Transcript 5s Game - UKnowledgeShare

The
5S Numbers Game
A fun and exciting way to present the
5S concepts to our team!
Introduction
Credits
This exercise is based
on an exercise from
www.superteams.com
which was adapted from
one created by
Kirt Tassmer of Stanley
Fastening Systems.
The original game was
developed by RWD
Technologies, Ltd.
Disclaimer
This is for entertainment purposes only. 5S Supply is not liable for any
unintended outcomes.
• This is a simple training
game we will use to show
how to perform 5S and to
drive home important key
points
• Hopefully you find it
challenging (like the realworld) and have some fun
along the way
“Behind all
workplace
successes and
failures are the
5S’s.”
From “5 Pillars of the
Visual Workplace: The
Sourcebook for 5S
Implementation” by
Hiroyuki Hirano
Agenda
•
•
•
•
•
•
•
Before State – Round 1
Sort – Round 2
Simplify – Round 3
Systematic Cleaning
Standardize
Sustain – Round 4
Benefits – Round 5
Instructions – Round 1
• Please wait until you hear the entire
instructions before starting – DO NOT
turn over the page until asked to do so
• Individually, with a pen or pencil locate
and strike out the numbers 1 through 50
in sequential order (1, 2, 3, 4, 5…)
• You will have 30 seconds to complete
this task
2
3
12
32
96
58
65
24
25
54 31
35
11
28
64
100
95
38
GO!
66
56
51
63
10 76
6
1
27
19
17
46
94
15
41
45
53
37
71
97
14
59
57
33
5
43
22
884
7
70
77
48
87
78
72
4
79
89
42
85
Report Out – Round 1
• Record your highest number found and a
comment on your Overall Scorecard sheet
• The instructor will ask for your score – the
lowest score is what’s recorded for the entire
group
• What was it like trying to do this? How did it
feel?
• How can we apply this to everyday life?
Were there any quality issues?
2
Is this3an 8, 88, 4, 84???
7
12
32
43
22
58
97
14
65
24
53
5 516 and which
the
one
37 is the 9?
56
33
63
71
6
1
27
19
17
64
Why
is 39 95
38
35 listed
100
45 twice?
25
54
31
Which one is
96
11
884
28
57
66
99? 89 or 68?
72
94
87
41
59
10 76 77 78
Is this 66 or
46
48
15
4
70
79
89
42
85
Sort
• To sort through, to sort out
• Guideline: If it is not needed in the next 30
days, Orange Tag it
• “When in doubt, move it out!”
• 5S Orange Tag Technique
• Place a Orange Tag on the item and move it
to the 5S Orange Tag Holding Area
• Items will be dispositioned: keep, throw out,
donate, scrap, shred, recycle, etc.
2
3
884
7
19
14
17
Let’s
orange
tag
the
65
32
11
24 need
25
numbers22we don’t
64
58
43
35 100
(51-100)
and the duplicate
96
39.
45
53
97
12
54 31
56
51
37
71
33
5
28
63
1
27
46
94
38
41
59
57
66
10 76
6
95
15
70
77
48
87
78
72
4
79
89
42
85
2
3
12
32
96
58
65
24
25
54 31
35
11
100
1
27
46
94
95
38
15
41
59
57
66
10 76
6
28
64
56
51
63
19
17
45
53
37
71
97
14
33
5
43
22
884
7
70
77
48
87
78
72
4
79
89
42
85
2
3
884
7
19
14 65to the 17
Now
let’s
move
them
32
11
24
25
5S Orange
22 58Tag Holding 64
43
35 100
Area.
96
97
12
56
51
37
71
63
1
27
46
94
38
41
59
57
66
10 76
6
95
15
45
53
33
5
54 31
28
70
77
48
87
78
72
4
79
89
42
85
2
3
12
32
96
58
65
24
25
54 31
35
11
100
1
27
46
94
95
38
15
41
59
57
66
10 76
6
28
64
56
51
63
19
17
45
53
37
71
97
14
33
5
43
22
884
7
77
48
87
70
78
72
4
79
89
42
85
2
3
7
14
12
32
43
24
22
25
31
5
11
8
19
17
15
28
35
41
38
45
33
37
10
6
1
27
46
48
4
42
Instructions – Round 2
• Let’s do the same exercise with the
unneeded items removed from the work
area - with a pen or pencil locate and
strike out the numbers 1 through 50 in
sequential order (1, 2, 3, 4, 5…)
• You will have 30 seconds to complete
this task
2
3
7
14
12
32
43
24
22
25
31
8
19
17
11
15
28
35
41
38
GO!
