Lean 5S Visual Workplace Organization Training Module

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The Lean 5S Visual Workplace Training Module v4.0 includes:

1. MS PowerPoint Presentation including 49 slides covering Introduction to 5S Visual Workplace Organization, Seven Lean Wastes & Productivity, Benefits, Types of Resistance, Key Success Factors, Step-by-Step 5S Implementation Process, Concept of Discipline, Red Tag Template, Marking Color Guidelines, 5S Area Evaluation Form and Scoring Guidelines.

2. MS PowerPoint Red Tag Template

3. MS Excel Red Tag Template

4. MS Excel Red Tag Inventory Sheet

5. MS Excel 5S Evaluation and Scoring Guidelines

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Lean 5S Visual Workplace Organization Training Module

  1. 1. 1 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Lean 5S Visual Workplace Organization by Operational Excellence Consulting LLC
  2. 2. 2 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Operational Excellence – 5S Visual Workplace The purpose of a 5S Visual Workplace initiative is to engage the entire organization in the design, implementation and maintenance of effective and efficient work areas and work processes.
  3. 3. 3 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Visual Workplace – Table of Content  The 7 Wastes - Muda  5S Visual Workplace – Benefits  5S Visual Workplace – Overview  5S Visual Workplace – Key Success Factors  5S Visual Workplace – Types of Resistance  5S Visual Workplace – Implementation Process  SORT – Red-Tag Strategy  SET-IN-ORDER – Signboard Strategy  SHINE – Cleaning & Inspection Standards  STANDARDIZE – Five-Point Standardized 5S Checklist  SUSTAIN
  4. 4. 4 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Waste elimination is one of the most effective ways to increase the efficiency and profitability of any organization. Processes either add value or waste to the production of a good or service. The concept of the seven wastes originated in Japan, where waste is known as “muda." Transportation Motion Over-Processing Over-Production Waiting The 7 Wastes Inventory Defects The 7 Wastes - Muda
  5. 5. 5 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Waiting Waiting Typically more than 99% of a product's life in traditional batch-and-queue manufacture will be spent waiting to be processed. Much of a product’s lead time is tied up in waiting for the next operation; this is usually because material flow is poor, production runs are too long, and distances between work centers are too great. Goldratt (Theory of Constraints) has stated many times that one hour lost in a bottleneck process is one hour lost to the entire factory’s output, which can never be recovered. Linking processes together so that one feeds directly into the next can dramatically reduce waiting.
  6. 6. 6 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Inventory Inventory Work in Progress (WIP) is a direct result of over-production and waiting. Excess inventory tends to hide problems on the plant floor, which must be identified and resolved in order to improve operating performance. Excess inventory consumes productive floor space, delays the identification of problems, and inhibits communication. By achieving a seamless flow between work centers, many manufacturers have been able to improve Customer service and slash inventories and their associated costs.
  7. 7. 7 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Motion Motion This waste is related to ergonomics and is seen in all instances of bending, stretching, walking, lifting, and reaching. These are also health and safety issues, which in today’s litigious society are becoming more of a problem for organizations. Jobs with excessive motion should be analyzed and redesigned for improvement with the involvement of plant personnel.
  8. 8. 8 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Over-Processing Extra Processing Steps Many organizations use expensive high precision equipment where simpler tools would be sufficient. This often results in poor plant layout because preceding or subsequent operations are located far apart. In addition they encourage high asset utilization (over-production with minimal changeovers) in order to recover the high cost of this equipment. Toyota is famous for their use of low-cost automation, combined with immaculately maintained, often older machines. Investing in smaller, more flexible equipment where possible; creating manufacturing cells; and combining steps will greatly reduce the waste of inappropriate processing.
  9. 9. 9 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Transportation Transportation Transporting product between processes is a cost incursion which adds no value to the product. Excessive movement and handling cause damage and are an opportunity for quality to deteriorate. Material handlers must be used to transport the materials, resulting in another organizational cost that adds no Customer value. Transportation can be difficult to reduce due to the perceived costs of moving equipment and processes closer together. Furthermore, it is often hard to determine which processes should be next to each other. Mapping product flows can make this easier to visualize.
