5S & Autonomous Maintenance
Training
A hands-on training program designed to build a culture of order, cleanliness, standardisation and equipment ownership in production areas. Participants learn the 5S methodology, visual management, basic equipment checks and an operator-based maintenance approach in a way that can be applied on the shop floor.
Why 5S and Autonomous Maintenance?
5S is not merely a cleaning activity; it is the foundation of a safe, efficient and sustainable production environment. Autonomous maintenance, in turn, gets operators to take ownership of their equipment and so reduces breakdowns, downtime and quality losses.
Program Content
Starting from the fundamentals of 5S, the training covers every step through to the autonomous maintenance system, from visual management to shop-floor auditing, with hands-on exercises.
01 5S Fundamentals and Objectives
- What is 5S and why is it applied?
- The place of 5S within lean manufacturing
- The link between workplace safety, quality and efficiency
- Types of waste and the effects of a disorderly shop floor
- Analysis of good and bad shop-floor examples
02 Applying the 5S Steps
- Seiri: Sorting out what is not needed
- Seiton: Layout and setting in order
- Seiso: Cleaning and preventing contamination at source
- Seiketsu: Standardisation
- Shitsuke: Discipline and sustainability
- Red tag exercise
03 The Autonomous Maintenance Approach
- The relationship between TPM and autonomous maintenance
- The operator's role in equipment ownership
- The logic of cleaning = inspection
- Spotting abnormal conditions early
- Checks for looseness, leaks, contamination and wear
- Operator maintenance responsibility matrix
04 Shop-Floor Application and Auditing
- 5S shop-floor walk and current state analysis
- Preparing a 5S audit form
- Building an autonomous maintenance checklist
- Visual management board design
- Action plan and responsibility tracking
- Before / after improvement assessment
Daily Program Flow
The training is made up of theory, shop-floor observation, practice and action plan sections. By the end of the day participants leave with 5S and autonomous maintenance actions they can apply in their own areas.
5S and Lean Manufacturing Fundamentals
Covers the 5S philosophy, types of waste, shop-floor order, and the relationship between workplace safety and efficiency.
5S Application Workshop
Red tagging, area classification, layout arrangement, standard setting and visual management exercises.
Autonomous Maintenance and Equipment Checks
Covers operator maintenance roles, core inspection points, abnormality detection and maintenance checklists.
Shop-Floor Audit and Action Plan
5S scoring, visual management recommendations, a responsibility matrix and a sustainability plan are prepared.
Who Is This Training For?
5S and autonomous maintenance training suits every operations team that wants to build a culture of order, responsibility and equipment ownership on the production floor.
Production Teams
Teams that want to make their work areas more orderly, safer and more efficient.
Maintenance Teams
Teams that want to make pre-failure signs visible on the floor and improve operator maintenance.
Quality Teams
Teams that want to reduce the impact of disorder, contamination and out-of-standard conditions on quality.
Process Development
Teams that systematically track 5S scores, shop-floor audits and improvement actions.
Consultant & Instructor
With strong experience in the automotive sector and in lean manufacturing, TPM, WCM and shop-floor transformation projects, Ertuğrul Turgay treats 5S and autonomous maintenance not as theoretical training but as a practical system that changes behaviour on the floor.
Request a Quote for 5S & Autonomous Maintenance Training
Contact the Opexera team for a shop-floor training plan, dates and content tailored to your organisation.