5s: a foundation for improvements...a place to start a lean journey is a learning journey!...
TRANSCRIPT
5S: A Foundation for Improvements(A Hands-on Experience Learning Module)
• Sort• Set in Order• Shine• Standardize• Sustain
Operating Model – Continuing Education
Hands-on Execution of Lean Principles (H.E.L.P.)
Luis Loya, Director Operational Excellence - Master Black Belt
March 2018
Module Objectives
After participating, you will know:
• What 5S is
• How 5S relates to Lean
• Why we do 5S
• How we do 5S
• The benefits of doing 5S
5S is a Cornerstone to a
Successful Lean Transformation
Time
Study
SOS
TaktRCPS
A PLACE TO START
A Lean journey is a Learning
journey!
“Don’t change people to help the process,
Change the process to help people!”
“Good employees follow processes;
Great employees tweak processes;
Exceptional employees find ways to reinvent processes …
Not just because they are expected to, but because they just can’t help themselves.”
People & Teamwork
Culture
Foundation
Pillars
Results
Impact
Co
nti
nu
ou
s F
low
Co
nti
nu
ou
s Im
pro
ve
me
nt
Ergonomics
Empowerment
Gemba3
Walks
Assessment
Goals:Greatest Safety Highest Quality Lowest Cost Shortest Lead Time
Lean Roadmap To Success
Business Profit
Shareholder SatisfactionCustomer Satisfaction Employee Engagement
Level Scheduling 4 Standard Work DMAIC• 5S / Visual Management
• Leader Standard Work
• Standard Operation Sheet
• Managed Inventory
• Smoothed demand
• Build to order
• Kaizen / BB / JDI
• Waste Reduction
• Genchi Genbutsu 5
StabilityPhilosophy Leadership Daily Management
Just-In-Time Built-In-QualityRight Item
Right TimeRight Quantity
• Takt Time
• Pull System
• One-Piece Flow
• Min Batch Size
• Value Stream Map
• Kanban
Jidoka 1
• Poke-Yoke 2
• Process Stability
• Design-for-Lean
• 5 Why’s
• Andon Signals
• Control Charts (SPC)
• PDCA
House of Lean
Tools
Lean
Tools
Early
Systems
Sustained
Systems
World
Class
Little or no evidence
of a 5S Lean Tool.
5S activity is visual with clear
indication of use and results
(maybe lack Standardization
and Sustain items).
Demonstrated evidence of all
5 S's with expanded focus on
Standardize and Sustain.
5S is used to continuously
improve processes and
countermeasures result in
action and long-term solutions.
5S is the way we visually
manage work. Abnormal
conditions are obvious and
corrected immediately.
Time
Keeper(s)
Time
Keeper(s)
5S Letters Game Seating
UPPER
CASE
lower
case
What’s In It For Me?
• A method that can be quickly applied to improve a work area.
✓ (it doesn’t require a large investment)
• Better, more sustainable solutions for all projects.
✓ (self-maintained solutions)
• The work itself gets easier when 5S has been applied.
✓ (faster, less draining)
A Workplace With a 5S Culture…
• Has higher productivity,
• Produces fewer defects and lost material,
• Meets deadlines better,
• Is a much safer place to work.
5S Explained• 5S is a process and method for creating and
maintaining an organized, clean and high performance Workplace.
• 5S enables anyone to distinguish between normal and abnormal conditions at a glance.
• 5S is a foundation for continuous improvement, zero defects, cost reduction and a safe work area.
• 5S is a systematic way to improve the workplace, our processes and our products through all employee involvement.
Critical Success FactorsFor effective 5S implementation:
• Have a Plan!!
• Leadership – Drive it from the top and Walk the Talk.
• Employee Involvement – Establish 5S Action Teams and each shift / functional area should end their day with area house keeping.
• Focus – Establish 5S Focus Areas with employee ownership.
• No Sacred Cows – 5S is not just about the warehouse floor, include all areas (office, maintenance, supply areas).
• Organize & Beautify – Maintain overall work area signage and paint.
• Accountability – Hold teams accountable to area requirements.
• Evaluate & Improve – Perform weekly audits with leadership, post and communicate progress results.
• Make it Fun and Celebrate Progress.
The 5S Letters Game
Sort - Set-in-Order - Shine - Standardize - Sustain
The 5S Letters Game is a metaphor that will give you a first-hand and personal experience of how much easier work can be when the workplace has been organized and improved by the 5S Process. It provides a clear understanding of the potential to increase efficiency and WIIFM – “What’s In It for Me”.
The experience is quick, powerful and fun …
The Letters Game
Perform a Team Exercise for NO 5S
Rules!
1. Listen & follow directions2. Do not work ahead3. Repeat rule #1
Template
T G E
Objective
Speed & Quality counts
No letters should be outside of a corresponding area.
