5 s training dennis j o-boyle - johnson controls 02 21 2008

2/25/2008 | Confidential and Proprietary1

Advanced Power Solutions

Johnson Controls – Saft 5S Program

The 5S Program

A JCS Quality SystemTraining Program



5S Objectives

• Describe each “S” of 5S

• Describe how 5S contributes to Safety

• Learn how 5S will improve work area efficiencyand reduce waste

• Apply the first 3 S’s in your work area– Put it on your schedule for the next two weeks

• Plan a system to sustain the 5S Principles



The 5S Program

• SORT

• STRAIGHTEN

• SWEEP

• SCHEDULE

• SUSTAIN



Basic Concepts of JCS Quality Production

• Minimize Mistakes–Only acceptable product

• Zero Tolerance For Scrap And Rework

• Stable Production Environment

• Customer Focus Drives Production



5S Supports Zero Tolerance for Scrap and Rework

• 5S is a system for identifying and eliminatingseveral different types of waste:–Wasted Motion–Wasted Time–Correction (Rework)



5S SupportsStable Production Environment

• The cleaner the work area,the sooner problems are identified

• A clean environment is safer

• A clean, organized environmentis more compatible with team functionality



5S SupportsEasy Visual Identification and Instant Status

• Workplace Organization is Simpler-- It’s easier to visually recognize items

• Improved Organization and StandardizationAllow Quicker Response (Flexibility)

• Inventory Levels are Easily Controlled

• Communication of Production Status is More Efficient



5SVisual Management Efficiency

5S SupportsEasy Visual Identification and Instant Status



This 5S Process Is A Means ToImproving Organization & Cleanliness

Is this important in your work area?



An Unclean EnvironmentContains Hidden Risks for Workers & Equipment



Best in Class

Name some companiesthat you consider

as the best in their class



What Companies Do You Think Of As Being Best In Class?



There Are Basically Three Different TypesOf Companies and Workplaces



A Third-Class Workplace

Third Class: People Throw Trash Around and No One Cleans It Up




Second Class: People Throw Trash Around & Someone Else Picks It Up




First Class: No One Throws Trash Around & Everyone Works To Keep Things Clean



A First-Class Company:Advantages of an Organized and Clean Environment

• Safety

• Quality

• Customer Responsiveness

• Visual Control

• Time Management



What Is 5S?

• The 5S PrinciplesAre a Means of Improving the Work Environment

• Each “S” Designatesa Progression in Implementation

• Today, We Will Examine Each “S”in Detail and Begin Implementation



5S SupportsA Safe Work Environment

• A Clean Work Area Results in Injury Reductionand Makes Prevention Easier

• Organization and Visual Management Support JobRotation (Force, Frequency, Duration, Posture)

• Work Conditioning is Organized and Effective



What Is 5S?

1S Sort2S Straighten3S Sweep4S Schedule5S Sustain



1S• Sort

• Sort – Separate and Scrap

• Separate needed from unneeded

• Initial “Deep Dive” is Usually Required

• Critically Examine Everything in Your Work Area and Get Rid of What Is Not Needed



1SSort, Separate, Scrap



1SSort, Separate, Scrap

• Are There Any Unnecessary Items In Your Work Area?

• Stock• Tools• Pallets• Shelves

• Machinery• Fixtures• Desk or Chairs• Documents



5SRed Tag Event

•Red Tags Identify Items Not Needed

• Either Scrap Items or Move Themto a Specified Storage Location

• Clearly Define Difference Between What Is Vs. What Might Be Needed

• Remove Items Not Neededon a Weekly or Daily Basis

RED TAG

NAME

TODAY'S DATE (check)

LOGGED

NAME OF ITEM (PART #)

REASON TAGGED

UnnecessaryDefective

Not UrgentOther ____

Purchased Component

Machine/Equipment

Finished Product

Work in Process

Raw Material

Other_____Supplies

CLASSIFICATION

SUGGESTED ACTION

ACTION DATE

Throw awayMove to Storage

Other ________

Return to ______

Y N Have you used in the last week?Y N Have you used in the last month?Y N Will you use next week?Y N Will you use next month?



