COURSE OVERVIEW:

The 5S methodology serves as the fundamental bedrock of Lean manufacturing and operational excellence, providing a systematic framework for organizing, cleaning, developing, and sustaining a productive work environment. This course explores the philosophy of "a place for everything and everything in its place" to eliminate waste, improve safety, and enhance overall process efficiency. By implementing these principles, organizations can create a visual workplace where abnormalities are immediately apparent and standard work is maintained through discipline.

The scope of this training extends beyond mere housekeeping to encompass a total cultural transformation within the workplace. Participants will delve into the technical application of Sort, Set in Order, Shine, Standardize, and Sustain, while also learning how to integrate visual management tools such as floor markings, color coding, and shadow boards. The curriculum addresses the psychological barriers to change and provides leadership strategies to ensure that improvements are not temporary but become a permanent part of the organizational DNA.

Coverage includes a comprehensive breakdown of the 5S steps, the integration of visual controls, and the development of robust auditing systems to measure progress. The course provides practical templates for red tagging, workplace scanning, and autonomous maintenance checklists. Furthermore, it explores the synergy between 5S and other Lean tools, demonstrating how a well-organized environment reduces cycle times and enhances quality by minimizing the potential for errors and accidents in both industrial and administrative settings.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Understand the fundamental philosophy of Lean and the critical role of 5S in waste reduction.
• Identify the eight types of waste (muda) within their specific work environments and processes.
• Execute a systematic "Sort" (Seiri) process to remove unnecessary items using red-tagging techniques.
• Design efficient "Set in Order" (Seiton) layouts based on frequency of use and ergonomic principles.
• Develop "Shine" (Seiso) schedules that integrate cleaning with equipment inspection and maintenance.
• Create "Standardize" (Seiketsu) protocols to maintain the first three pillars across different shifts.
• Implement "Sustain" (Shitsuke) strategies through effective communication and management commitment.
• Apply visual management techniques to make operational status and performance visible at a glance.
• Design and utilize 5S audit checklists to objectively measure workplace organization levels.
• Calculate the Return on Investment (ROI) of 5S initiatives through productivity and safety metrics.
• Facilitate a 5S "Kaizen" event to achieve rapid workplace improvement and team engagement.
• Overcome common resistance to 5S implementation through effective change management and leadership.

TARGET AUDIENCE:

Operations Managers, Production Supervisors, Quality Assurance Professionals, Lean Practitioners, Maintenance Engineers, Workshop Foremen, Warehouse Managers, and Continuous Improvement Team Members.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.