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5S: Five Keys for High Workplace Productivity

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This Slideshare presentation is a partial preview of the full business document. To view and download the full document, please go …

This Slideshare presentation is a partial preview of the full business document. To view and download the full document, please go here:
https://flevy.com/browse/business-document/5S-Five-Keys-for-High-Workplace-Productivity-154

The 5S workplace organization system applies a set of basic management principles that many companies widely adopt to maximize productivity and organization. As a cornerstone of Lean management, 5S improves workplace morale, safety and efficiency.

In this training presentation, you will learn how to mobilize and align your management team to launch or improve a 5S and Visual Management implementation in your organization. The presentation covers 5S and Visual Management best practices, step-by-step implementation guidance, and the best ways to integrate lean 5S into the organization's culture to achieve sustainable world-class excellence.

CONTENTS:

Introduction & Overview
5S Provides a Solid Foundation to Lean Implementation
Types of Waste in the Workplace
What is 5S?
Benefits of 5S
5S Principles - Step By Step
How to Conduct a Red Tagging Exercise
Creating a Visual Workplace
Applying 5S to Safety, Quality, Equipment Reliability & Productivity
5S in the Office
How to Implement 5S
How to Sustain 5S
5S Audit System
Supporting Lean Tools for 5S
Critical Success Factors

