5S Set

Determining Locations

After Sort and Shine, "Set" determines and identifies the location of each item. The methods for determining such locations may be elementary and intuitive or formal and elaborate. 

Often the elementary methods work quite well, especially during in the early phases. Workers simply look at each item, visualize its use, estimate the frequency of use and then select a location. After a few days, they can review and revise their locations. Locations should be identified at both a micro and sub-micro level. String diagrams can assist at the micro-level.  Principles of Ergonomics can assist at the sub-micro level. Horizontal and vertical reach zones help to determine the best sub-micro location. The heaviest and most frequently used items should be in the nearest reach zones. 

Once people develop awareness, their body sense will alert them to excessive reaching, walking or awkward positions. They learn to "SET" items instinctively.

Reach Zones

Reach zones help to establish optimum location for tools and parts. Lower zones are reachable quicker and with less strain on joints and muscles. Reserve these lower zones for the most frequently used items. 

String Diagrams

String diagrams can assist at the micro-level.  Principles of Ergonomics can assist at the sub-micro level. Horizontal and vertical reach zones help to determine the best sub-micro location. The heaviest and most frequently used items should be in the nearest reach zones. 

Once people develop awareness, their body sense will alert them to excessive reaching, walking or awkward positions. They learn to "SET" items instinctively.

Tool  Boards

Tool boards and similar devices ensure that frequently used items always have the same location.  This reduces reach time eliminates searching and reduces frustration.

Boundaries

Boundaries identify the designated and location and space for each item. They encourage recoil, that is the proper return of an item, as shown below. They also tend to prevent people from placing other items in a designated space. When combined with addresses and nameplates, boundaries are a powerful tool for ensuring that every item returns to its proper place, every time. 

The barrel should be here.	A missing barrel is not obvious.
A boundary designates the proper location.	Clearly, something is missing.
An address shows what Is missing.	A complete address on the barrel & location, encourages return.

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