9.0 seconds
Goal
T A R G E T
Time
Keeper(s)
Time
Keeper(s)UPPER
CASE
lower
case
5S is None Existent
S1: Sort
Definition of Sort
• Sort means to remove all items from the workplace that are not needed for current production or clerical operations.
• It does not mean that you only remove the items that you know you may never need.
• It does not mean that you simply arrange things in a neater fashion.
• If you sort: you only leave the bare essentials –“When in doubt, Sort it out ”
Examples of Sort
• Defective or excess, unneeded items that accumulate.
• Unneeded email or process steps
• Outdated or broken equipment (staplers, tape guns, office equipment, etc.)
• Carts with bad wheels, heavy, hard to roll.
• Outdated or broken tools or inspection equipment.
• Old rags, broken brooms, and other cleaning supplies.
• Electrical tools / equipment with broken cords.
• Disorganized office supply cabinets and print areas.
• Outdated posters, signs, notices and memos.
Benefits of Sort
• The workplace becomes less crowded and easier in which to work.
• Data storage becomes less confusing to locate information.
• Racks and cabinets of unneeded items are removed, eliminating walls that hinder communication between employees.
• Less time searching for parts , tools, data and information.
• Improved process flow.
• Example: Unneeded conveyors removed lowering maintenance costs.
Benefits of Sort
• Less time searching for necessary programs and documents.
• Improved process flow.
Transactional Example - SharePoint
Implementing Sort
Red-Tagging
• Identifying potentially unneeded items.
− Is this item needed?
− If it is needed, is it needed in this quantity?
− If it is needed, does it need to be located here?
• Evaluating and dealing with unneeded items.
− Move to a red tag holding area for a period of time.(this area must be created & maintained)
− After an agreeable period of time, Dispose of it – Sell, Relocate, Donate or Throw Away.
25
Red Tag Examples
Date Tagged
QTY
1
2
3
4
A
B
C
D
Item Description
5's Red TagRed Tag Number
Department/Area
A-Hold Until
Category
Packing Supply
Tool or Equipment
Computer Equipment
Office Supply
Disposition
Move to Red Tag Holding Area
Disposed of
Moved to General Supply Storage
Remain in Location to Evaluate
Number of times needed
D-Remain in Location Until
Number of times used
26
Red Tag Area
27
Red Tag Examples
28
Red Tag Area
Transactional Example
The Letters Game
Perform a Team Exercise for SORT
Time
Keeper(s)
Time
Keeper(s)UPPER
CASE
lower
case
1S - SORT
S2: Set-In-Order (Simplify)
Definition of Set-In-Order
• Set in order means that you arrange the items or information that are needed in the area and identify them or label them so that anyone can find them, put them away or file them correctly.
• The key word is “anyone”.
Think of a pit crew at a Formula 1 race, every item is positioned to error proof and speed the process, and to eliminate all wasted motion:
4 Seconds or less to change 4 tires.
Benefits of Set-In-Order
• Person sent to find something finds it easily.
• Time spent looking for things or information is reduced.
• Wrong parts or data are not retrieved in error.
• Adequate space is allocated for storage of items and information.
• Items have “their place” and not left in walkways, etc.
Anatomy of a Pit Stop
67 sec 3.9 sec
Implementing Set-In-Order
• Draw a 5S map showing the best location for tools, equipment and materials based on frequency of use.
• Store items or information together if they are used together, and store them in a sequence they are used.
• If tools are being set in order, design a system that keeps the tools in their location.
• Store infrequently used items away from the point of use.
• Remember to use the Principles of Motion Economy.
See next slides
Principles of Motion Economyexample:
Before After
The Basic Components of a Visual Organization System Are:
• Border – Sets boundaries, areas.
• Home Address – Tells what item belongs inside the border.
• Label – Tells what the item is and where it belongs.
Implementing Set-In-OrderEmploying Visual Tools
Border Example
A line around an item to identify its area/boundaries:
• Traffic lanes
• Stationary items
• Mobile items
• Walkways
• Surface items
5S – Dashboard
Transactional Example
5S – Dashboard
Transactional Example
5S – Desk Drawer
5S – Kaizen Supplies
Before After
wrench 38-91 4in. Drive Shaft cell
wrench
38-91
4in.
Drive
Shaft
Cell
Home Address & Label Example
• A sign on the “shadow board” at the item’s home. It should include:
− Item name
− Location
− Picture / silhouette of item (opt)
• A sign on the “item”. It should include:
− Name of item
− Item’s home location
Home Address & Label Example
5S is Not … stating the obvious
9th Type of Waste = Wasting tape to do unnecessary 5S work.
Office Standard
Before – No Set in Order After – 5S
Transactional Example
Transactional Example
Email Signatures:
• Adding signatures containing your contact information to all emails saves time.
