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5S On the Shop Floor
By Peterson Lean Consulting, LLC 
by Robert Leonardo 
by Robert Leonardo 
Saw these colored rings to go around gas cylinders to signify the gas type. What was missing from the area however was a matrix defining the colors. Overall, the idea was promising just needing a little tweaking. 
Fantastic example of the first 3 phases of 5S. 
The Andon is placed outside the First Aid Room, to notify anyone walking by. Red – if there is an emergency in process in the first aid room and should not enter, Yellow – if supplies are getting low, the person who restocks the first aid room walks by it everyday going to their office. Green – is all clear access.
by Linda Wesley
Storage area for IT computers was filled with many unnecessary things. After doing 5S the area is clearly marked, and sustainable by IT themselves, The area is audited for sustainment.
by Linda Wesley
by Linda Wesley 
Nice effort Setting in Order material handling equipment in the warehouse. 
Everyone on has an for their PPE items, no one is sharing hats or gloves. Everything is labeled and with work instructions for area.
by Linda Wesley
Use of colored cones in depts. to visually see there is a problem with an order.
by Linda Wesley
Parts room, before and after. 
Fantastic transformation on this shop floor. 
Very well done organization of hoses and equipment. 
Great improvement – notice the floors were even redone 
Do you consider this 5S gone wrong? 
Great example of Shine and TPM together. 
Creative method of insuring that the kanban card is going to be turned in. Great visual queue. 
by Ryan Slaney 
Great example of marking off where equipment should be stored. 
Great visual. Love the image of the person too. 
Nice improvement and use of space. 
Desktop space efficiency and
and making it clean to keep it clean.
by David Ranby
5S even works in outer space. Gotta love it! 
Nice visual kanban. I’ve seen this concept used to manage pallets of corrugate as well. 
by Robert Leonardo 
Newer 5S supply board seen here. Several through facility to eliminate motion and need to store inventory elsewhere.
by Robert Leonardo
Test equipment and controlled samples.
by Robert Leonardo
Custom designed Safety Zone to be placed in front of equipment with moving parts. 
Great visual solutions to busy intersections. 
Simple , clean, safe, well manufactured area – I am proud to work here.
by Dean Kosnica
Clean lines, lanes labeled, product squared and fronted to the pick line. Good stuff!
by Stefan Thomas
by Stefan Thomas 
Visual Management for a gas burner.
by Carlos Pecino.
by M Farouk 
by M Farouk 
by M Farouk 
by M Farouk 
1S corner.
by Sathya
Red Tag area
by Billy Kritinar
5S Hospital Example 
Inventory Kanban
Simple visual for flagging out of stock.
by Cassidy Laudadio 
Signs, red tag area, junk removed.
by Cassidy Laudadio
A clever way of setting material handling equipment in order. 
Here are some great 5S examples implemented at a busy distribution center. 
Neatly arranged warehouse.
by S.L. Subramanian
by S.L. Subramanian 
Team Leader desk at Gemba.
by Hiroaki Kokudai
Workbench before and after. 
Nice use of floor symbols and signage to create a travel aisle. 
Great first step at getting the docks set in order. Nice job team! 
Nice example of setting regularly used equipment in order. Prior to this step, the pallet jacks would be left scattered throughout the warehouse. Also, drivers returning for the day would just leave them anywhere on the dock. Now, each unit is labeled with a corresponding location. 
Stockroom before and after. 
Pallet corners and a little signage can go a long way at keeping things in order. 
Here’s a great single point lesson regarding visual controls for your grease program. Utilize color coded grease fitting caps and then place the same color lube label on the grease gun sleeve. This will help ensure you are using the correct grease for the right machine.
This SPL was brought to you by John Kravontka at Fuss and Oneill.
A great easy way to ensure the visual signal (a.k.a. kanban) triggers when necessary. Provided by John Kravontka from Fuss and O’Neill 
Outgoing goods consolidated to a home!
by Robert Leonardo
by Robert Leonardo 
Inventory labeled and tidied. Was not so good before. Now implementing controls, audits and cycle inventory counting for prevention of issues. 