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  • 1. © Operational Excellence Consulting. All rights reserved. Sort Set In Order Shine Standardize Sustain 5S - Five Disciplines for High Workplace Productivity
  • 2. © Operational Excellence Consulting. All rights reserved. 4 Outline • Introduction to 5S • 5S Provides a Solid Foundation to Lean Implementation • Types of Waste in the Workplace • What is 5S? • Benefits of 5S • 5S Principles - Step By Step • How to Conduct a Red Tagging Exercise • Creating a Visual Workplace • Applying 5S to: Safety Quality Equipment Reliability Productivity • 5S in the Office • How to Implement 5S • How to Sustain 5S • 5S Audit System • Supporting Lean Tools for 5S • Critical Success Factors This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 3. © Operational Excellence Consulting. All rights reserved. 7 5S and Kaizen Standardize Standardize StandardizeKaizen Kaizen Kaizen P DC A Kaizen (改 善) = Continuous Improvement Plan DoCheck Act This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 4. © Operational Excellence Consulting. All rights reserved. 10 5S Integration with Corporate Initiatives Business Excellence Initiatives Safety SSS 5S TPM TQM others JITThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 5. © Operational Excellence Consulting. All rights reserved. 13 Benefits of 5S • 5S makes our workplace more pleasant • 5S improves work efficiency • 5S and safety go hand-in-hand • 5S leads to better customer satisfaction and higher productivityThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 6. © Operational Excellence Consulting. All rights reserved. 16 1S : Sort • The first step in 5S is to get rid of what we do not need • Go through all the tools, equipment, materials, etc. in the plant and work areas Keep only essential items Everything else is stored away or discarded This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 7. © Operational Excellence Consulting. All rights reserved. 19 1S : Sort Degree of Need Frequency of Use Storage Method Low • Things you have not used in the past year • Things you have used once in the last 6-12 months • Throw them out • Store at a distance Medium • Things you have only used between 1-6 months • Store in a central place in the workplace High • Things used once a week • Things used daily • Things used hourly • Store near the work site or carry on the person This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 8. © Operational Excellence Consulting. All rights reserved. 22 2S : Set In Order • Set In Order is about locating and placing items in an organization. It determines the rate at which things can be located or placed. Test: Can you find an item in less than 30 seconds? • Set In Order emphasizes on: Functional placement of parts, tools and materials Clearly designated names and places Easy-to-read notice boards Quick and easy retrieval of documents, parts and tools This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 9. © Operational Excellence Consulting. All rights reserved. 25 2S : Set In Order - Check Sheet Equipment • Machines • Small tools • Dies • Jigs • Bits • Conveyance equipment • Cleaning equipment Furniture • Cabinets • Benches, tables • Chairs • Carts • Shelves • Racks Materials • Raw material • Supplies • Parts • Work-in-process • Finished goods • Shipping materials • Cleaning supplies Other items • Charts, graphs, bulletin boards • Pens, pencils • Work clothes • Helmets • Work shoes • Trash cans This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 10. © Operational Excellence Consulting. All rights reserved. 28 2S : Set In Order - Examples This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 11. © Operational Excellence Consulting. All rights reserved. 31 2S : Set In Order - Examples This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 12. © Operational Excellence Consulting. All rights reserved. 34 3-Step Approach to Cleaning Common areas, walls, ceilings, lights, storage areas, toilets, “junk yards”, shelves, filing cabinets, etc. Individual workstations, chairs, drawers, computers, cabinets, shelves, etc. Clear away things underneath your table! Measuring instruments, e.g. micrometer, gauges, vernier calipers, contact surfaces, etc. Macro Individual Micro This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 13. © Operational Excellence Consulting. All rights reserved. 37 3S : Shine - Check Sheet • Ceilings • Aisles • Workstations • Corners, under equipment • Loading docks • Walls • Doors • Pillars, posts • Floors • Machines • Conveyance equipment • Plumbing, sinks • Cabinets, shelves, racks • Carts, Racks • Drawers, storage bins • Fixtures, power boxes This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 14. © Operational Excellence Consulting. All rights reserved. 40 4S : Standardize – Practice Tips • Define work instructions and procedures • Define standards by which personnel must maintain and measure the first 3S's • Make standards to detect abnormality This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 15. © Operational Excellence Consulting. All rights reserved. 43 Foundations of Standardized Work Simplify the Work Site This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 16. © Operational Excellence Consulting. All rights reserved. 46 5S : Sustain • Principle Habit formation Disciplined workplace • Meaning Training ‘Before’ and ‘after’ photos Daily 5S five-minute activities Self-discipline This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 17. © Operational Excellence Consulting. All rights reserved. 49 How to Sustain 5S? 2 • Get everyone involved 5S is not the responsibility of a concerned few All levels of management should take part in decision making required to ensure 5S implementation Incorporate 5S as part of the organization’s Small Group Activities 5S Continuous Improvement Teams Suggestion System This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 18. © Operational Excellence Consulting. All rights reserved. 52 How to Sustain 5S? 5 • Do it all the way Carry out proper red tag campaigns Use correct red-tagging formats and procedures Use signboards for establishing orderliness Ensure signboards have proper format, descriptions and locations Prepare your organization’s own 5S Manual, complete with all the necessary procedures, forms and templates This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 19. © Operational Excellence Consulting. All rights reserved. 55 How to Sustain 5S? 8 • Use 5S as a platform to launch other continuous improvement programs/initiatives Do not stop with 5S – follow through with other Continuous Improvement programs/initiatives, e.g. Zero Defects, Cost Reduction, Productivity Improvement, Lean, etc. Continue to look for all types of waste and eliminate themThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 20. © Operational Excellence Consulting. All rights reserved. How To Conduct A Red Tag Sort Event 2 This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 21. © Operational Excellence Consulting. All rights reserved. 61 How to Conduct a Red Tag Sort Event: Starting the 5S Sort 2 • If there is any doubt that something is used ask the employee who works in the area to find out if an item is needed • Some employees will be resistant and want to keep items not needed. When this happens management must step in to remove the item and avoid conflict. • During the sort event look for any obvious safety issues and resolve them immediately. You may find frayed wires or leaking equipment that was covered up. At the end of the sort event each workstation should only contain a small amount of work-in-progress and the tools and supplies needed to do the work. