What is the 5’s Toolkit?• An approach to establishing standards that will allow you to detect an abnormality when it occurs.• A process and method for creating and maintaining an organized,clean,safe, and high performance work area.• A conditioning discipline for Action workout.
5’s for Success• Sort-Separate what is needed now from what is not needed now.• Simplify-Organize and arrange what you need.• Sweep-Keep the area clean.• Standardize-Standardize workstations and processes to remove variation and maintain safety and quality.• Self-Discipline-Sustain 5’s through leadership. MANAGE THE ABNORMAL RATHER THAN THE NORMAL CONDITION
Step 1- Sort• Purpose: -Eliminate all unnecessary items-those things which are not needed for present task.• Ask Yourself:-What do we need.-What do we not need?-What can we remove?-What can we throw away?• Remove what is not Needed:-Equipment -Computer -File Cabinet -Storage selves-Chairs -Fixtures -Documents - Machine work Benches-Parts -Empty Barrels -Scraps -Unused machines.
Step 2-Simplify• Purpose:-Organize the necessary items close to where they are needed and in such a way that any waste or abnormality is apparent1. Anyone can quickly assess the condition of the cell and determine whether or not abnormal conditions exist.2. Anyone can help maintain the system.• Example:1. Tools and fixtures -Can fixtures/tool be eliminated? -Can complexity/variety of tools be reduced? -Are tools/fixtures arranged ergonomically? -Can workers easily identify storage locations for tools/fixtures(shadow boards)?2. Cutting Tools/Gauges/Lubricants -High frequency usage: instrument stored at line position. -Sensitive tools (gauges,micrometers,etc.): Kept free from dust, dirt, vibration, corrosion. -Lubricants/bulk material: stored in bulk seperately, delivered in small containers and color-coded to avoid confusing one for another.
Arrange and Identify• Define item placement by frequency of use.• Decide how items will be stored(small containers, shelves, pallets, boxes, etc.)• Determine a location(address, spot, etc.) for the container/item.• Label the container (What, where, how much) to indicate visually how much should be stored.• Make good arrangement a habit.
Step 3- Sweep• Purpose: -Regular cleaning is a form of inspection. -Irregularities or malfunctions can be easily noticed when machine is clean. -Repetitive cleaning gives opportunity to implement improvements to- Cleaning procedures, which enhances efficiency.• Eliminate: – Empty Boxes, Pallets – Broken parts – Oil scrap paper – Dust – Dirt
Step 4- Standarize• Purpose: – Revisit and maintain Sorting, Simplify, and Sweeping. Develop Countermeasures to prevent dirt from occurring in the first place. – Constant adherence to the first three steps• Objectives: – Create and maintain a safe work environment – Standardize cleanup activities so they are focused and easy to do• Communicate: – Share information between shifts – Share information with internal customers and suppliers – Post measurements: • Takt Time/Cycle Time • Standard Work/Standard WIP • Output/Variance • Open Action Items
Step 5- Self Discipline• Leadership Responsibility: – Management at all levels must be committed to establishing and maintaining the 5’s process – Suggested cycles of review should include • Cell coordinators- Daily review • Bussiness leaders-Weekly review • Bussiness Team Leader-Monthly review – Use a checklist for monitoring adherence, quantifying results of cell inspections; a prominent display of each area’s results is a tool which management can use to help sustain the process – Management must lead by example.
Step 6- Safety When the first five Ss are practiced daily, safety issues are recognized and given priority. Make maintaining a safe workplace a part of your daily routune. DISCIPLINE IN ALL AREA’s OF SAFETY-Tripping Hazards. -Hazardous Chemicals -Lifting Procedure-LOTOV -Material Handling -Eye Protection-Equipment Operation -Hearing Conservation
5’s Hints• Involve a cross-section of job responsibilities on the team.• Focus on one area at a time: -Review of 5s concepts- What is 5s? -Use a Red Tag program -Clean up entire focus area -Arrange area -Prepare a check list -Plan for an audit: Review methods and cycle.• Do not try all S’s at once, focus on the first 2.• During the event, each day, communicate on progress so employees understand what is changing and why.
Keys to 5s Success• Get everyone involved.• Integrate 5’s principles into daily work requirements.• Communicate need for 5’s, roles of all participants, how it is implemented.• Be consistent in following 5’s principles in all areas.• Bussiness Team leader involvement is a must!• Follow through-finish what is started-5’s takes effort and persistence.• Link 5’s activity with all other Action workout initiatives.