Presentation on theme: "Management Meeting Month X, 20XX"— Presentation transcript:
1 Management Meeting Month X, 20XX Lean in Action 5S System: Techniques for Efficient Workplace OrganizationManagement MeetingMonth X, 20XX
2 What is 5S? A visual method of workplace organization 5S helps to: Have needed material, tools, supplies, and documentation at hand, organized, and identifiedMaintain a clean work area with tools and equipment in top conditionStandardize workplace organizationMaintain a occupationally-safe, ESD-safe, FOD-free workplace
3 In short, an organized workspace Why employ 5S?An organized, clean workplace:Shortens Span TimesReduces the non-value added work of searching for materials, tools, equipment and paperworkReduces Floor Space requirementsPrevents and detects errors and defectsRaises team pride and job satisfactionMakes work easier to accomplishIn short, an organized workspaceenhances safetyimproves qualityand reduces cost and cycle time
4 Elements of a 5S ProgramSortSet in OrderShineStandardizeSustain
5 5S - Down to BasicsSORTRemove allnon-essentialitems fromaround thework area.Any essentialitems that donot fit or work,or are broken,are taggedfor action.SET IN ORDERA place foreverythingandin its place.Arrange itemsso they canbe found,retrievedand returnedeasily.SHINERemove dust,dirt & debris.Cleaning willalso highlightany previouslyunforeseenproblems.Prioritizesafety, qualityand reliabilityissues.STANDARDIZESpreadthrough thework place.Checklists aremade showingexactly whereand whenregularmaintenanceshould takeplace.SUSTAINEveryonewho uses thework area isencouragedto adopt thenew system.Eventuallythe newarrangementswill becomethe culture.For 5S to be effective, everyone must take full responsibility for their own area of work, while supporting 5S throughout the shared workplace
6 Elements of a 5S Program Sort Set in Order Shine Standardize Sustain Eliminate the clutter“When in Doubt, Throw It Out!”Create a place for everything and put everything in its placeArrange needed items so that they are easy to use and label them so that “anyone” can find them and put them awayUse Visual Aids to aid understanding and minimize complexityShadow BoardsLabels (“Return addresses”)Clearly marked places for items that are movableArea Identification signsLines on the floorSet in OrderShineStandardizeSustain
9 Sort: 5S Holding AreaIf unsure whether or not to discard an item, a 5S Holding Area should be establishedItems should remain in the area for a short period of time, reassessed, and either discarded or (if needed) placed back into the work areaAll items should have a 5S Holding Tag for identification (next slide)Items will be logged in a database and tracked
10 Sort: 5S Holding Tag (example) Tag is used for tracking and maintaining items that are in the 5S Holding area that are to be reevaluated for either disposal or for placement back into appropriate area5S Holding Tag should be filled out completely and logged into databaseDate placed in Holding AreaIndividual that tagged the itemArea item came from (stock, assembly, Test area etc.)Short description (include P/Ns if necessary)Reason why in Holding Area (obsolete, not needed, broken, etc.)Proposed next steps to takeUsed to track all itemsexample
11 Elements of a 5S Program Sort Set in Order Organize and label, set boundaries and limits“A Place for Everything and Everything in its Place”Why: Makes things easy to locate, easy to put away, readily apparent if missingResults: No wasted time looking for tools or documents; they are identified and on hand when neededOne-Step Rule: Nothing that is used daily is stored more than a step away. Improve economy of motion, save valuable seconds, and make the job less frustrating.45 Degree Rule: Arrange the immediate work area layout to minimize twisting, especially applicable for bench work. If something weighs more than a few pounds, make sure it is beyond immediate reach so the lifter must reposition the body properly for lifting.Strike Zone Rule: Store things above the knees and below the chest. This will help to reduce the chance of back strain.Higher the Pounds - Closer to Knuckles: Locate heavy items to eliminate bending, stooping or unnecessary arm movements during lifting.
16 Elements of a 5S Program Sort Set in Order Shine Standardize Sustain Clean everything, inside and out“Inspection Through Cleaning”Why: Nobody works well around a mess; FOD can ruin or delay a mission; a clean workplace promotes pride and demonstrates an interest in quality; cleaning allows us to find problems with equipment and tools in time to prevent delaysResults: A bright, clean, organized, work area that promotes confidence, quality, and on time deliveryStandardizeSustain