  10. 10. 10 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Over-Production Over-Production Simply put, over-production is to manufacture an item before it is actually required. Over-production is highly costly to a manufacturing plant because it prohibits the smooth flow of materials and actually degrades quality and productivity. Over-production manufacturing is referred to as “Just in Case.” This results in high storage costs and makes it difficult to detect defects in a timely manner. The simple solution to over-production is turning off the tap; this requires a lot of courage because the problems that over-production is hiding will be revealed. The concept is to schedule and produce only what can be immediately sold/shipped and improve machine changeover/set-up capability.
  11. 11. 11 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Defects Defects Having a direct impact to the bottom line, quality defects resulting in rework or scrap are a tremendous cost to organizations. Associated costs include quarantining inventory, re-inspecting, rescheduling, and capacity loss. In many organizations the total cost of defects is often a significant percentage of total manufacturing cost. Through employee involvement and Continuous Process Improvement (CPI), there is a huge opportunity to reduce defects at many facilities.
  12. 12. 12 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The 7 Wastes – Summary In the latest edition of the Lean Manufacturing classic Lean Thinking, Under-Utilization of Employees has been added as an eighth waste. Organizations employ their staff for their nimble fingers and strong muscles but forget they come to work everyday with a free brain. It is only by capitalizing on employees' creativity that organizations can eliminate the other seven wastes and continuously improve their performance. Many changes over recent years have driven organizations to become world class organizations or Lean Enterprises. The first step in achieving that goal is to identify and attack the seven wastes. As Toyota and other world-class organizations have come to realize, Customers will pay for value added work, but never for waste.
  13. 13. 13 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 1. Reduction of Waste (mainly defects, motion, waiting, & transportation) results in lower costs ! 2. Reduction in equipment breakdowns results in higher equipment availability ! 3. Reduction in delays results in a higher fill rate and on-time deliveries! 4. Reduction in defects results in less rework ! 5. Reduction in complaints results in greater Customer satisfaction ! 6. Reduction in injuries results in lower costs ! 7. Reduction in changeover time results in less downtime ! 8. A cleaner work environment results in higher employee satisfaction ! 5S Visual Workplace - The Benefits Ownership Moral Productivity Safety Shareholder Satisfaction 9. Lower costs and higher shareholder satisfaction result in improved profitability !!!
  14. 14. 14 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Visual Workplace - Overview 1. Sort (Seiri) 2. Set-in-Order (Seiton) 3. Shine (Seiso) 4. Standardize (Seiketsu) 5. Sustain (Shitsuke) 5S Visual Workplace is generally the first step toward implementing a lean- based Operational Excellence initiative. It facilitates a structured dialog about standardization which builds a clear understanding, between employees, of how work should be done.
  15. 15. 15 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Visual Workplace requires (self-) discipline from everyone involved. dis·ci·pline [ díssəplin ] noun Definition: training to ensure proper behavior: the practice or methods of teaching and enforcing acceptable patterns of behavior. Definition: make yourself do something regularly: to make yourself act or work in a controlled or systematic way 5S Visual Workplace - Discipline
  16. 16. 16 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G It all starts with YOU !!! You need to WALK the TALK in EVERYTHING you do !!! 5S Visual Workplace - Walking the Talk
  17. 17. 17 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 1. Have an Implementation & Communication Plan !!! 2. Leadership – Drive it from the Top and Walk the Talk. 3. Employee Involvement & Empowerment – Provide adequate training, nominate 5S Leaders, and establish a 5S Action and Audit Teams. 4. Focus – Establish 5S focus areas with employee ownership. 5. No Scared Cows – 5S is not just about the production floor. Include shipping & receiving, warehouses, and offices. 5S Visual Workplace - Key Success Factors 6. Organize & Beautify – Paint is an inexpensive and terrific tool for supporting any 5S implementation. 7. Accountability – Hold leaders and teams accountable to the established work area requirements (discipline). 8. Evaluate & Improve – Perform weekly 5S audits with owners in each focus area. Measure progress and post scores. Make it fun and celebrate progress !!!
