Transcript Slide 1

Supplemental
Material:
Program Administration
for 5S Roll-out
5S Implementation Guide
1.
The scope, size and timeliness of completing the 5S event must
will be impacted by the availability of dedicated resources who
are capable of actively participating in the event.
Note: Some sites do not have enough dedicated resources to complete a
5S event within a brief period of time (similar to a kaizen activity),
under these circumstances each of the 5S can be completed
separately over a planned time frame.
2.
A visual display board should be established in a centralized
location within the work area in order to provide a location for
pictures and other standard work documentation.
Management Responsibility
1.
Management must provide the following:
• The area where the 5S activity will take place,
• The 5S team lead and support personnel who will participate in
the event,
Note: The event can be accomplished by personnel who work outside the
area where the event is taking place but team selection should
primarily be comprised of personnel from within the impacted area
to assure direction and ownership.
• Necessary resources including:
• Available time and materials to perform the activities
• Concise directions regarding dispositioning of tagged items
Area Preparation
Identify workers, processes, and functions of the area.
1. Target Area Name:
2. Define the boundaries of the target area and tape it off.
3. State the primary purpose of the target area.
Criteria
Draw area map (event scope)
Identify all necessary equipment,
tools and materials
Identify unnecessary equipment,
tools and materials
Yellow tag unnecessary items
Who
When
Status
5S Action Checklist
BEFORE AFTER
• Distinguish between what is needed and not needed
Unneeded equipment, tools, furniture, etc. are present
Unneeded items are on walls, bulletin boards, etc.
Sort
Items are in aisles, stairways, corners, etc.
Unneeded inventory, supplies, parts, or materials are present
Safety hazards (debris, water, oil, chemical, machines) exist
• A place for everything and everything in its place
Correct places for items are not obvious
Straighten
Items are not in their correct places
Aisles, workstations, equipment locations are not identified
Items are not put away immediately after use
Height and quantity limits are not obvious
• Cleaning, and looking for ways to keep it clean and organized
Shine
Floors, walls, stairs, and surfaces are not free of dirt, oil, and grease
Equipment is not kept clean and free of dirt, oil, and grease
Cleaning materials are not easily accessible
Lines, labels, signs, etc. are not clean and unbroken
Other cleaning problems of any kind exist
• Systematically maintain and monitor the first three S’s
Standardize
Necessary information is not visible
All standards are not known and visible
Standard Work doesn’t exist for all cleaning and maintenance jobs
All quantities and limits are not easily recognizable
Items cannot be located in 5 seconds
• Stick to the rules
Area workers have not had 5-S training
Sustain
5-S is not performed routinely
Personal belongings are not stowed neatly
Standard Work is not available or up-to-date
Daily 5-S audits are not performed
Note: Check all that apply, plan countermeasures.
Sort Guidelines
1.
2.
3.
The team lead should work with management to develop a work
schedule to complete the Sort process in a expeditious manner.
If necessary management should provide 5S training to new team
members.
Management will provide guidance and materials to support the
following:
• Focused area where the event will occur
• Expected outcomes including allotted time to conduct the activity
• Directions (criteria) and materials to sort, tag and disposition
equipment, materials, tools etc.
• Pictures should be taken in advance of and after the event to provide
before and after perspective
Sort
Red Tag Checklist
Directions
• Tag every item that may not be needed
• Enter a X when a category is inspected
• Examine all items in each category
Floors
Aisles
Operation areas
Work Stations
Corners, behind/under equipment
Stairs
Small rooms
Offices
Loading docks
Inside cabinets and drawers
Machines
Small tools
Dies
Jigs
Bits
Conveyance equipment
Plumbing, pipes, etc.
Electrical equipment
Wire, fixtures, junction boxes
Cabinets
Benches and tables
Chairs
Carts
Other
Inspect storage places
Shelves
Racks
Closets
Sheds
Other storage areas
Inspect the walls, boards, etc.
