify if tagged inventory duplicates active purchase agreements.
- Documenting disposal decisions for hazardous materials in compliance with environmental regulations.
- Engaging floor supervisors in validating “essential” vs. “just-in-case” tool retention.
- Tracking space recovery metrics (square feet cleared) to demonstrate immediate physical impact.
Module 4: Set in Order (Seiton) – Structured Workplace Organization
- Designing tool shadowing layouts based on operator ergonomic assessments and frequency-of-use data.
- Implementing color-coded labeling systems aligned with existing facility safety standards (e.g., NFPA, OSHA).
- Positioning consumables within defined motion paths to reduce walking time per work cycle.
- Standardizing bin sizes and labeling fonts to ensure consistency across departments.
- Integrating point-of-use storage solutions that minimize replenishment frequency.
- Validating layout changes through time-motion studies before full deployment.
Module 5: Shine (Seiso) – Deep Cleaning and Equipment Inspection
- Developing cleaning checklists that include inspection points for early equipment wear detection.
- Assigning cleaning responsibilities using RACI matrices to avoid accountability gaps.
- Training operators to identify leaks, misalignments, or loose components during routine wipe-downs.
- Integrating cleaning schedules with preventive maintenance work orders in CMMS systems.
- Specifying cleaning agents compatible with machinery seals and control panels.
- Conducting pre- and post-shine audits to measure particulate reduction in critical zones.
Module 6: Standardize (Seiketsu) – Sustaining Visual Controls
- Creating standardized 5S audit forms with weighted scoring for high-risk areas.
- Embedding photo-based work instructions at stations to reinforce correct tool placement.
- Linking 5S compliance data to daily huddle reporting templates used by shift leads.
- Rolling out digital audit tools with GPS-tagged photo uploads to prevent falsification.
- Negotiating with IT to integrate 5S KPIs into operational dashboards without custom coding.
- Establishing uniform shift handover protocols that include workspace verification steps.
Module 7: Sustain (Shitsuke) – Embedding Behavioral Discipline
- Designing recognition systems that reward teams for audit consistency, not one-time cleanups.
- Conducting monthly leadership gemba walks with documented feedback loops to workcells.
- Updating onboarding materials to include 5S expectations for new hires.
- Revising performance evaluations to include 5S stewardship for supervisory roles.
- Rotating audit team members across departments to prevent normalization of deviations.
- Analyzing audit trend data quarterly to identify systemic gaps in training or accountability.
Module 8: Integrating 5S with Broader Operational Systems
- Aligning 5S checklists with ISO 9001 or IATF 16949 internal audit requirements.
- Mapping 5S outcomes to Lean KPIs such as changeover time, first-pass yield, or downtime.
- Linking visual management boards to Andon systems for real-time anomaly escalation.
- Using 5S audit findings as input for Kaizen event backlogs.
- Coordinating with EHS teams to ensure visual controls support incident prevention programs.
- Feeding 5S space optimization data into facility expansion or layout redesign projects.