  18. 18. 18 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 1. “What’s so great about Organization (Sort) and Orderliness (Set-in-Order)?”  Response: The purpose of a 5S Visual Workplace initiative is to develop, implement, and maintain an effective and efficient workplace. 2. “You want us, the Operations and Service Managers, to be 5S Leaders?”  Response: The development, implementation, and maintenance of an effective and efficient workplace is a management responsibility. A 5S Visual Workplace initiative requires leadership and leadership involvement. 3. “Why clean up when it will soon get dirty again?”  Response: When management and employees are indifferent to making and maintaining improvements, it is no surprise that defect rate remains high and productivity low. 4. “Implementing Organization (Sort) and Orderliness (Set-in-Order) will not boost output.”  Response: Being busy does not mean being productive. Everyone must learn the important difference between “moving” and “working”. 5. “Why concern ourselves with such trivial matter?”  Response: Managers who fail to promote an effective, efficient and safe workplace end up not only with a sloppy and undisciplined work force, but also with higher costs and higher defects. 5S Visual Workplace - Types of Resistance
  19. 19. 19 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 6. “We already implemented them.”  Response: Some managers believe that rearranging things a little and putting them into neat rows is all there is to it. Such orderliness only scratches the surface of what the 5S’s are all about, as this training program will show. 7. “I know my filing system’s a mess, but I know my way around it.”  Response: The first step in standardizing clerical operations is to open up private messes so that books, files, and paper work is easily accessible to anyone who needs them when they need them. 8. “5S and improvement stuff is just for the factory.”  Response: The purpose of a 5S Visual Workplace initiative is to develop, implement, and maintain effective and efficient work processes. This is and must be a companywide initiative. 9. “We are too busy to spend time on Organization (Sort) and Orderliness (Set-in- Order).”  Response: “Are you also too busy to take a shower and brush your teeth?”. Developing, implementing, and maintaining effective and efficient work processes is not an option, it is a necessity in today's competitive business environment. 5S Visual Workplace - Types of Resistance
  20. 20. 20 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Visual Workplace - Types of Resistance 10. “We did the 5S’s 10 years ago.”  Response: “Has it also been 10 years since you took a bath?” 5S Visual Workplace is not a project with a start and end date, it is an integral part of any highly productive world-class organization. 11. “Why should anyone tell me what to do?”  Response: Most 5S initiatives run into human-relation issues early on. It pays of form cross-functional 5S Promotion Teams with members skilled at applying the 5S’s to human relations. 12. “We don’t need 5S. We are making money, so let us do our work the way we want to.”  Response: Operations has a rhythm, and this rhythm gets upset when employees care only about their individual tasks. By allowing employees to do things “their way”, we grant a selfish kind of freedom that hurts everyone in the long-term.
  21. 21. 21 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Visual Workplace - Implementation Process Step 1 Establish a 5S Organization Step 2 Establish a 5S Implementation Plan Step 3 Create 5S Campaign Material Step 4 In-House 5S Education Step 6 5S Evaluation, Scoring and Follow-Up Step 5 5S Implementation SORT (Red-Tag Strategy) SHINE SET-IN-ORDER (Signboard Strategy) STANDARDIZE SUSTAIN
  22. 22. 22 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 1. Establish a 5S Implementation Organization The 5S Implementation Team handles such tasks as on-site 5S education, “discipline” training, 5S standardization, guidance in 5S techniques, and provision of 5S tools. The 5S Leader(s) are Site Manager(s) and heads the 5S Implementation Team. The 5S Audit Team makes weekly inspection tours to check up on 5S conditions and suggest & document remedial measures when conditions have begun to deteriorate. The 5S Action Team, which consists of workshop leaders and ordinary employees, is responsible for the nuts and bolts of 5S implementation. The team members study 5S theory while putting it into practice in making 5S- oriented improvements.
  23. 23. 23 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 2.1 Prioritize Opportunities  Divide plant or office area into manageable sections  Evaluate and prioritize opportunities, risks and success factors  Schedule 5S Visual Workplace implementation for each section
  24. 24. 24 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 2.2 Establish a 5S Implementation Plan The main purpose of a 5S Campaign is not so much to announce the beginning of the 5S initiative as it is to show the enthusiasm and commitment of 5S Leaders. The 5S Leaders should address the organization’s current conditions, its goals, and its plan to use the 5S Visual Workplace initiative to lay a foundation for achieving those goals. A 5S Implementation Plan should cover 90 days at a time.
