Basic 5S Management

Curriculum

9 Sections
22 Lessons
10 Weeks

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History of 5S, why it becomes the most easiest technique to boost up productivity.
1
- 1.1
  5S in early year. “The Time Line”
Why 5S is matter?
1
- 2.1
  Production lines
Benchmarks as a "Before vs. After"
2
- 3.1
  Comparison between with and without 5S
  1 Hour
- 3.2
  The keys to success
Course Module Structure
6
Key Performance Indicators (KPIs) to Track
1
- 5.1
  Successful 5S is a culture
  1 Hour
5S Audit Checklist
0
Audit Execution Tips
3
The Killers' of the 5S
8
Successful show case
0

Module 2: Set in Order (Seiton) – Functional Layout

It definitely gets tougher here! Set in Order (Seiton) is where the physical labor kicks in because you aren’t just throwing things away—you are engineering a “home” for every single nut, bolt, and 20-foot rail. In an aluminum plant, this is hard because your “parts” are heavy, long, and can scratch easily.

The “Golden Rules” for Aluminum Railing Layout

To make this module practical for your client, focus on these three industrial design principles:

1. The 30-Second Rule

An operator should be able to find any tool (hex key, de-burring blade, or tape measure) and return it within 30 seconds.

The Fix: Shadow Boards. Paint the outline of the tool on the board. If the tool is in use, the “shadow” shows exactly what is missing.

2. Frequency of Use (The “Zone” System)

Don’t store everything in the same place. Organize by how often the workers touch the item:

Zone A (Every Hour): Tools kept on the worker’s belt or right at the saw station.
Zone B (Every Day): Specific jigs for common rail profiles, kept within 5 steps.
Zone C (Every Week): Maintenance tools or rare extrusion dies, kept in a central rack.

3. Heavy & Long Material Logic

Aluminum rails are awkward.

Vertical Racks: Save floor space by storing lightweight profiles vertically.
Cantilever Racks: Use these for heavy bundles so forklifts can grab them without moving three other piles first.
Point-of-Use Storage: Store the fasteners (screws/brackets) exactly where the railing is assembled, not in a far-off warehouse.

Basic 5S Management

Curriculum

Module 2: Set in Order (Seiton) – Functional Layout

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