5SWork Place Org

Standardize Schedule cleaning and maintaining
Sustain Make 5S a way of life
First Impressions
“You never get a second chance to create a first impression.”
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First Impressions
• What does the workplace tell the customer and associates? • Items to consider: – Openness of work area – Color coordination – Straight lines (desks, benches, equipment, walls, power drops) – Product displays – Performance metrics – Condition of walls, floors, equipment – Visual controls
Work Place Organization - Philosophy
• First Impression • Cost of Poor Work Place Organization
• 5S
Sort Eliminate what is not needed Straighten – Set-In-Order Organize what remains Shine Clean work area
Standards Self Discipline
• Good manufacturing is about rules (standards). • Good manufacturing management is about maintaining the discipline of sticking to the rules and when unable to, acting. • 5 S is a systematic, disciplined method of Lean management.
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5S - The foundation of Lean Organisations
“There are no world class manufacturing companies without 5S in place.”
What is 5S ?
• The two main aspects are:
5S Sort, Set-In-Order, Shine, Standardize, & Sustain
Objectives
As a result of attending this module, you will be able to: • Recognize and/or create a model work environment • Participate in, encourage, support, and promote the implementation of 5S and visual management • Recognize the potential for using 5S and visual management as a continuous improvement tool
First Impressions Main Entrance to Plant
First Impressions Main Entrance to Plant
First Impressions Plant Main Aisle
Key Characteristics of a 5S Environment
– All the stable routines being adhered to religiously.
• 5 S is about identifying waste and abnormalities
5S Overview Lear Training Video
/cr/ci/lean/index.htm
Sort
Before Sort...
After Sort...
5S GAME SORT
SET-IN-ORDER:
• Organize everything that remains; make locations visible and self-explanatory so everyone knows what goes where • Designate storage locations – tooling – incoming parts – outgoing parts – gages – cleaning supplies – job aides, information sheets, etc. • “A place for everything, and everything in its place.” – Benjamin Franklin
Increases Operator Value Add
Promotes Employee satisfaction
QCD
Enables Visual Controls
Promotes Safe Practice
Enables Waste Identification
5S GAME
Audit
Establish the start point - things can only get better! Using audit sheets assess each area Take pictures of the before condition and make reference to where they are for future comparison (footprints) Record other problem areas, such as safety issues or machine breakdowns
What is 5S ?
• 5 S is NOT just about “HOUSEKEEPING”.
• It is about maintaining all the standards relating to a line, such as;
• Defined Takt time, fixed manning, OEE, SMED, accurate data collection, working exactly to WI, correctly completing first off’s, timekeeping, etc….
• Inspection – Detect slight abnormalities in equipment units – Check for proper amounts of oil, air, ventilation, etc. • Maintenance – Instant maintenance – Requested maintenance • Attach a TPM Card to the site or equipment identifying the problem
SHINE:
Three Types of Cleaning
• Daily – Sweep and wipe away dirt and dust daily – Mop floors, walkways and shelves until they shine – Scrub away oil and dirt from equipment surfaces
SET-IN-ORDER:
• Mark and label locations for each item – Use floor tape to mark locations for equipment, racks, parts, pallets and aisles • Build racks and/or signboards for frequently used items such as tools, fixtures, gages, work aids, and other small items – Create shadow boards to store necessary items at a workstation
Sort • Clearly distinguish between what is needed and what is not needed. “When in doubt, move it out!”
NECESSARY
UNNECESSARY
Sort
Do you see any unnecessary items?
SHINE:
Keys to Cleanliness • Must be done on a regular basis • Necessary cleaning tools and supplies to be available at point of usage • Determine what to clean, then assign specific individuals to tasks • Designate specific cleaning time 5S Supports a Safe Work Environment • A clean work area results in injury reduction and makes prevention easier • Reduced ergonomic stress to the operator • Work conditioning is organized and effective