  25. 25. 25 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 3. Create 5S Campaign Material 5S Campaign Materials could include face-to-face meetings, newsletters, slogans, boards, posters, banners, badges, 5S news, photo exhibits of before and after, … .
  26. 26. 26 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 4. In-House Education 5S Visual Workplace education materials could include training classes, single- point 5S lessons, on-the-job training, posters, in-house bulletins, 5S news, videos, books, … . Point 1. Make education continuous Point 2. Don’t be a perfectionist, but strive for perfection. 50% is a good start. Point 3. The primary place for 5S Visual Workplace implementation is the individual workplace Point 4. Encourage independent thinking Point 5. Encourage motivation, skill-building and participation Make it Relevant, Specific & Engaging !!!
  27. 27. 27 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.1 5S Implementation - SORT SORT means clearly distinguishing between (1) what is needed and to be kept and (2) what is unneeded and to be discarded. SET-IN-ORDER means organizing the way needed things are kept so that anyone can find, use and return them easily. SHINE means thoroughly cleaning the work area and everything in it. The goal is (1) to turn the work area into a clean, bright place where people enjoy working, (2) to review the first two Ss, and (3) to find the source of dirt or litter and eliminate it. Shine should become so deeply ingrained as a daily work habit that tools are always kept in top condition and are ready for use at any time. STANDARDIZE means the development and implementation of a detailed plan to maintain SORT, SET- IN-ORDER, and SHINE. The plan should include the creation of procedures and simple daily checklists that are to be visibly posted in each work area; the checklist should serve as a visual to ensure that the daily 5S requirements are being met. Standardized cleanup integrates sort, set in order, and shine into a unified whole. 1. Sort (Seiri) 2. Set-in-Order (Seiton) 3. Shine (Seiso) 4. Standardize (Seiketsu) 5. Sustain (Shitsuke) SUSTAIN means always following specified (and standardized) procedures. Sustain requires self- discipline. Without discipline, it is impossible to maintain consistent standards of quality, safety, clean production, and process operation. SAFETY  Sometimes used as the 6th S. We believe that Safety is a natural consequence of the successful implementation of a 5S Visual Workplace initiative.
  28. 28. 28 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.1 5S Implementation - SORT What is the Red-Tag Strategy? Step 1. Launch the Red-Tag Project – Members: Employees across the organization – Period: 1-2 months – Key Points: Help the employees understand the objectives of SORT and how to identify what items are not needed. Step 2. Identify Red-Tag Targets – Targets: Inventory – Equipment – Space Step 3. Set Red-Tag Criteria – Set the criteria for determining what is needed and what is not. Step 4. Make or Order the Red-Tags – Red, Eye-catching, Category – Name – Quantity – Value – Tagging Reason – Date – …
  29. 29. 29 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.1 5S Implementation - SORT What is the Red-Tag Strategy? (cont.) Step 5. Attach the Red Tags – People from indirectly related organizations should come to the workshop, listen to the description of current conditions, and be objective in attaching red tags to all unneeded items. • Look with a critical eye, • Don’t let the workshop’s own workers decide where to stick the red tags. They tend to think everything is necessary. • Be merciless when attaching red tags! • Set a target of at least 3-4 red tags per employee in the organization • If in doubt, red-tag it! – Red-tagging should be done intensively over a short period of time.