Workstation 5S
by Robert Leonardo
White boards are everywhere in our building now!
by Robert Leonardo
Admin area by Robert Leonardo 
Internal department supermarkets by Robert Leonardo 
More internal department supermarkets.
by Robert Leonardo
Customized bench.
by Robert Leonardo
First aid room has proven very helpful in safety 5S, supply control and monitoring and accuracy of incidences.
by Robert Leonardo
5S at work by Robert Leonardo 
5S tool room by Robert Leonardo 
5S grinding room by Robert Leonardo 
5S Ventilation by Robert Leonardo 
5S toolbench by Robert Leonardo 
Tool Room, clean benches.
by Robert Leonardo
Only essential tools and materials now in labeled and functional bins at polishing station.
by Robert Leonardo
Better equipment=better safety
by Robert Leonardo
Huge transformation! From scores of 45% in 2008-2009 to now 75-80%
by Robert Leonardo
Cleared workbench.
by Robert Leonardo
Huge transformation! From scores of 45% in 2008-2009 to now 75-80%
by Robert Leonardo
Using the restaurant concept we call this the kitchen. Materials are prepped here using smarter timing and small frequent delivery to machines. Before 2006 they did not even have a real workspace.
by Robert Leonardo
For warehouse supervisor and change agent.
by Rober Leonardo
Signage helps keep order and educate.
by Robert Leonardo
A recent improvement to this area raised the 5S score from 60-% to 80+%.
by Robert Leonardo
With management and 5S this TB Cell is the best it has ever run and with reduced labour, nearly no defects and higher output.
by Robert Leonardo
Controlled Welding Area
by Robert Leonardo
Controlled welding area at work.
by Robert Leonardo
Proper equipment at every workstation. All standardized.
by Robert Leonardo
Aisles clear, a home for each item.
by Robert Leonardo
5S in progress.
by Robert Leonardo
Added power to operators and Cell Champions to print own labels and clock in/out for job costing. Has made a great impact on financial assessments and exposing truths.
by Robert Leonardo
5S in action.
by Robert Leonardo
We used to shut machines off and lose thousands of production $$ and time because we could not find things. This has a sign in/out system that is monitored and owned by the people! 
An awesome job by our maintenance guy! Collected all of the documentation, placed in binders, cataloged and organized. Previously information was all over the building, if we had at all.
by Robert Leonardo
Quality Control Lab
by Robert Leonardo
Where the change all started.
by Robert Leonardo
Yard during cleanup.
by Robert Leonardo
Safety FAIL, pre-5S
by Robert Leonardo
Safety FAIL, pre-5S
by Robert Leonardo
2007-2008 First draft of workbenches.
by Robert Leonardo
2008 QC Lab
by Robert Leonardo
by Gaurav Naik 
Here’s a great idea for eliminating the scuff marks from forklift tires! 
TePee Archery in Acton Mass is on the path of continuous improvement. Here is the first go around at getting things cleaned up. A long way to go but they’ve started. 
Nice example of making sure everything has its place. 
Nice visual indicator not to leave anything in this space. 
Stanchions are a great tool for adding flexible visual controls. You can also add colors by using different color belts. Additionally signs can be added to the tops for additional direction. 
Ready to ship!
by LeanLab
What a great improvement! 
Sure it’s basic, but you wouldn’t believe how many times this went missing!
by Mike Healey
Glass stroage before 5S
This was a major issue for product movement.
by Mike Healey
Glass Storage AFTER 5S
No breakage, no mess
by Mike Healey
Efficient small part storage.
by Mike Healey
Small part storage.
by Mike Healey
Dock Trash beofre 5S
Glad my mother never visited.
by Mike Healey
Dock Trash After 5S
No kidding, everyone got on board!
by Mike Healey
Simple example of how to keep your hand trucks Set in Order.
5S Visual Organization Images
When you need a trusted source for all things 5S, we’re here for you! Everything 5S. Answers included. 
If so, it’s time for an upgrade! Get organized in 2018… let us help! 
Many industries are using workplace organization tools to complement 5S initiatives. “A place for everything… and everything in its place.” 
