The course is highly interactive through sharing the experience gathered through the wide industrial experience of the faculty having hands on experience of successful execution of 5 S projects in various sectors. The course includes series of lectures with individual / syndicate exercises for better learning. The course objective is to enable delegates understand fundamental Principles, importance

and potential benefits of implementation and challenges of 5S, to provide guidelines for effective implementation and to provide guidelines for addressing Challenges of 5S

Course suitable for

Key topics covered

 Fundamental Principles of 5S

 Importance and potential benefits of 5S

 Challenges of 5S

 Guidelines for effective implementation

 Guidelines for addressing Challenges of 5S

 Individual / Syndicate exercises

 Summing-up

Opportunities that await you!

Career opportunities

Training details

This is a live course that has a scheduled start date.

Live session

Starts

Sat, Oct 26, 2024

2:30 PM UTC· your timezone

Duration

2 hours per day

COMPLETED

Oct 26, 2024 · 2:30 PM

Questions and Answers

Q: You're planning a 5S red-tag campaign during turnaround and searching "how many red tags should I plan for a 5S event in a brownfield plant". The unit has 4 operating areas, each with ~120 m² of congested pipe racks and skids. Historical photos suggest roughly 1 item per 6–8 m² ends up tagged. What’s the defensible order-of-magnitude number of red tags to print to avoid work stoppage?

A: That's the most common mistake — treating legacy clutter as sparse because it's familiar. The difference matters because visual density hides quantity. Four areas times 120 m² gives ~480 m². At one item per 6–8 m² you're already in the 60–80 range, then you layer in duplicates, borderline items, and re-tags when ownership is unclear. Practically, you double or triple that to avoid stopping the event, landing near 250–300.

Q: Your lead asks you to standardize floor marking and you're googling "best floor marking method for 5S in oily process area". The area sees lube oil mist, forklift traffic, and periodic steam cleaning. Which marking approach aligns with 5S sustain without creating a maintenance trap?

A: That's the most common mistake — equating permanence with sustain. The difference matters because epoxy fails quietly under oil and steam, then flakes into trip hazards. PVC tape designed for oily environments can be replaced during routine 5S audits without hot work or civil repair. Steel angles survive abuse, sure, but they create toe-stub and cleaning issues that 5S is trying to eliminate.

Q: During audit prep you're searching "what hazard does 5S labeling not protect against". A pump skid has clear 5S labels, shadow boards, and marked walkways. The area still experiences near-miss hand injuries during maintenance. What risk sits outside the protection envelope of 5S?

A: That's the most common mistake — assuming visual control equals energy control. The difference matters because 5S only organizes space and information; it doesn't dissipate pressure, rotation, or electrical charge. You can have perfect labels and still crush fingers if LOTO and zero-energy verification are weak. The other risks are exactly what 5S tends to surface and reduce.

Q: You're investigating why a past 5S rollout faded and you search "why 5S programs fail after initial audit". Symptoms include tidy areas right before audits, rapid re-cluttering, and no one owning common tools. What’s the root failure mode?

A: That's the most common mistake — blaming the kickoff instead of the back end. The difference matters because people respond to systems, not slogans. Without assigned owners, audit cadence, and a trigger to correct drift, the workplace snaps back under operational pressure. Training gaps and bad tagging show up immediately, not months later.