Items hung on walls
Bulletin boards
Signboards
Other
Identify unnecessary material / supplies
Raw materials
Supplies
Parts
Work in process
Finished products
Shipping materials
Work clothes
Helmets
Work shoes
Trash cans
Other
Tag Log
Item
Serial #
Date
Tag Status
Notes /Disposition
Directions
Disposition Guidelines
• Determine the category each tagged item belongs
• Determine required yellow tag action, record status on tag and update log
• Take action
Category
Action
Obsolete
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Sell
Hold for depreciation
Give away
Throw away
Defective
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•
Return to supplier
Throw away
Repair
•
Remove to proper location
•
Dispose of
•
Recycle
Scrap
Trash /Waste
Not needed in area
• Relocate to new location
Used daily
• Keep at place of use
Used weekly
• Store in area
Used monthly
• Store adjacent to area
Seldom used
• Store in distant location
Unknown use
• Determine use and storage location
Straighten Guidelines
“Everything should be assigned to a designated place and everything
should be in its place”.
1. The team should identify specific locations based on work
performance and frequency of use for each piece of equipment, tool
and materials that are in the work area.
Note: When possible place frequently shared items on carts to
establish mobility
2. Refer to the 5S training for examples on how create designated
locations for tool shadowing in tool boxes and placement on shadow
boards, etc.
3. Pictures should be taken in advance of and after the event to provide
before and after perspective.
Note: Default to company policy for the application of tape protocols
i.e. colors, patterns etc.
Straighten
Inspection Sheet
Directions
• Identify location for each
• Move item to designated place
• Enter a X when a category is inspected
Equipment
Materials / supplies / inventory
Machines
Small tools
Dies
Jigs
Raw material
Supplies
Parts
Work in process
Bits
Conveyance equipment
Finished product
Shipping materials
Cleaning equipment
Electrical equipment
Fixtures, junction boxes, etc.
Computer equipment
Cleaning supplies
Other items
Furniture
Cabinets
Benches and tables
Chairs
Carts
Shelves
Racks
Charts, graphs, etc.
Books, checklists, etc.
Bulletin boards
Signboards
Pens, pencils, rulers, etc.
Work clothes
Helmets
Work shoes
Trash cans
Personal items
Shine Guidelines
1.
2.
3.
4.
The team leader should assign team members specific areas to
clean (see Initial Cleaning Plan).
The work area and each piece of equipment should be cleaned,
assuring the removal of excess grease, oil fluids etc. to assure
equipment isn’t leaking or in need of repair.
Assure the work area is cleaned (inspection ready) to establish a
baseline score.
Pictures should be taken in advance of and after the event to
provide before and after perspective.
Shine
Inspection Sheet
Directions
• Use this with the Initial Cleaning Plan
• Enter a X when a category is completed
Large Surfaces
Inside equipment / furniture
Ceilings
Aisles
Work Stations
Corners, behind/under equipment
Machines
Conveyance equipment
Closets
Drawers
Stairs
Loading docks
Cabinets
Sheds
Walls
Doors
Pillars and posts
Floors
Other
Tool boxes
Storage bins
Carts
Shelves
Racks
Surfaces of equipment and furniture
Other items
Machines
Conveyance equipment
Plumbing, pipes, sinks
Electrical equipment
Materials and supplies
Trash cans
Bulletin boards
Labels and signs
Fixtures, junction boxes
Chairs
Small tools
Hoses, cords, tubing, etc.
Other
Initial Cleaning Plan
List tasks and complete the columns below
Target Area
Task
Area
Who
When
Materials & Tools
Standardize Guidelines
1.
2.
The basic purpose of ‘standardizing’ is to prevent set backs of the
first three S’s. Management’s focus is to make them a daily habit
assuring that sort, straighten and shine are maintained in there
fully implemented state.
Immediately after the event has been completed management
should establish a 5S job chart and assign work space personnel
with daily responsibilities to maintain the 5S’d area in accordance
with established standards.
5S Assignment Chart
List tasks and complete the columns below
Target Area
Task
Area
Who
When
Materials & Tools
Sustain Guidelines
1.
2.
3.
The basic purpose if event lead should work with management to
develop a working schedule to cover the 5S.
Management should assemble the team and provide 5S training
overview.