  30. 30. 30 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.1 5S Implementation - SORT What is the Red-Tag Strategy? (cont.) Step 6. Evaluate the Red Tags Inventory – Divide into two types: 1. “dead stock” and 2. “retained stock” – Set the “need” period for service parts and keep them in the warehouse for the appropriate need period. – Make a list of all unneeded inventory (name, quantity, value) to facilitate understanding and for use in accounting and create and execute schedule to dispose “dead stock”. Equipment – Whatever gets in the way during improvement activities should either be moved or disposed of. – Follow companies procedure to dispose of unneeded equipment. – If equipment in the way during improvement activities is an off-the- book asset, simply get rid of it. Spaces & Shelves
  31. 31. 31 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.1 5S Implementation - SORT Red-Tag Criteria Inventory or Equipment Cannot be used or unlikely to be used Red-Tag Discard Can be used Used about twice per year Red-Tag Remove from Service Center & Store elsewhere Used every one or two months Store near process where used Used about once a week Store near operation where used Keep close at hand at all time Used every hour or every day
  32. 32. 32 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.2 5S Implementation - SET-IN-ORDER SORT means clearly distinguishing between (1) what is needed and to be kept and (2) what is unneeded and to be discarded. SET-IN-ORDER means organizing the way needed things are kept so that anyone can find, use and return them easily. SHINE means thoroughly cleaning the work area and everything in it. The goal is (1) to turn the work area into a clean, bright place where people enjoy working, (2) to review the first two Ss, and (3) to find the source of dirt or litter and eliminate it. Shine should become so deeply ingrained as a daily work habit that tools are always kept in top condition and are ready for use at any time. STANDARDIZE means the development and implementation of a detailed plan to maintain SORT, SET- IN-ORDER, and SHINE. The plan should include the creation of procedures and simple daily checklists that are to be visibly posted in each work area; the checklist should serve as a visual to ensure that the daily 5S requirements are being met. Standardized cleanup integrates sort, set in order, and shine into a unified whole. 1. Sort (Seiri) 2. Set-in-Order (Seiton) 3. Shine (Seiso) 4. Standardize (Seiketsu) 5. Sustain (Shitsuke) SUSTAIN means always following specified (and standardized) procedures. Sustain requires self- discipline. Without discipline, it is impossible to maintain consistent standards of quality, safety, clean production, and process operation. SAFETY  Sometimes used as the 6th S. We believe that Safety is a natural consequence of the successful implementation of a 5S Visual Workplace initiative.
  33. 33. 33 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G A Everything Everything In Its Everything in its Place and A Place for Everything Step 5.2 5S Implementation - SET-IN-ORDER
  34. 34. 34 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.2 5S Implementation - SET-IN-ORDER
  35. 35. 35 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.2 5S Implementation - SET-IN-ORDER “Everything has its Place.” and “There is a Place for Everything.”
  36. 36. 36 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.2 5S Implementation - SET-IN-ORDER 5S Visual Workplace Floor Marking Guidelines and Best Practices  Use as few colors as possible: This will make it easier for employees to remember the intended meaning of each color and reduce the number of vinyl tape products kept in inventory.  Identify specific colors with specific purposes: Some companies opt to mark equipment locations using the same color for aisle ways and work cell boundaries. This choice adheres to the principle of keeping the color code system as numbered as possible, but for some, it may be more effective to use two different colors for two different work areas. When a plant differentiates between colors when marking specific work areas, it creates a visually clear environment that helps employees quickly correlate colors with purposes.  Raw Materials, WIP and finished goods: Try and use the same color for all material storage areas, unless there is an important reason for differentiating between them. As an alternative, use different colored labels to visually distinguish between the various material types.  Do more with less: Many companies use different colored stripes to border areas in front of fire fighting equipment, safety equipment and electrical panels. Instead of having three different floor tape products, choose one color for all applications where the intent is to keep the area clear for safety or compliance reasons.
  37. 37. 37 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Visual Workplace – Signboard Strategy Without Signboards of one kind or another, only veteran employees would know where to find things. To turn a work area into a workplace where everyone can see at a glance what goes where, we need signboards.
  38. 38. 38 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.2 5S Implementation - SET-IN-ORDER What is the Signboard Strategy? Step 1. Determine Locations – After consolidating the remaining items, decide where to place them to best suit the way operations will be done. – Note: Be sure to put frequently used items as close as possible to the operations for easy retrieval. Step 2. Prepare Locations – Organize shelving and cabinets in their specified places. – Note: Use your ingenuity (e.g. make parts easier to remove from shelves and cabinets or set up a first-in first-out FIFO stocking system). Step 3. Indicate Locations – Make and post (or hang) signboards that clearly indicate where each item belongs. – Note: Use either a place name/diagram signboard or an address signboard to indicate where things belong.
