5S "SET in Place"

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 To Determine Location              Typical Workstation                              "String Diagram" for Material Flow         

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.

Here, a boundary designates the proper location.

Clearly, something is missing.

An address informs us what Is missing.

A complete address on both the barrel and location, encourages its return.