Mastering 5S - Building Workplace Excellence

Module 1: Introduction to 5S and Lean Foundations

• Purpose: Understand the philosophy and origins of 5S in Lean Manufacturing.

• Topics Covered:

  • What is 5S? (Sort, Set in Order, Shine, Standardize, Sustain)

  • History and roots in Toyota Production System

  • Benefits: safety, efficiency, morale, and quality

  • Common challenges and misconceptions

• Activities: Pre-training workplace walk-through, initial waste identification exercise.

Module 2: Step 1 – Sort (Seiri)

• Purpose: Learn how to distinguish what is necessary vs. unnecessary in the workplace.

• Topics Covered:

  • The Red Tag method

  • Criteria for disposal, relocation, or retention

  • Reducing clutter to enhance efficiency

• Activities: Red-tagging simulation or workplace decluttering project.

Module 3: Step 2 – Set in Order (Seiton)

• Purpose: Organize workspaces for efficiency and accessibility.

• Topics Covered:

  • Principles of visual management

  • “A place for everything and everything in its place”

  • Labeling, color coding, and shadow boards

  • Layout design for flow and ergonomics

• Activities: Design a tool board or workstation layout, 5-minute retrieval test.

Module 4: Step 3 – Shine (Seiso)

• Purpose: Build habits for cleanliness and proactive maintenance.

• Topics Covered:

  • Daily cleaning routines

  • Inspection through cleaning

  • Linking Shine with safety and equipment reliability

• Activities: Workplace cleaning event, before/after comparison, maintenance checklist.

Module 5: Step 4 & 5 – Standardize and Sustain (Seiketsu & Shitsuke)

• Purpose: Maintain workplace improvements and embed 5S into culture.

• Topics Covered:

  • Creating visual standards, checklists, and audits

  • Training and communication strategies

  • Leadership’s role in reinforcing behaviors

  • Avoiding “backsliding” into old habits

• Activities: Develop a 5S checklist, create a standard operating procedure (SOP), team role assignments.

Module 6: Implementation, Audits, and Continuous Improvement

• Purpose: Apply 5S in real-world environments and integrate with Lean practices.

• Topics Covered:

  • 5S audit processes and scoring

  • Kaizen (continuous improvement) mindset

  • Linking 5S with safety programs, quality systems, and Lean projects

  • Measuring ROI of 5S

• Activities: Conduct a mock 5S audit, present findings, and propose improvement actions.