  39. 39. 39 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.2 5S Implementation - SET-IN-ORDER What is the Signboard Strategy? (cont.) Step 4. Indicate Item Names – Make and post (or hang) signboards that clearly indicate item names and the name/number of the shelf or cabinet where items will be kept. – Note: Use a shelved item signboard or other place-specific item signboard. Step 5. Indicate Amounts – Indicate the number of inventory items covered by each signboard. – Note: Indicate both maximum and minimum amounts. Step 6. Make Orderliness (SET-IN-ORDER) a Habit – Make Orderliness (SET-IN-ORDER) a habit so that the workplace does not lapse into disorder. – Note: 1. Make Orderliness (SET-IN-ORDER) easy to maintain 2. Maintain discipline 3. Make the 5’s a daily habit
  40. 40. 40 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.3 5S Implementation - SHINE SORT means clearly distinguishing between (1) what is needed and to be kept and (2) what is unneeded and to be discarded. SET-IN-ORDER means organizing the way needed things are kept so that anyone can find, use and return them easily. SHINE means thoroughly cleaning the work area and everything in it. The goal is (1) to turn the work area into a clean, bright place where people enjoy working, (2) to review the first two Ss, and (3) to find the source of dirt or litter and eliminate it. Shine should become so deeply ingrained as a daily work habit that tools are always kept in top condition and are ready for use at any time. STANDARDIZE means the development and implementation of a detailed plan to maintain SORT, SET- IN-ORDER, and SHINE. The plan should include the creation of procedures and simple daily checklists that are to be visibly posted in each work area; the checklist should serve as a visual to ensure that the daily 5S requirements are being met. Standardized cleanup integrates sort, set in order, and shine into a unified whole. 1. Sort (Seiri) 2. Set-in-Order (Seiton) 3. Shine (Seiso) 4. Standardize (Seiketsu) 5. Sustain (Shitsuke) SUSTAIN means always following specified (and standardized) procedures. Sustain requires self- discipline. Without discipline, it is impossible to maintain consistent standards of quality, safety, clean production, and process operation. SAFETY  Sometimes used as the 6th S. We believe that Safety is a natural consequence of the successful implementation of a 5S Visual Workplace initiative.
  41. 41. 41 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.3 5S Implementation - SHINE Work Duties Incorporate Cleanliness = SHINE into regular Work Duties Cleanliness Work Duties + Cleanliness Incorporate Inspections into regular Cleanliness Inspection Work Duties Cleanliness Inspection Work Duties + Inspection Incorporate Maintenance into Cleanliness Inspection Work Duties Cleanliness Maintenance and Inspection Work Duties + Maintenance
  42. 42. 42 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.3 5S Implementation - SHINE No. Category CleaningStandards CleaningMethods CleaningTime Day Week Month 1 Equipmentsurfaceandsurroundings Nolintontheequimentsurface 5min X 2 … … X 3 … … X X X X No. Category LubricationStandards LubricationMethods LubricationTime Day Week Month 1 Frictiongear Nolintontheequimentsurface 5min X 2 … … X 3 … … X X X X 3.… CleaningCycle 1.Tightenoilsupplyvalveandcheckforleaks 2.… CleaningCycle 1.Tightenoilsupplyvalveandcheckforleaks 2.… 3.… LubricationAreas CleaningCheckPoints LubricationCheckPoints Drawings& Pictures TLCMaintenanceStandardforXYZ CleaningAreas
  43. 43. 43 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Step 5.4 5S Implementation - STANDARDIZE SORT means clearly distinguishing between (1) what is needed and to be kept and (2) what is unneeded and to be discarded. SET-IN-ORDER means organizing the way needed things are kept so that anyone can find, use and return them easily. SHINE means thoroughly cleaning the work area and everything in it. The goal is (1) to turn the work area into a clean, bright place where people enjoy working, (2) to review the first two Ss, and (3) to find the source of dirt or litter and eliminate it. Shine should become so deeply ingrained as a daily work habit that tools are always kept in top condition and are ready for use at any time. STANDARDIZE means the development and implementation of a detailed plan to maintain SORT, SET- IN-ORDER, and SHINE. The plan should include the creation of procedures and simple daily checklists that are to be visibly posted in each work area; the checklist should serve as a visual to ensure that the daily 5S requirements are being met. Standardized cleanup integrates sort, set in order, and shine into a unified whole. 1. Sort (Seiri) 2. Set-in-Order (Seiton) 3. Shine (Seiso) 4. Standardize (Seiketsu) 5. Sustain (Shitsuke) SUSTAIN means always following specified (and standardized) procedures. Sustain requires self- discipline. Without discipline, it is impossible to maintain consistent standards of quality, safety, clean production, and process operation. SAFETY  Sometimes used as the 6th S. We believe that Safety is a natural consequence of the successful implementation of a 5S Visual Workplace initiative.
