does your shop look like this? - arkansas trucking association · 2016-07-22 · 1. implement 5s in...
TRANSCRIPT
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Does this look efficient?
Does your shop look like this?
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5S Standardization Method
WHAT IS 5S?
• A structured program designed to systematically achieve total
organization, cleanliness, and standardization in the workplace.
• The backbone of the organization’s Continuous Improvement
program.
WHAT DOES 5S
MEAN?
• Developed in Japan to remove waste from manufacturing
operations.
• 5S is based on the 5 Japanese words that describe the 5 steps in the
systematic process.
WHY IS 5S
IMPORTANT?
• Promotes individual commitment and responsibility to a well
organized work environment.
• Enhances morale and safety.
• Improves communication.
• Makes variations in the normal process visible.
• Reduces waste and improves productivity.
SeriSORT
SeitonSET IN ORDER
SeisoSHINE
SeiketsuSTANDARDIZE
ShitsukeSUSTAIN
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5S Standardization Method
WHEN / WHERE IS
5S USED?
• Implementation should be throughout the entire organization
including the shop floor, warehouse, exterior, and office spaces.
• Maintained daily on each shift.
• Verified at the start/end of each shift.
• Scheduled improvement events.
WHO IS
RESPONSIBLE?
• All employees must be responsible for the application of 5S within
their workspaces.
• Must be supported from the top, down.
WHAT IS THE
END VISION?
• A safe, clean, orderly, and efficient work environment where
everything has a place.
• To create a “culture” that breeds continuous improvement.
Makes variations in normal process visible
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STEP 2: SET IN ORDER
STEP 1: SORT
STEP 3: SHINE
STEP 4: STANDARDIZE
STEP 5: SUSTAIN
Visualizing 5S
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STEP 2: SET IN ORDER
STEP 1: SORT
STEP 3: SHINE
STEP 4: STANDARDIZE
STEP 5: SUSTAIN
Visualizing 5SSeparate the
essential from the
non-essential
Arrange and label for
easy access
Clean and inspect
work area
Standardize practices in work area
Perform 5S process on an
on-going basis
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What is the usefulness of the items for performing the work?
What is the frequency for which the item is needed?
What is the quantity of the item needed to perform this work?
Dispose of unneeded items.
When in doubt, throw it out!
STEP 1: SORT
Separate the essential from the non-essential by
identifying unneeded items, evaluating their usefulness,
and dealing with them appropriately.
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Utilize external services to dispose of unneeded items.
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STEP 2: SET IN ORDER
Locate items according to their frequency of use
Label locations where it makes sense
Address overall work flow to improve efficiency
XXXXX
YYYYY
ZZZZZ
A place for everything and everything in its place!
Organize the necessary items by arranging them so they are easy to find, use,
and return. The result is a streamlined workplace and the elimination of time
spent searching for items and information.
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STEP 3: SHINE
Determine what needs to be cleaned
Determine proper cleaning supplies and make available
Painting an area really supports the shine step
Start to shine!
If it doesn’t get dirty,then it doesn’t need to be cleaned!
The act of cleaning the work area, and inspecting tools and equipment.
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STEP 4: STANDARDIZE
Assign responsibilities – everyone must know exactly what they are responsible for maintaining.
Utilize a 5S schedule and a 5S assignment map.
Visual 5S
5 minute shine
Without standards, there can be no Continuous Improvement!
The act of making sure that the results of Sort, Set in Order, and Shine are
maintained. Assures that conditions do not go back to their old, undesirable
levels and makes implementing 5S a habit.
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Foot Printing/Labeling
What is it?
• A standardized method of identification that visually marks work locations, materials, tools, and other important areas within the facility.
What are the benefits?
• Creates an organized work area.• Increases process efficiency.• Makes abnormal conditions obvious.• Eliminates wasted space.• Promotes visual management.• Enhances morale and safety.
How is it used?• Used to designate locations for shared equipment, toolboxes,
parking, parts, and safety equipment. • Used to direct customers to certain areas within the dealership.
Who uses it?
• Used primarily in the parts and service departments.• All employees will benefit from the use of this tool and should be
aware of its purpose.
1 2Axe Example
Foot Printing /Labeling
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Techs all aware of location.
Visible and stored in the middle of the shop.
Clean area free of debris and grease.
Foot Printing /Labeling
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Foot Printing /Labeling
Signs can be used in
lieu of floor markings.
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Shadow Boards all should have contrasting colors standardized throughout the dealership.
Shadow Boards can be used for marking where tools need to be returned when not in use.
Shadow Boards are labeled according to engine models, wheel end sockets, etc.
Tools are outlined in a color that is easily visible.
Size should be adequate for the number of tools.
Shadow Boards / Tool Boxes
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Shadow Boards / Tool Boxes
The shadow boards can be displayed with picture and description format.
A quick, visual identification for missing tools is the result.
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Shadow Boards / Tool Boxes
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STEP 5: SUSTAIN
What is the best method to make sure the results of the other steps are maintained?
How can we assess how well we are doing with 5S?
5S audits - used to evaluate and measure the implementation of 5S.
5S creates a simpler work environment!
Address the need to perform the 5S process on an on-going and
systematic basis to maintain the new standard. 5S should become
second nature, a habit. Success is based on Discipline.
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Before After
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Before After
Safety (all hoses have hooks, spills immediately cleaned, reduce trip hazards).
Reduced waste (limit the walking and searching for equipment).
Improved efficiency (Shared equipment should be placed in the most efficient location within the shop).
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Before After
5S should also be practiced in the office.
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5S - SHOP FLOOR Trash cans in every bay
Clean Floors and Aisle ways
Good Lighting
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5S - PARTS STORAGE
Organized shelves
Clean Floors and Aisle ways
Managed Part Locations
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NEXT STEPS
1. Implement 5S in one area of the Service shop.Key Considerations:
• Assign a 5S Champion to lead implementation of the 5S dealership wide. • Take Before and After pictures to document improvement. • Assure that each step in the 5 step process is completed thoroughly
before moving to the next step. Each of the steps builds upon the prior, so take your time on each step.
• This area should be used to train and visually demonstrate expectations for the remaining areas of the facility.
2. Create a 5S Assignment Map and begin Sorting the remaining areas of the dealership.
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5S ASSIGNMENT AND SHINE MAP
Nate F.Aisles
Front Offices
Parts Front and Back
S. Brown
Ray S.
Bruce M.
Bay #1 Bay #2 Bay #3
Bay #11 and #12
Jeff T.
Bay # 12
Bay #4 Bay #5 Bay #6
Bay # 11
Pat W.
Brian M.
Matt S.
Joe S.
Parts Inventory
Paint/Body Shop
Bay # 7 Bay # 8 Bay # 9 Bay # 10
Service Offices
Fro
nt
Off
ices
Assigned Area Champion
John F.
Service
Area
Parts
Parts
Inv
5S Red Tag Champion
Bay #7 and #8
Paint and Body Shop
John S.
Marty M.
Bay #5 and #6
Paul D.
Bay #9 and #10
Bay #1 and # 2
Bay #3 and #4
John F. Joe S. Matt S.
Matt S.
Ray S. Paul D. Brian M.
John S.
Jeff T.
Nate F.
Bruce M.
Marty M.