5
45
33
37
10
6
1
27
46
48
4
42
Report Out – Round 2
• Record your highest number found and
a comment on your Overall Scorecard
sheet
• The lowest score is what’s recorded for
the entire group
• What was the exercise like this time?
• What can we learn from this?
Simplify
• Now that the area has been cleared out of
unnecessary items, it is time to find a “home” for
items that will remain
• Guideline: Any item that you want to keep after the
5S Orange Tagging Event needs to have a specific
home
• “A place for everything and everything in its place.”
• Organize items to make them convenient to get and
put away
• Use visual controls to help this process (signs, lines,
labels, color-coding)
2
3
7
14 numbers 17
Let’s
rearrange
the
in
32
11
24
25
order that
22 we will use them.
8
19
12
43
31
5
35
15
28
41
38
45
33
37
10
6
1
27
46
48
4
42
2
3
7
14
12
32
43
24
22
25
31
5
11
8
19
17
15
28
35
41
38
45
33
37
10
6
1
27
46
48
4
42
2
1
3
5
4
10
8
6 7
19
11
12
22
41
17
27
24
32
33
31
14 15
43
42
25
35
37
45
46
28
48
38
2
1
3
5
4
6 7
10
8
Did you notice that we had to work
around a few things like the
19
11
14 15
17
numbers
that were
already there?
27 28
12
41
24
32
33
31
22
43
42
25
35
37
45
46
48
38
Instructions – Round 3
• Let’s do the same exercise with the
numbers better organized - with a pen
or pencil locate and strike out the
numbers 1 through 50 in sequential
order (1, 2, 3, 4, 5…)
• You will have 30 seconds to complete
this task
2
1
3
5
4
10
8
6 7
19
11
12
41
17
GO!
22
24
32
33
31
14 15
43
42
27
25
35
37
45
46
28
48
38
Report Out – Round 3
• Record your highest number found and a
comment on your Overall Scorecard sheet
• The lowest score is what’s recorded for the
entire group
• What was the exercise like this time?
• What benefits can you see from “Sort” and
“Simplify”?
• Record on Scorecard sheet
Systematic Cleaning
• Now that the area has been cleared out of
unnecessary items, it is time to “shine” the
items that remain
• Guideline: Get items to a “like-new” condition
• “Clean and inspect or inspect through
cleaning”
• Everyone participates, make it simple and
easy to get cleaning supplies and schedule it!
• If you find something out that may become an
issue, fix it or have it fixed
2
1
3
5
4
6 7
10
8
For Shine we will make sure the
numbers are in good working
11 So let’s clean
14 15
order.
this mess17up!
27 28
19
12
41
24
32
33
31
22
43
42
25
35
37
45
46
48
38
1
11
2
12
4
3
13
5
14 15
23
21
22
31
32
33 34
41
42
43
24
44
25
16
17
26
27
35
45
8
6 7
36
46
10
9
18 19
20
28 29
30
37
38
47 48
39
40
49
50
Standardize
• We need to have standards for the first three
S’s: Sort, Simplify and Systematic Cleaning
• Guideline: Make up the rules for the first three
S’s and then follow and enforce them.
• “Make up the rules and then follow them”
• Don’t forget to consider companywide
policies like color-coding, signage,
replenishment, etc
• Make the rules easy to follow
4
5 6 7 8 9 10
3
2
After looking at all the styles of
font and sizes the team determined
13 14 15 16
17 18 19 20
11
that some of these items can be
standardized.
21
24 25
22
27 28 29 30
1
12
26
23
31
32
33 34
41
42
43
44
35
45
36
46
37
38
47 48
39
40
49
50
1 2
3
4
5
6
7
8
9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
1 2
3
4
5
6
7
8
9 10
Let’s
some
14 more
11 add
12 13
15 16visuals
17 18like19
color-coding and lines.
20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
1 2
3
4
5
6
7
8
9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
Sustain
• Now that you have a well organized,
clean and safe work environment, we
must keep it that way
• Guideline: It’s not something extra, it’s
part of everyday work
• “Make 5S part of everyday life.”
• Sustain helps build the discipline we
need to have a great Lean organization
Instructions – Round 4
• In order to Sustain our gains we must
be able to recognize abnormal
conditions
• Let’s do a quick 5S Audit of the area
• Circle any “defects” that you find
• You will have 30 seconds to complete
this task
3
4
5
6
16
12 11 13 14 15
7
8
9
1
10
17 18 19 20
21 22 23 34 25 26 27 28 29 30
31 32 33 24 35 36 37 38
40
GO!
47 48 49 50
41 42 43 44 45
Report Out – Round 4
How many did you find?
