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The 5S Methodology

A Free Beginner’s Guide for Understanding and Applying the 5S Maintenance Procedures

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Doctrina Nam Laurus

(Learning for Success)

Sort (Seiri)

Overview

Sort is the first step in the 5S process. This task refers to the practice of identifying all the items you need to fully and safely perform your current job function and the removal of any unnecessary items from your workplace.

The workplace includes all areas or space for which you are responsible, e.g. bench top, under the bench, shelves, draws, shop floor, storage containers attached to machinery, walls and building supports.

Unnecessary items can be tools, equipment, materials, rubbish or anything that is causing clutter, with clutter being anything that is not essential for your current job function.

The Sorting process can also creating more space in which to work and move around in and have the affect of a general cleaning and tidying to the area involved.

You will need a ruthless approach to this task, but do not be careless and avoid keeping items for JIC (Just In Case) reasons.

Categorising Unwanted Items

The Sort visual method of identifying unwanted items is called Red Tagging. This involves placing a red tag on selected items that are not needed in your workplace. You could just place a red tag on everything to be moved from your work area to a designated holding area for unwanted items. However, a more beneficial approach is described below.

All the items identified as being unnecessary can be categorised as follows.

1. Rubbish

This can be immediately disposed of in the appropriate waste container.

2. Wrong Location

Items to be returned to their correct location – can be done immediately

3. Green Tag

Items identified as needed, but not by your work area – attach a Green Tag (sample below) and place in the holding area identified for surplus and unwanted items.

This could include items that are used in your work area, but you either rarely use them so they can be stored at another location or you don’t need multiple quantities of the same item.

Holding / Disposal Area

Leaving items in a designated holding / disposal area for a short time, typically no more than two weeks, allows you time to recover any item that you discover you do need.

The temporary location of items in this area also allows time for the appropriate people to make the necessary, redistribution, repair, scrap or rubbish assessments.

Some items, like unwanted chemicals, will have to be identified for disposal in accordance with the appropriate environmental procedures

The Advantages of Sort

If the Sort methodology is fully implemented in your workplace, you will recognise the following changes and improvements.

1. More space in all work areas that can be left as desired working space or used for new equipment to aid productivity.
2. Less clutter making it easier and safer to do your job.
3. Fewer hazards when moving around your workplace.
4. Improvements in work flow, quality and productivity.
5. Many tasks can become simplified.
6. Time is not wasted looking for tools and material.
7. Unnecessary storage does not form walls making communication more difficult.
8. No unnecessary tools, equipment and materials to get in the way.
9. Easier to identify tools and equipment that need maintenance.
10. Future purchases and the introduction of new items into the workplace are done with more care and consideration.

Summary

The practice of Seiri can be succinctly described as:

• Keeping the essential
• Storing the useful
• Discarding everything else

Discarding should be without concern because everything that remains should promote productivity.

The old adage of, When in doubt, throw it out, can be readily applied to the practice of Seiri.

The next step is Set In Order.

4. Yellow Tag

Items identified as something that may be needed, but are only to be kept for a short time before disposal – attach a Yellow Tag (sample below) and place in the holding area identified for surplus and unwanted items

This could include damaged tools that may be repairable if they are still needed, out of date items that could be recycled or materials that could be used in another area.

5. Red Tag

Items identified as clearly not having or no longer having any useful purpose in your work area – attach a Red Tag (sample below) and place in the holding area identified for surplus and unwanted items

This could include items that may be, but are not necessarily rubbish because they could have a rework or scrap value. If not, the decision should made quickly for disposal as rubbish.