18 Recognize and Reward the Team !! Shine: After CleaningRecognize and Reward the Team !!
19 Elements of a 5S Program Sort Set in Order Shine Standardize Sustain Document the standard method for workplace organization so we always do things in the same way“Everything in a State of Readiness”Why: Standardizing the way we maintain a work area and perform our work promotes consistency in how work is approached and accomplished, and allows easier cross training and movement of personnelResults: Standardized presentation of work areas, material and tools for workSustain
20 Standardize: Best Practices for Organization Old wayNew Standard
21 Standardize: Best Practices for Organization Old wayNew Standard
23 Elements of a 5S Program Sort Set in Order Shine Standardize Sustain Maintain discipline through systems and a supportive culture“Launching quality with persistence.”Why: Without sustaining the first 4 Ss, they will die; promotes a continuous improvement environmentResults: Ever improving quality, cycle times, on time commitments; high motivation, recognition for excellence
24 Sustain: Teams set Standards to meet Customer Demand Communications Board in the area shows the Continuous Improvement List, Current Schedules and MetricsWhite board is for anyone to post any issue to be put on the Continuous Improvement List
25 Sustain: Teams set Standards to meet Customer Demand – Show progress Publicity !
26 Sustain: Standard Assessment Score (spider web chart)
27 Getting Started Form 5S Teams: Conduct 5S Kaizen event: All players who regularly work in the work are/ centerIf you use tools, hook up & use test equipment, handle parts, or regularly handle travelers, drawings or Work Procedures in the area, we want you on the teamConduct 5S Kaizen event:Learn what a 5S workplace looks likeOnly needed things presentClean; dustlessAll things organized, arranged and identifiedVisuals help tell at-a-glance the state of the workplace (signs, posters, arrows, charts, schedules, etc.)
28 Getting Started Plan for Success: First Steps: Set team 5S goals Appoint 5S champion(s)First Steps:Post 5S team roster with leader, champions, and backups for calibration, shelf life, job suppliesCreate a 5S holding areaSort unneeded items and move them to the 5S holding areaConduct monthly 5S AssessmentsUsing Standard 5S Assessment
30 What Level is Your Work Area? Levels of AchievementWhat Level is Your Work Area?SORTSET IN ORDERSHINESTANDARDIZESUSTAINLEVEL 1Just BeginningNecessary andunnecessary items aremixed together in thework area.Tools, supplies andmaterials are randomlylocated.Work/break areas andmachinery are dirty anddisorganized.Work place methods are notconsistently followed and arenot documented.Work place checks arerandomly performed andthere is no visualmeasurement of 5Sperformance.LEVEL 2Focus on Basicsseparated.Designated locationestablished for all itemsas needed.machinery are cleaned ona regularly scheduledbasis. Key itemsidentified.Methods are being improved,but changes have not beendocumented.A recognizable effort hasbeen made to improve thecondition of theworkplace.LEVEL 3Make It VisualAll unnecessary itemshave been removedfrom the work area.Designated locations aremarked to makeorganization more visible(color, outlines, labels,numbers, etc).Visual Controls are inplace for labeling andquantity levels. Machinesare cleaned daily.Working environment changesare documented andperformed the same by allemployees. Visual Controls arein place for labeling andquantity levels.5S schedules and safetypractices have beendeveloped and areutilized.LEVEL 4Focus OnConsistencyA dependable,documented methodhas been established tokeep the work area freeof unnecessary items.Documented method ofvisual sweep to identifyitems out of place orexceeding quantitylimits.5S techniques areunderstood and practicedcontinually. 5S schedulesare posted and followed.Substantial processdocumentation is available andfollowed.Follow through with 5Sschedules and safetypractices is evident.LEVEL 5Focus onPreventionWaste is immediatelyvisible and triggers aplanned response withroot cause analysis andcorrective action.Defined process toevaluate and improvemovement and motion.Dependable, documentedmethod of preventativecleaning andmaintenance.Everyone is continually seekingthe elimination of waste withchanges documented andinformation shared.There is a generalappearance of a confidentunderstanding of, andadherence to, the 5Sprinciples.
31 Let’s Go ! Designate and identify location(s) for cleaning gear Tape aisle ways and perimeter of work areasShadow box all needed tools; hang large tools on outline boardsSweep/ shine floors; post a cleaning schedule w/ names & assignmentsClean in corners, around I-beams & columns; wipe off wire molds, vents, equipment, cabinets so that there is no dirt, dust, paper clips, loose pens, loose papers, sticky notes, throw away or put away ANYTHING laying aroundRemove things from the top of cabinets, consoles, tables, chairs, etc.
32 Let’s Go !ANYTHING that HAS to be stacked is stacked neatly (90°) in a designated locationImplement visual helps to indicate where things go, including cleaning and safety gearConscientiously conduct FOD and ESD surveillancePerform TPM on equipmentKeep aisles clear; limit extension cords; no tripping or tipping hazards; call attention to safety equipment locationsVisually highlight equipment safety features (emergency stops, stay out areas, etc.)
33 Let’s Go ! Post evacuation routes near exits ID chemical storage cabinet locations and check frequentlyID and Wear protective equipmentHave MSDS sheets in a clearly marked areaFind a place for EVERYTHING; mark its perimeter and identify itMaintain the 5S bulletin boardEvidence “clean-as-you-go” throughout the dayAssess the area monthly; discuss and act on resultsPost results in 5S display areaHang posters, signs, etc. to sustain 5S
34 Management Meeting Month X, 20XX Lean in Action 5S System: Techniques for Efficient Workplace OrganizationManagement MeetingMonth X, 20XX