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Manufacturing companies have a growing, market-driven need to adopt World Class operating technologies, including Lean manufacturing 5S principles. Understanding the program's importance and knowing how to get started are the most crucial steps.

Workplace organization and visual order are the foundation of excellence in manufacturing. The company that has implemented Lean manufacturing 5S displays a level of visual clarity that many organizations never dream of. When these principles are in place on the production floor, work is completed efficiently and effectively.

Implementing 5S is not difficult but it requires discipline and persistence. TCA can help you overcome the barriers:

• Our expertise in education, Lean manufacturing training, and teambuilding underpins the success of any manufacturing performance improvement effort

• TCA's capabilities in operations consulting and specific experience in 5S implementation, will help you achieve the benefits in a short time

• By recognizing implementation pitfalls and introducing creative, effective strategies, TCA can guide you to sustained application of 5S principles


The objectives of a 5S implementation program are to:

• Educate the management team in World Class manufacturing and show how 5S supports World Class performance

• Plan and carry out pilot applications of lean manufacturing 5S principles

• Develop an internal resource person for training and coordination of the 5S program


TCA has designed a practical systematic approach to achieve these objectives—with minimum time and effort—as summarized in the following flow chart:

TCA Contributions

We support the execution of these work steps by:

• Preparing and facilitating a management education and planning workshop

• Participating in structuring and documenting the 5S pilot projects

• Preparing and delivering formal pilot team training

• Assisting in the development of expanded orientation and education materials

• Leading interim project reviews

• Educating an in-house resource to carry out 5S training and coordination

• Presenting a summary of observations and recommendations


An investment in TCA’s assistance with your lean manufacturing 5S implementation will yield many advantages:

• You will overcome the inertia or “organizational procrastination” that can indefinitely delay implementation of a 5S program

• We will help you identify the best possible starting point through carefully selected pilot projects

• Execution of the pilot projects will provide early economic benefits—improved quality, increased productivity, and reduced waste—which usually at least offset the entire cost of the pilot projects

• Your management team will become knowledgeable in World Class and 5S concepts by seeing firsthand the effects of their application

• You will be spared the frustration and expense of false starts

• Those who planned and implemented the pilot projects can now help other teams in the expansion phase

• Your in-house 5S resource will be capable of providing training and project management support in the expansion phase

• You will have a clear vision of the role Lean manufacturing 5S principles play in addressing vital business needs and opportunities

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