  44. 44. 44 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Area Evaluation & Scoring Guidelines Score Sort Set-in-Order Shine Standardize Sustain Comments / Actions 5 Prevention The culture of the area has all employees engaged and on constant vigilance keeping anything un-necessary from remaining in the work area. A process is in place to introduce new items or equipment to the work area and to implement improvement regularly in the layout of the work area. Employees participate in preventative maintenance for all area equipment. Employees are adding improvements on their own regularly for 6S in the work area. Other work areas seek the input of work area employees to improve 6S in their work areas. Employees reflect a spirit of pride in the work area and ownership to keep it looking great. They do not wait for supervisors or engineers to discover equipment issues or leaks, but proactively engage and even demand fixes immediately and participate in implementing those solutions. 4 Consistent Application Standard Work is in place and visual to prevent un-necessary items from finding a way back to the work area or for idenifying items that become un-necessary over time. Standard Work is in place to audit an area to detemine if every item is present and in its assigned location. Work areas are cleaned each shift. There is a checklist posted at each work center of things to check for to ensure the area is clean. The working team regularly improves the area beyond the current level of acceptability by painting, taping, or adding other visual improvements. Employees participate in mitigating issues and leaks in the work area. The 6S method is documented and posted in the work area. Photos are posted of how the area should look each day at the end of the shift. A rotation has been established and is posted involving all employees in the work area in the weekly 6S audit. The 6S audit results are posted. The 6S audit yields improvement opportunities that are documented and posted each week. Improvements are taking place each week. 3 Make it Visual The area only contains items that are necessary. Each item or piece of equipment has a location that has been visually indicated (signs, tape, paint, etc) in the work area. There's a place for every item and every item has a place. Work areas are cleaned on a daily basis. There is a checklist posted at each work center of things to check for to ensure the area is clean. Leaks are obvious when they occur. Employees participate in reporting leaks or other problems that are not "normal" for the 6S plan. The 6S method for the work area is documented for the work area.All employees have been trained and can describe their roles and ownership relative to 6S. Visual controls are in place for kanbans, and-on lights, and inventory levels. The 6S audit is taking place each week and is posted. The audit is performed by all employees on a rotational basis. 2 Foundational Un-necessary items have been identified and separated from necessary items. Each item or piece of equipment has a designated location. The work area has a regularly scheduled clean up routine. There is no dirt, debris or lint in the work area older then a single day. Improvements are being made to 6S, but are not following a regular schedule. The 6S plan for the area is not yet documented. The 6S audit is taking place each week and is posted. 1 Just Beginning Area still contains both necessary and un-necessary items. Equipment and other items are at random locations throughout the work area. The work area is dirty. Debris and other items are located randomly. The work area has dust, dirt, lint, and other debris more then 1 day old. 6S methods are not consistently followed and maintained and are not documented. 6S improvements have started but are irregular. The 6S audit is not taking place regularly. 0 Haven't Started Haven't Started this 6S activity yet Haven't Started this 6S activity yet Haven't Started this 6S activity yet Haven't Started this 6S activity yet Haven't Started this 6S activity yet Average = Average = Area ______________ Auditor Name __________________________ Auditor Signature ___________________________________________Audit Date _______________ Current Score Last Score
  45. 45. 45 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Site Evaluation & Follow-Up Service Center: Entered by: Date: Page: No Process & Checkpoint SORT Level SET-IN-ORDER Level SHINE Level STANDARDIZE Level SUSTAIN Level SAFETY Level Total Previous Total 1 Soil - Soil Staging 2 Soil - Soil Loading 3 Soil - Soil Sorting 4 … 5 … 6 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … Average & Total 0 0 Observations: 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 of 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Five-Point Standardized Visual Workplace Checklist 1 2 3 4 5 1 2 3 4 5 1 2 3 4 51 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
