Chapter 4 5S

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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. IT-465 Lean Manufacturing

The 8 General Types of Waste Scrap/Rework/Remake Transportation Motion Waiting Time Inventory Overproduction Overprocessing Underutilized Human Resources IT-465 Lean Manufacturing

IT-465 Lean Manufacturing The 5S’s Sort Proper arrangement Straighten (Store) Orderliness Sweep (Shine) Cleanliness Schedule (Standardize) Cleaned up, standardized. Sustain Discipline, practice and repeat. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing The Origin of 5S Step # 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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) IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing Implementing 5S Step #2. Develop the 5S Models: The “Islands of Excellence” Using the Grading/Recognition Teams. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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. IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing

IT-465 Lean Manufacturing 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 IT-465 Lean Manufacturing