1. Lean
Manufacturing
Visual Systems
XYZ Company

2. Source: The MEP Lean Network
Lean Building Blocks
Continuous Improvement
Pull/Kanban
Cellular/Flow
Quick Changeover
Quality at Source
Plant Layout
Batch Reduction
TPM
5S System
Standardized Work
Visual Systems
POUS
Value
Stream
Mapping
Teams/Employee Involvement
XYZ Company
Source: The MEP Lean Network

3. Visual Factory
“Ability to understand the status of a production area in 5 minutes or less by simple observation without use of computers or speaking to anyone.”
XYZ Company

4. creating and maintaining5S
Method for
creating and maintaining
an organized and clean
workplace.
XYZ Company

5. XYZ Company

6. 1S - Sort - Seri
Separate and Discard
XYZ Company

7. 1S - Sort - Seri Identify all necessary and unnecessary items.
Move unnecessary items from workplace to a designated area or “throw it out”.
Remove all excess items from working areas – work pieces, personal items etc.
Organize all remaining necessary items.
Designate a team to “hunt down unnecessary items”.
XYZ Company

8. Arrange and identify for ease of use
2S - Stabilize - Seiton
Set – in – Order
Straighten
Arrange and identify for ease of use
XYZ Company

9. 2S - Stabilize - Seiton
Locate materials and tools at POINT- OF- USE (POUS).
Store items needed by most people in a common storage area.
Make items easily identifiable and easy to obtain.
Label all containers, totes, supplies etc.
Storage areas, work areas, containers should have floor marking and identifying labels.
Place Maintenance/Operator instructions close to the point of use.
Use special device (carts/shelves/racks) to organize tools and fixtures.
Performance boards – daily/weekly production, scrap/rework rate chart….
XYZ Company

10. 2S – Visual Controls
Label – Containers, Cabinets, Supplies, Inventory, Machines, Tools, Scrap, Rework,……..
Color – Parts container, floor markings, safety, work areas, trash cans,..
Green – Shipping, Yellow – Work in process, Blue – Storage/Trash.
Checkered – Aisles.
Footprints – Anything that is movable.
Tool Boards – Shadow board, Peg board.
Performance Boards – Hour by hour, 5S Measurement,…
Standard Work visible.
Re-order points, Inventory levels.
Material Flow indicators within, into, out of your cell.
Equipment related information.
Documents on safety, quality,…
XYZ Company

11. 3S - Shine - Seiso
Clean – up
Scrub
XYZ Company

12. A Clean Workplace enhances QUALITY, SAFETY, and PRIDE.
3S - Shine - Seiso
Use dust collecting devices to prevent possible dirt.
Ensure that electrical and other cords are not a hindrance to all personnel.
Operators should clean their work area and equipment and perform preventive maintenance.
Keep everything clean for constant state of readiness.
A Clean Workplace enhances QUALITY, SAFETY, and PRIDE.
XYZ Company

13. 4S - Standardize - Seiketsu
Keep Clean
XYZ Company

14. 4S - Standardize - Seiketsu
Implement a plan to keep the workplace clean all the time
No – unnecessary items, mess, dirt
Who?
When?
How?
XYZ Company

15. 5S Schedule
XYZ Company

16. 5S - Sustain - Shitsuke
Motivate
XYZ Company

17. 5S - Sustain - Shitsuke Commitment Adherence
Cell meets 5S principles at the end of each shift
5S Daily Checklist
XYZ Company

18. 5 Minute 5S Five Minute 5S Area: Contact: Sort Remove unwanted tooling
(red tag to holding area)
Set
Mark out product variants
(floor tape from Joe)
Shine
Degrease banjo press
(gloves, solvent from Joe)
Standardise
Why is banjo press greasy,
Why are variants mixed
Sustain
Who is/are responsible for press
XYZ Company