• The “2” is missing
• “9” is upside down
• 11 and 12 are mixed up
• “16” is not completely in it’s home
• 24 and 34 are in the wrong location
• “39” is missing
• 46 is askew
How did you know?
3
4
5
6
16
12 11 13 14 15
7
8
9
1
10
17 18 19 20
21 22 23 34 25 26 27 28 29 30
31 32 33 24 35 36 37 38
41 42 43 44 45
40
47 48 49 50
Instructions – Round 5
• Let’s do the same exercise after
applying our 5S principles - with a pen
or pencil strike out the numbers 1
through 50 in sequential order (1, 2, 3,
4, 5…)
• You will have 30 seconds to complete
this task
1 2
3
4
5
6
7
8
9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
GO!
41 42 43 44 45 46 47 48 49 50
Report Out – Round 5
• Record your highest number found and a
comment on your Overall Scorecard sheet
• The lowest score is what’s recorded for the
entire group
• What was the exercise like this time?
• What benefits can you see from “Sort” and
“Simplify”?
• How can we apply this to everyday life?
Before & After State
Before
•
• Excess materials
•
• Excessive search time •
• Large area
•
• Cluttered
•
• Difficult
•
After
The correct materials
Minimal search time
Smaller area
Clean, neat &
organized
Easy
2
3
Before
32
96
22
58
65
24
25
54 31
35
11
100
1
27
46
94
95
38
15
41
59
57
66
10 76
6
28
64
56
51
63
19
17
45
53
37
71
97
14
33
5
43
12
884
7
70
77
48
87
78
72
4
79
89
42
85
1 2
After
11
3
4
5
6
7
8
9 10
12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
Benefits of 5S
• What benefits did we
realize by applying 5S
to our simulated
workplace?
• Quality
• Cost
• Delivery/Service
• Quantitative
• Qualitative
•
•
•
•
•
•
•
•
_________________
_________________
_________________
_________________
_________________
_________________
_________________
_________________
Wrap-up
• Can we apply this to the real world?
• Share an “Ah-ha” – something you
learned, something that’s new,
something that’s different or something
that made an impression on you
• ________________________________
________________________________
Thank You
for participating
Follow us @
• www.blog.5Ssupply.com
• Twitter.com/5Ssupply
• LinkedIn Group 5S Supply
• YouTube.com/5Ssupply
www.5Ssupply.com
888 4 LEAN 5S
5S Simplified. Everything you
need… all in one place!
Forms and Facilitator Notes
Participant Forms &
Tips and Tricks
Instructor Notes
• This section has the forms and instructor
notes to use during this training exercise
• Items needed:
PowerPoint presentation (if desired)
Pens or pencils, enough for each participant
Stopwatch, timer or watch with seconds hand to
time each round (30 seconds)
One copy each of the forms for each participant
(see next slide)
Forms
• Print the Overall Scorecard form single
sided
• Print the Rounds 1, 2, 3, 4 and 5 forms
double sided with the words “Please do
not turn over until told to do so.” on the
front and the exercise on the back
Overall Scorecard
• Handout the Overall Scorecard at the
beginning when you are explaining the
exercise
• Ask the participants to record their
individual scores on this sheet and any
comments or “take-aways” from the
round
Overall Scorecard
Exercise
Round 1
Round 2
Round 3
Round 4
Round 5
Number
Comments
• _________________
• _________________
• _________________
• _________________
• _________________
• _________________
• _________________
• _________________
Round 1
Please do not turn over until told
to do so.
TOP
2
3
12
32
96
58
65
24
25
54 31
35
11
100
1
27
46
94
95
38
15
41
59
57
66
10 76
6
28
64
56
51
63
19
17
45
53
37
71
97
14
33
5
43
22
884
7
70
77
48
87
78
72
4
79
89
42
85
Round 2
Please do not turn over until told
to do so.
TOP
2
3
7
14
12
32
43
24
22
25
31
5
11
8
19
17
15
28
35
41
38
45
33
37
10
6
1
27
46
48
4
42
Round 3
Please do not turn over until told
to do so.
TOP
2
1
3
5
4
10
8
6 7
19
11
12
22
41
17
27
24
32
33
31
14 15
43
42
25
35
37
45
46
28
48
38
Round 4
Please do not turn over until told
to do so.
TOP
3
4
5
6
12 11 13 14 15 16
7
8
9
1
10
17 18 19 20
21 22 23 34 25 26 27 28 29 30
31 32 33 24 35 36 37 38
41 42 43 44 45
Circle the “defects”.
How many did you find?
40
47 48 49 50
Round 5
Please do not turn over until told
to do so.
TOP
1 2
3
4
5
6
7
8
9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50