Management should provide information and materials to support
the following:
• Focused area where the event will occur
• Expected outcomes including allotted time to conduct the activity
• Directions (criteria) and materials to sort and tag equipment,
materials, tools etc.
Sustain Guidelines
Without organizational commitment to Sustain the benefits of
the 5S activities quickly falls apart.
Positive conditions to support Sustain are:
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•
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Awareness – Use approved communication methods to help
sustain 5S
Time – schedule time to perform the 5S
Support – management should provide acknowledgement,
leadership and resources
Rewards & Recognition – Good efforts should be rewarded.
Conduct scheduled audits to maintain focus.
5S Audit Form
5S
Sort
Straighten
Shine
Standardize
Sustain
Audit Form
Level 5
Needed items can be retrieved in
30 seconds or less. Obsolete
materials are routinely removed
from the area. Preventative
measures are in place to keep
unnecessary items, reports etc.
from entering the area.
Anyone can walk into the work area
and easily locate work by priority.
Corrective measures are in place to
address abnormal conditions.
Work area housekeeping is a
routine way of life. Corrective
action measures are in place to
address cleanliness issues.
Team is adhering to standards
work methods, visuals and work
area controls. A system of
improving work methods and work
area controls is clearly being
utilized
Information on the area information
board is meaningful and influences the
daily decisions of the work area. Root
causes of problems are eliminated and
actions focus on preventative methods.
Level 4
All work material has been sorted
according to what will be worked
today, this week. Materials, tooling,
files and reports are routinely
reviewed for necessity.
Team members can easily determine
what items are currently in-use and
their priority. Visual controls are in
place to indicate normal / abnormal
work conditions.
Work area housekeeping
responsibilities are established and
being followed on a daily basis.
Cleaning materials are stored and
readily available.
Team is utilizing standard work
methods and work area controls on a
daily basis. Possible for visitors to tell
what work is performed and where in
most cases.
Team routinely checks area to maintain
the 5S's. Information on the area
information board is meaningful to the
work area. Source and frequency of
problems are documented and
corrective actions taken. Planning occurs
to reach next 5S levels.
Level 3
Only documents and tools
necessary to the work area are
stored at the workstations and are
stored in an orderly manner.
A priority system has been
established to highlight the order in
which jobs will be performed. All
tooling, gages, hand tools have
designated locations.
Cleanliness problems have been
identified and preventative
measures are documented and in
place.
Team has documented needed items,
work methods, and work area controls
and has made them available in the
work area. Possible for visitors to tell
what work is performed and where in
some cases.
5S presentation has been made to all
Team members and a general
understanding for the need and
direction exists. Area information
board is present, visible, and
maintained.
Level 2
Needed and unneeded items have
been identified and unneeded items
have been removed from the area.
Nothing is placed on top of
machines, cabinets, etc.
Needed items have been organized
according to use, including
production tooling, hard tools and
work procedures.
Initial cleaning has been performed.
All machines and equipment are
neatly painted. Workbenches and
desks are free of unnecessary
objects.
Team has agreed on needed items,
work methods, and work area controls.
Hard for visitors to tell what type of
work is performed and where, but
employees generally know.
Team members have knowledge of and
are employing some aspects of 5S.
Level 1
Team has identified needed items
for the work area.
Alll needed items are present in the
work area. It is not difficult to
determine
Area cleaning is performed on a
random basis.
Work methods are documented in some
cases.
Some 5S awareness exists among Team
members in the area.
Total =
Total =
Total =
Total =
Total =
Habit
Commitment
Organization
Understanding
Awareness of
Need
Initial Effort
Overall Score
(Sum of Totals divided
by 5)
_____ 5 =
5S Rating Form
5S Assessment Form
Department:
5S Rating for week of:
___ / ___ / ___
Opportunities for Improvement:


File:
5S Rating:
Event Closeout & Follow-up
1.
2.
3.
The event lead should work with management to develop a
working schedule to cover the 5S.
Management should assemble the team and provide 5S training
overview.
Management should provide information and materials to
support the following:
• Focused area where the event will occur
• Expected outcomes including allotted time to conduct the activity
• Directions (criteria) and materials to sort and tag equipment,
materials, tools etc.