Tool Organization
Examples of tool drawer foam storage by Robert Leonardo 
Examples of tool drawer foam storage by Robert Leonardo 
Examples of tool drawer foam storage by Robert Leonardo 
Tool Drawer with Labeling by Robert Leonardo 
Examples of tool drawer foam storage by Robert Leonardo 
Testing Station Drawer (Before) by Robert Leonardo 
Testing Station Drawer (after) by Robert Leonardo 
Why continue to just throw your cleaning supplies in the corner or place spray bottles on the counter. You could make organization look really good, if you wanted to. A little effort can go a long way. 
Think about all the benefits a tool shadow board provides – 5S, organization, cleanliness, and time. A clean and organized workplace adds value to your business and something as simple as a visual tool shadow board will help your workers be more productive!
Don’t just sit on the sidelines, get in the game!
Getting organized doesn’t have to be impossible. Creating a foam tool organizer like this eliminates the time wasted searching for tools and spending money replacing them because you can’t find them. 
by Linda Wesley 
With the matching mating parts, it is very easy for operators to visually see whats needed. Very helpful for new people.
By Linda Wesley
Tools shadows before and after 
by Ryan Slaney 
by Ryan Slaney 
Cleaning supply station 
Much safer and easier access to necessary tools for getting the job done. 
by Manfred Gaisie 
A great method for organizing your cleaning supplies. Each are custom made and can include company logos and formats. You can reach out to The 5S Store for more information. 
Clever method for organizing your printer supplies 
Simple visual control idea 
Check out these new creative totally mobile dry erase boards. Go to http://www.the5sstore.com/tawh.html for more information. 
This example how to set in order the desk drawer.
by Agus Susanto
Visual cleanroom shadow board. 
Rather interesting tool shadow don’t ya think? 
One interesting way to mark off your tools. Nice use of vertical space using a magnetic strip to hold the tools. 
Most folks think shadow boards are only made of foam and therefore can not be used in clean rooms. The 5S Store found FDA approved materials for clean rooms. Here is an example of just one of them. Offsetting colors helps reveal where the tool belongs and the finger cut outs make removal easy. nice, simple way to keep your tools organized and the work area tidy. 
Several years ago we started reducing our consumables for production. By asking why and how can we improve, we have reduced down to one cabinet where, before 5S, there was 1 skid plus! Most of it was wasted and disorganized.
Even after “re-5Sing” this cabinet last week, we found we can eliminate and reduce some items!
by Robert Leonardo
Parts moving carts, improved standardization and shine. 
If you’ve got a bunch of RF Guns, pegboard and drill holders work great for organizing.
by Stephan Thomas
This idea has become one of our best practices. A rolling 5S tool cart. Equipped with Red Tags/Logsheet, pegboard hooks, floor tape/guidelines, label maker, cleaning supplies, etc. It allows our teams to grab the cart and go for their daily 5S activities. The back side of the cart is the “Shine” side and holds brooms, cleaning agents, towel dispenser, etc. Most rolling pegboard carts sell for about $1000 online…we were creative and built this one using pegboard and a rolling floor mat wash rack for about $200.
by Stefan Thomas
Check out this awesome custom rotating cube we designed. 
5S File Storage by Sathya 
by Billy Kritinar 
Billy Kritinar 
These mobile tool trolley’s are a great use of vertical space. I suppose the only improvement I’d suggest is to add tool shadows. 
The 5S Store helped with this custom foam tool shadow board. Set in Order with a durable black on red foam. 
Nice improvement. Safer, cleaner and Set in Order. 
Nice example of a 5S Set in Order for tools. 
Hazardous good cabinet. 
Labled tool chest
by Robert Leonardo
5S Community Toolboard. No more “borrowing” and loosing. No more searching!
by Robert Leonardo
Set in order by Robert Leonardo 
Organized moulds
by Robert Leonardo
In an effort to sustain, we provide 5S supplies within reach. A few of these boards are in key areas of the plant.
by Robert Leonardo
by Gaurav Naik 
by Gaurav Naik 
by Gaurav Naik 
by William R. Knipp 
Repair Area Assembly
by William R. Knipp
Tear Down Area
by William R. Knipp
Repair Area
by William R. Knipp
Workbench
by William R. Knipp
Another nice binder visual management system. 
Here’s an example of the new cleanroom shadowboards put to use. 
Nice job at keeping shine materials set in order. 
by LeanLab
Do you have examples of 5S in action on your facility floor?
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