Chapter 4 5S. IT-465 Lean Manufacturing2 What are the 5S’s? They are the keys to workplace...

Chapter 4

5S

IT-465 Lean Manufacturing 2

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


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.


The 8 General Types of Waste

• Scrap/Rework/Remake• Transportation• Motion• Waiting Time• Inventory• Overproduction• Overprocessing• Underutilized Human Resources


The 5S’s

• Sort– Proper arrangement

• Straighten (Store)– Orderliness

• Sweep (Shine)– Cleanliness

• Schedule (Standardize)– Cleaned up, standardized.

• Sustain– Discipline, practice and repeat.


The Origin of 5SStep # Japanese

Word

English

Translation

5S Word

1 Seiri Proper

Arrangement

Sort

2 Seiton Orderliness Straighten

3 Seiso Cleanliness Sweep

4 Seiketsu Cleaned Up Schedule

5 Shitsuke Discipline Sustain


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)


Implementing 5S

5S Implementation Steps Outline

• Prelaunch– Step #1. Form, train, & develop 5S teams.– Step #2. Develop the 5S model

• Launch– Step #3. Announcement– Step #4. Train the plant in 5S


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


Implementing 5S

• Step #2. Develop the 5S Models: The “Islands of Excellence” Using the Grading/Recognition Teams.


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.


Implementing 5S

• Step #4. Train the Entire Plant in 5S.– Sorting, proper arrangement.

• 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.


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– 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.


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.


Implementing 5S

• Step #4 Continued.– Straighten, orderliness. (Store)

• Organize everything that remains– Make locations visible and self-explanatory.

• Designate storage locations for everything– Tools– Gauges– Cleaning supplies– Job aides, information sheets, etc.

• Keys to organization– Visual controls– Immediate retrieval– Immediate return


Implementing 5S

• Step #4 Continued.– Sweep, cleanliness. (Shine)

• 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.


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• 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


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


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


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.


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


Implementing 5S

Chart production schedules and team improvements• 5S Benefits

– 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


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

Chapter 4 5S. IT-465 Lean Manufacturing2 What are the 5S’s? They are the keys to workplace...

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