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 22. © Operational Excellence Consulting. All rights reserved. Creating a Visual Workplace 3 This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 23. © Operational Excellence Consulting. All rights reserved. 67 Everyday Visual Controls This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 24. © Operational Excellence Consulting. All rights reserved. 70 Andon • A visual control device in a production area Typically a lighted overhead display Gives the current status of the production system Alerts team members to emerging problems • Serves as warning system to signal and identify problems in the process #1 #2 #3 #4 ANDON BOARD This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 25. © Operational Excellence Consulting. All rights reserved. 73 5S Visibility Tools – Example Process Costs Product Profitability 100% Revenue Rework On TimeCycle Time Reduction WIP Backlog Internal Quality This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 26. © Operational Excellence Consulting. All rights reserved. 76 Examples of Poka Yoke (Error-Proofing) This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 27. © Operational Excellence Consulting. All rights reserved. 79 5S and Safety 1 • Wear protective clothes, goggles and shoes in the lab • Install protective covers on equipment and machines • Label warning signs prominently High voltage, Radiation, Slippery/Wet floor, etc. ‘Under Test – Do Not Switch Off’ This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 28. © Operational Excellence Consulting. All rights reserved. 82 5S and Safety 4 • Install mirrors at corners • Install safety devices to prevent accidents Emergency stops Interlocking pneumatic devices • Switch off equipment/machine that is not in use This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 29. © Operational Excellence Consulting. All rights reserved. 85 5S and Safety 7 • Plan and hold fire drills at least once a year • Display floor plan and indicate evacuation route clearly • Make available contact numbers of key staff in cases of fire or other emergencies This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 30. © Operational Excellence Consulting. All rights reserved. 88 5S and Quality 3 • Design forms and templates that are clear and in logical work order • Use the latest versions of standards and forms Do not store downloaded forms in your computer! • Seek appropriate approvals for deviations to the Quality Manual or Standards This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 31. © Operational Excellence Consulting. All rights reserved. 91 5S and Equipment Maintenance 2 • Set up a master calibration schedule for all equipment/machines Update the list regularly • Do not use equipment that have not been calibrated or past its calibration date This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 32. © Operational Excellence Consulting. All rights reserved. 94 5S and Productivity 1 • Use jigs and fixtures • Follow the production schedule • Reduce/Eliminate waste Eight types of waste This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 33. © Operational Excellence Consulting. All rights reserved. 5S for the Office 5 This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 34. © Operational Excellence Consulting. All rights reserved. 100 Chairs • Place your chair under the desk when you leave the office • Clean your chair using a brush or towel regularly • Fix your chair when it is unstable or noisy This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 35. © Operational Excellence Consulting. All rights reserved. 103 Office Machines 1 • Set electrical wirings neatly for safety and good appearance • Place expendable papers neatly at designated locations by type and size • Clean notebooks, computers, copier machines, etc. regularly with soft detergent This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 36. © Operational Excellence Consulting. All rights reserved. 106 Whiteboards • Remove and discard outdated notices or posters on whiteboards • Check markers for replenishment • Clean whiteboards completely after use for the next user • Clean erasers from time to time for good function This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 37. © Operational Excellence Consulting. All rights reserved. 109 Conference/Training Rooms 2 • Do not scribble on tables and walls • Do not eat or drink in the rooms • Switch off lights and power points after use • Be punctual for meetings or training sessions This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 38. © Operational Excellence Consulting. All rights reserved. 112 Book Shelves 2 • Keep book shelves clean and tidy for good appearance • Do not place anything other than books in book shelves This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 39. © Operational Excellence Consulting. All rights reserved. 115 Lunch Room / Canteen • Replace chairs under dining tables after use • Return tables and chairs to their original locations when relocated for meetings or functions after use • Do not leave unnecessary things on dining tables • Put all cups and plates away right after each meal • Clean up tables immediately after meals This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 40. © Operational Excellence Consulting. All rights reserved. 118 Toilets 1 • Flush WC after use • Wash your hands after visiting the toilet • Clean up toilets and wash basins at least once a day • Replenish toilet paper rolls, soaps and paper towels at least once a dayThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 41. © Operational Excellence Consulting. All rights reserved. 121 1. One-page Emails • Limit all emails to one page Write from the reader’s perspective Limit distribution Do not copy to others unnecessarily This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 42. © Operational Excellence Consulting. All rights reserved. 124 4. One-day Processing • Institute same-day processing. This will dramatically reduce the amount of work held over. Reduce processing time. Reduce the number of sections that have to see things and the number of people who have to sign. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 43. © Operational Excellence Consulting. All rights reserved. 127 5S : Getting Started 1 • 5S publicity materials Booklets, badges, brochures, cups, pens, etc. • 5S training and education Provide 5S training to managers and staff 5S pamphlets • 5S notice boards/intranet 5S news ‘Before’ and ‘After’ photos This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 44. © Operational Excellence Consulting. All rights reserved. 130 5S Launch Day in a Company Getting rid of things that are not needed This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 45. © Operational Excellence Consulting. All rights reserved. 133 Supporting Lean Tools for 5S D D D E AAA AA B B A A A A AA F FGG OFFICE C 2 1 3 5 7 9 11 4 6 8 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 36 33 34 3537 38 39 40 41 42 43 44 45 46 47 49 51 48 50 X Transport using truck or man Inventory or buffer stocks Value adding processX X Machining (10) Drilling (20) Welding (28) Assembly (34) Packaging(44) 4. Spaghetti Diagram 3.7 2.71.9 2.2 4.4 0 1 2 3 4 5 Sort Set In Order ShineStandardize Sustain 6. Performance Chart 5. Radar Chart Complaints 10 5 0 On-time Ship % 100% 50% 0% This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 46. © Operational Excellence Consulting. All rights reserved. 136 Summary This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
  • 47. © Operational Excellence Consulting. All rights reserved. 5S – Five Disciplines for High Workplace Productivity This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/5s-five-keys-for-high-workplace-productivity-154
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