• The amount of wasted time spent searching for this information would definitely make the top 10 list of wasteful office activities.
• Please help solve this epidemic.
The Letters Game
Perform a Team Exercise for SET-IN-ORDER
Time
Keeper(s)
Time
Keeper(s)UPPER
CASE
lower
case
2S – SET IN ORDER
S3: Shine (Sweep)
Definition of Shine
• Shine emphasizes removing the dirt, grime and dust from the work area.
• This is a program of keeping the work area swept and clean of debris.
• Key component for preventive maintenance.
The best time to find defects, dents, and scratches is when you are hand washing your automobile. Likewise,
the best time to find defects and safety problems is when you are
cleaning your work area.
Benefits of of Shine
• Defects are easier to see in a well lit and clean environment.
• A work area clean of debris is less likely to cause a tripping hazard.
• Machines that are clean and maintained work more efficiently.
• A clean work area promotes improved morale.
The proper approach, when focusing on this 3rd S, is to not only thoroughly clean the area… it’s also to understand why it’s dirty in the first place.In other words, we should clean to inspect. We should clean in such a way as to identify the source of the grime so we can eliminate it.For example, if we’re cleaning oil off the floor we must find out why it got there. Simply cleaning it and not fixing the problem that created the spill or leak is pointless.
Shop Shining … Clean to Inspect
Most people completely miss what this 3rd S is all about. Many seem to think it’s all about sweeping up the dirt and perhaps even getting on our hands and knees to scrub the floor. And it is to some extent. But it’s so much more.
Shop Shining … Clean to Inspect
Shop Shining … Clean to Inspect
This is the president of a company in Japan participating in the site’s daily 5-S activities. Each morning, the entire salaried management team works side by side to clean and organize the plant. From washing floors and trimming hedges to cleaning bathrooms, no task is left undone.
What kind of message do you think the president’s actions sends his employees?
Implementing Shine
• Determine the shine targets – what are we going to clean?
• Set a schedule and assign individuals.
• Create procedures for continued daily shine processes.
• Set periodic area inspections and maintenance targets.
Front Back
Before After5S Responsibility Board
Task Criteria
5S Assignment Board
The Letters Game
Perform a Team Exercise for SHINE
Time
Keeper(s)
Time
Keeper(s)UPPER
CASE
lower
case
3S – SHINE
S4: Standardize
Definition of Standardize
• Creating a consistent way of implementing the tasks that are performed on a daily basis, including “Sort” , “Set-In-Order” and “Shine”.
• “Do the right things the right way, every time!”
Just like in our personal lives, if the rules are in writing and right in front of us, we are much more likely to understand and follow
them - especially if they have our signature on them!
Benefits of Standardization
• Easier to train new employees.
• Less room for errors.
• Work area is more organized.
• Files and information is more organized
• Work area is safer.
Implementing Standardization
• Integrate the benefits found through Sort, Set-In-Order, and Shine into everyday work activity.
• Make it a way of life.
• Items that are not in their place should be able to be noticed at a glance.
• Keep it “Visual”.
• All 5S activities should be scheduled at the frequency rate necessary to maintain a clean, orderly, and safe work environment.
What an area would look like if a robust 4th S was in place
Examples of Standardize
Examples of Standardize
Examples of Standardize
Inventory Management
Brand and Generics metrics
boards are standardized
to similar formats
Transactional Example
Examples of Standardize
Is this good or bad?
Examples of Standardize
The Letters Game
Perform a Team Exercise for STANDARDIZE
Time
Keeper(s)
Time
Keeper(s)UPPER
CASE
lower
case
4S – STANDARDIZE
S5: Sustain
Definition of Sustain
• Sustain means that the 5S program has a discipline that ensures its continued success.
• Sustain means that the 5S mentality is ingrained in everyday work life and procedures.
− Don’t let it become another “flavor of the day.”
Benefits of Sustain
• Detailed tasks are documented to make processes more efficient.
• Work place is maintained in an organized fashion without clutter.
• Standard Work is established and adhered.
Implementing Sustain
• Keep everyone aware of 5S and its benefits.
• Make time each day to perform daily tasks.
• Make it structured.
• Give recognition where it is due.
• Establish checklist for visitors to review.
• Engagement is across all levels.
The Letters Game
Perform a Team Exercise for SUSTAIN
Time
Keeper(s)
Time
Keeper(s)UPPER
CASE
lower
case
5S – SUSTAIN
How Is 5S Done?
• 5S is accomplished by following all of the steps …
• DON’T SKIP A STEP!
• 5S is a team oriented process between the members of the work area and their leadership.
Do your results look like this?
58.5
35.0
21.7
14.810.5
4.98.0
05
1015202530354045505560657075
Tim
e (s
eco
nd
s)
Average TimeAverage Time