Transcript Chapter 4

Chapter 4
5S
What are the 5S’s?
• They are the keys to workplace
organization, housekeeping, and visual
management.
• Simple and produces:
– Increase in quality
– Increase in productivity
– Cleaner workplace which produces a safer
workplace
– Earlier i.d. of abnormal business situations
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Waste
• Waste is anything other than the
MINIMUM amount of people, time,
equipment, material, parts, and space
required to ADD VALUE to the product.
• The 5S’s apply everywhere.
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The 8 General Types of Waste
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Scrap/Rework/Remake
Transportation
Motion
Waiting Time
Inventory
Overproduction
Overprocessing
Underutilized Human Resources
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The 5S’s
• Sort
– Proper arrangement
• Straighten (Store)
– Orderliness
• Sweep (Shine)
– Cleanliness
• Schedule (Standardize)
– Cleaned up, standardized.
• Sustain
– Discipline, practice and repeat.
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The Origin of 5S
Step #
1
Japanese
Word
Seiri
English
5S Word
Translation
Proper
Sort
Arrangement
Orderliness Straighten
2
Seiton
3
Seiso
Cleanliness
Sweep
4
Seiketsu
Cleaned Up
Schedule
5
Shitsuke
Discipline
Sustain
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Lack of 5S
• Hides safety problem
• Creates waste
• Limits a company’s ability to satisfy their
customers.
You never get a second chance to make a
first impression.
World class facilities develop beginning with
the 5S’s, and facilities that fall, fall apart
beginning with the 5S’s (Hiroyuki Hirano)
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Implementing 5S
5S Implementation Steps Outline
• Prelaunch
– Step #1.
– Step #2.
Form, train, & develop 5S teams.
Develop the 5S model
• Launch
– Step #3.
– Step #4.
Announcement
Train the plant in 5S
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Implementing 5S
• Step #1. Form, Train, and Develop 5S
Grading/Recognition Teams.
– Rule #1:
Leaders must lead. Everyone
must be involved. Applies to the office and the
shop floor.
– Rule #2:
Everyone must be trained in 5S
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Implementing 5S
• Step #2. Develop the 5S Models: The
“Islands of Excellence” Using the
Grading/Recognition Teams.
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Implementing 5S
• Step #3. Kick Off the 5S Implementation: Tell
Your Entire Team About the Importance, Goals,
and Vision of 5S.
– Importance
• Establish plant wide discipline & org baseline that supports
all improvement activities.
– Goals
• Improve safety & pride in the work place. Improve quality and
productivity.
– Vision
• “Islands of Excellence”, World Class Enterprise.
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Implementing 5S
• Step #4. Train the Entire Plant in 5S.
– Sorting, proper arrangement.
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Improved safety
Improved communication between team members
Smoother work flow
Improved quality and productivity
– Clearly distinguish between what is needed and what
is not needed.
– “When in doubt, move it out”
– Rule #3. Facility environmental, health, and safety
procedures must be followed at all times in the
cleaning, moving, and disposal of equipment and
material.
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Implementing 5S
• Step #4 Continued.
– Sorting using the Red Tag system
• A method used to i.d. items that are found in the work area,
but their use and need are unknown.
• Red Tag Procedure
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Dedicate a red tag storage site
Look at all items critically, then place tags
Record all tags on log sheet
Give all users and shifts 48 hours to review
Move items to red tag storage site
Management review in one week
Make a list of tools that are required, but not available.
– Rule #4. The Red Tag System is for one-time use
only; it is not an ongoing crutch for future clean-ups.
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Implementing 5S
• Step #4 Continued.
– Straighten, orderliness. (Store)
• Improved safety
• Improved quality
• Improved productivity
– A place for everything, and everything in its
place.
– Rule #6. Use a ceiling-down strategy. The first
straighten and sweep begins with the ceilings,
walls, and floor.
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Implementing 5S
• Step #4 Continued.
– Straighten, orderliness. (Store)
• Organize everything that remains
– Make locations visible and self-explanatory.
• Designate storage locations for everything
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Tools
Gauges
Cleaning supplies
Job aides, information sheets, etc.
• Keys to organization
– Visual controls
– Immediate retrieval
– Immediate return
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Implementing 5S
• Step #4 Continued.
– Sweep, cleanliness. (Shine)
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Improved safety
Improved team morale and ownership
Improved quality
Reduced equipment downtime
– Sweep the floors, wipe off equipment, paint if
necessary, and make sure everything stays
clean.
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Implementing 5S
• Step #4 Continued.
– Sweep, cleanliness. (Shine)
– Three Phases of Shine
• Daily cleanliness
• Cleanliness inspections
• Cleanliness Maintenance
Attach a maintenance card (or TPM Card) to identify the
problem.
– Keys to Cleanliness
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Must be done on a regular basis
Cleaning tools and supplies available at point od usage
Assign specific individuals to tasks
Designate specific cleaning time
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Implementing 5S
• Step 4 Continued:
– Schedule, Cleaned up. (Standardize)
• Improved safety
• Improved team morale and ownership
• Pave the path to step #5, Sustain.
– Standardize and maintain the use of sort, straighten,
and sweep.
– Develop 5S activity checklists for all mfg and office
areas.
– Rule #7. Have regular inspections.
– Rule #8. Have recognition and reward programs
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Implementing 5S
• Step 4 Continued:
– Schedule, Cleaned up. (Standardize)
Develop and implement best practices
• Use a 5S checklist to i.d. what will be done, who is
responsible and when the task is to be done.
Visual Workplace – Color-coded Zones
• Red – Inventory too low, re-order
• Green – Inventory level ok
• Yellow – Inventory too high, stop production
Visual Standards
• Quality board to record problems
• Pictures representing types of defects
• Everyone can easily identify defects
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Implementing 5S
• Step #4 Continued.
– Sustain, Discipline
• Improved safety through better housekeeping
• Improved team morale and ownership
• Reduced overhead costs.
– Practice and repeat these procedures until they
become a way of life throughout the entire company.
– “Sustain” is the discipline or rope that ties the other
4S’s together.
– Rule #9. 5S has to be self sustaining.
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Implementing 5S
• Step 4 Continued:
– Sustain, Discipline
• Continue to sort, store, shine, standardize, and
sustain the work area.
• Companywide promotion of discipline
• Make properly maintaining correct procedures a
habit:
– Use inspections/audits by top managers to evaluate each
workstation and to provide feedback.
– Chart the audit scores on a visual display board to show
progress/deterioration
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Implementing 5S
Chart production schedules and team improvements
• 5S Benefits
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Eliminates excess equipment & inventory
Reduced absenteeism
Fewer equipment breakdowns & longer life
Better understanding of equipment conditions
Fewer defects and higher quality
Defects are made obvious
Efficient and effective organization
Saves time, cost, and makes workplace easier to maintain
Improves production schedules
Motion and waste reductions
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Implementing 5S
Summary
• Improve Visuals
• Brainstorm better visuals
• Photograph completed area
• Create a “to do” list
• Conduct final 5S Audit using scorecard
• Assign ownership of completed area
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