5SRed Tag Procedure

• Team Places Tags In Area

• Give All Users 48 Hours To Review

• Management Response/ActionIn One Week or Less

• Challenge Yourself.Look at All Items Very Critically.



5SRed Tag Event

Red Tag Evaluation & Action

• Designation

• Defective Items• Excess Stock• Obsolete Stock• Useful to another group, but not

needed by our group

• Action

• Eliminate• Store • Dispose• Give Away



5SRed Tag Procedure

Red Tag CampaignSeparate – Scrap - Straighten

Distinction Between Things Needed & Not Needed

Separate/ScrapRed Tag Campaign

Red Tag Storage Area

Dispose

Straighten & Organize

WhereWhatHow Many

Visible

Needed



2SStraighten

• Organize• Arrange items so they are easy to findand readily retrieved

• A Place for Everythingand

Everything In Its Place



2SStraighten



How Will You Know If Good Organization Is In Place?

Can Anybody Immediately:• See Where, What & How Many?• Take Item out?• Return Item After Use?



5SKeys to Organizing

• Visual ManagementWhere, What and How Many

• Ready Retrieval

• Ready Return



5SKeys to Organizing

Which Bench Would You Prefer?



3SSweep – Sweep & Shine – Clean – Repair

• Sweep, Clean, and Repair the Work Area

• Initial “Deep Cleaning” May Be Necessary

• The Challenge Is to Implement Regular HousekeepingSo That Any Dirt, Debris, or Grease Is Immediately Obvious



3SWhy Sweep?

• Rid Workplace of Undesired Debris, Dirt, Dust, etc.

• Healthier, Safer Environment for Both Humansand Machines

• Improves Visual Inspection Portionof Preventive Maintenance



3SSweep

Inspect While Cleaning

• Faulty Parts• Hidden, Broken, Uncalibrated Gauges• Loose Nuts and Bolts• Damaged Equipment

• Cleaning is Inspection,Inspection is Detection,Detection is Correction



3SSweep

Sweep Targets

• Storage Areas: Shelves, Cabinets, Closets,Tool Storage

• Equipment: Machinery, Material Handling, Lift, Packaging Materials, and more

• Surroundings: Aisles, Windows,Conference Rooms, Tops of Cabinets, etc.



3SSweep

Sweep Management

• Must Be Done On A Regular Basis

• Determine What to Sweep and Clean,Then Assign Tasks to Specific Individuals

• Necessary Cleaning Tools and SuppliesAvailable At Usage Point

• Designate Specific Cleaning Time;e.g., Last Five Minutes of Shift



3SSweep



4SSchedule

• Implement A Routine ScheduleIn All Workplace Areas

• Implement Best PracticesThroughout The Workplace



4SSchedule

• 4S Means Scheduled Routines Throughout The Shop



4SSchedule

Audit the Workplace for Progress On:

• Sort: Separate and EliminateUnnecessary Items

• Straighten: Needed Itemsin Designated Places

• Sweep: Everything Is Clean & Repaired;Dirt & Damage Are Noticed Immediately



5SSustain

Sustain

• Personal Commitment to High Housekeeping Standards.

• Are All Workers Intolerant Of A Dirty, Damaged Workplace?

• Would You Stop To Pick Up A Piece Of PaperOn The Floor?



5SSustain

Make a visual record of your progress



5SNext Steps

Next Steps

• Choose a “model” area of the BTC

• Conduct the first three of the 5S steps•Do a 5S Red Tag event

• Do the 4th & 5th “S” – Schedule A Routine! – Sustain!



5S TrainingQuestions and Answers

Thank you

5 s training dennis j o-boyle - johnson controls 02 21 2008

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