  46. 46. 46 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Implementation - SUSTAIN SORT means clearly distinguishing between (1) what is needed and to be kept and (2) what is unneeded and to be discarded. SET-IN-ORDER means organizing the way needed things are kept so that anyone can find, use and return them easily. SHINE means thoroughly cleaning the work area and everything in it. The goal is (1) to turn the work area into a clean, bright place where people enjoy working, (2) to review the first two Ss, and (3) to find the source of dirt or litter and eliminate it. Shine should become so deeply ingrained as a daily work habit that tools are always kept in top condition and are ready for use at any time. STANDARDIZE means the development and implementation of a detailed plan to maintain SORT, SET- IN-ORDER, and SHINE. The plan should include the creation of procedures and simple daily checklists that are to be visibly posted in each work area; the checklist should serve as a visual to ensure that the daily 5S requirements are being met. Standardized cleanup integrates sort, set in order, and shine into a unified whole. 1. Sort (Seiri) 2. Set-in-Order (Seiton) 3. Shine (Seiso) 4. Standardize (Seiketsu) 5. Sustain (Shitsuke) SUSTAIN means always following specified (and standardized) procedures. Sustain requires self- discipline. Without discipline, it is impossible to maintain consistent standards of quality, safety, clean production, and process operation. SAFETY  Sometimes used as the 6th S. We believe that Safety is a natural consequence of the successful implementation of a 5S Visual Workplace initiative.
  47. 47. 47 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Implementation - SUSTAIN SORT means clearly distinguishing between (1) what is needed and to be kept and (2) what is unneeded and to be discarded. SET-IN-ORDER means organizing the way needed things are kept so that anyone can find, use and return them easily. SHINE means thoroughly cleaning the work area and everything in it. The goal is (1) to turn the work area into a clean, bright place where people enjoy working, (2) to review the first two Ss, and (3) to find the source of dirt or litter and eliminate it. Shine should become so deeply ingrained as a daily work habit that tools are always kept in top condition and are ready for use at any time. STANDARDIZE means the development and implementation of a detailed plan to maintain SORT, SET- IN-ORDER, and SHINE. The plan should include the creation of procedures and simple daily checklists that are to be visibly posted in each work area; the checklist should serve as a visual to ensure that the daily 5S requirements are being met. Standardized cleanup integrates sort, set in order, and shine into a unified whole. 1. Sort (Seiri) 2. Set-in-Order (Seiton) 3. Shine (Seiso) 4. Standardize (Seiketsu) 5. Sustain (Shitsuke) SUSTAIN means always following specified (and standardized) procedures. Sustain requires self- discipline. Without discipline, it is impossible to maintain consistent standards of quality, safety, clean production, and process operation. SAFETY  Sometimes used as the 6th S. We believe that Safety is a natural consequence of the successful implementation of a 5S Visual Workplace initiative.
  48. 48. 48 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Visual Workplace requires (self-) discipline from everyone involved. dis·ci·pline [ díssəplin ] noun Definition: training to ensure proper behavior: the practice or methods of teaching and enforcing acceptable patterns of behavior. Definition: make yourself do something regularly: to make yourself act or work in a controlled or systematic way 5S Visual Workplace - Discipline
  49. 49. 49 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G 5S Implementation - Your 30s Elevator Speech An ‘elevator speech’ is a concise, punchy, planned description that overviews the value provided by a 5S Visual Workplace implementation. Target Audience: - Operator - Lead - Supervisor - Maintenance Technician - Customer Please take 15 minutes to work on yours and share it with the team. 15 Minutes
  50. 50. 50 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G The End … “Perfection is not attainable, but if we chase perfection we can catch excellence.” - Vince Lombardi
  51. 51. 51 April 9, 2016 – v 4.0 OPERATIONAL EXCELLENCE C O N S U L T I N G Terms & Conditions After you have downloaded the training material to your own computer, you can change any part of the course material and remove all logos and references to Operational Excellence Consulting. You can share the material with your colleagues and re-use it as you need. The main restriction is that you cannot distribute, sell, rent or license the material as though it is your own. These training course materials are for your — and your organization's — usage only. Thank you.

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