Step 2: Set In Order

Step 2 of 5S is Set in order, or “Seiton”, which translates to “orderliness”. The goal is to organize the work area so every item is easy to find, use and put back: a place for everything, and everything in its place.^[1]

Japanese term

Seiton

Meaning

Orderliness

Goal

Easy to find, use and return

Things to consider^[2]

• ?Which people or workstations use which items?
• ?When are items used, and which are used most often?
• ?Should items be grouped by type?
• ?Where is the most logical place for each item? Would some placements be more ergonomic, or cut down on unnecessary motion?
• ?Are more storage containers needed to keep things organized?

Building a 5S map

1. Close at handStore frequently used tools and equipment near where they are used.
2. Central for the restKeep less-used tools, equipment and supplies in a central, easy-to-reach spot.
3. Like with likeStore similar items, such as drill bits and power tools, next to each other.

Then draw a 5S map: a diagram or floor plan showing where tools, supplies, workers and travel paths are. Whether you draw the map first or rearrange first, the diagram helps new and experienced staff alike find any item.

Putting the map to work

Once storage locations are set, label cabinet doors, drawers, racks and bins with what is inside, and label the interiors too. Many facilities build a “shadow board” for tools: with each tool’s outline on the board, putting it back is easy, with no second-guessing. Organization can extend to the floor as well, with work areas, walkways and storage for supplies and finished products marked out with floor tape.^[3]

At our shop

Creating a diagram and a shadow board, and teaching them to the team, has noticeably improved productivity. The whole production team knows where materials and tools are, which has cut downtime considerably, and anyone unsure can check a diagram or shadow board. Before this, chaos and clutter were the norm, production suffered, and ultimately that burdened the customer. With tools and materials properly set in order, even onboarding new staff is far more efficient.

As we continue, Set in order helps us tackle five kinds of waste:

• Wasted time
• Extra motion
• Over-processing
• Unnecessary transport
• Under-used talent