5S Performance Excellence Model Systematic-Systematic Organization Scrubbing clean Self-Discipline- Control Customer Expectations Sorting Visual Placement Standardizing Control Improved Quality Improved Safety Reduced costs Consistent Deliveries Improved Product/ Service Options 5s
The Five Elements of 5S Systematic Systematic Organization - Identifying what items are required and which are not. Sorting Visual Placement- Items should be easily retrievable, easy to get, and visual-easy to see. Self-Discipline/Control- Ensuring that Systematic Organization, Visual Placement & Cleanliness are maintained. Scrubbing Clean- Keep the area free from debris, dirt, oil, items not needed. Standardizing Control- Maintain and continually improve the previous improvements. 5s
Tool Kit Comparison Major CPI Tools (6 ) Kaizen Lean Description Cp/Cpk Process capability assessment DOE Design of experiments SPC Process control based on statistics and data analysis FMEA Risk assessment tool Regression Correlate effect one variable has on another Process Map Map process steps to communicate and identify opportunities 5 whys /2 hows Determination methods for root cause discovery Pareto Column chart ranking items highest to lowest Fishbone Cause / Effect Diagram 5S Elimination waste Visual Mgmt Emphasis on visual techniques to manage process Poka-Yoke Error proofing techniques Spagetti Chart Kanban Material storage technique used to control process Takt Time Determine pace or beat of a process Std Work Evaluate tasks done during a process SMED Single minute exchange of dies - Quick machine set up TPM Integrate maintenance strategy with process Cellular Flow Reduce inventory & cycle time thru process layout and pull production techniques Expand Process Improvement Program to Utilize Kaizen Tool Kit 5s
Kaizen/Lean best applied to achieve incremental changes and eliminate wastes.
Measure - Data Collection - Determine Process Potential / Goals Evaluate - Root Cause / Vital Few - Statistical Analysis Improve & Verify - Implement Improvement - Validate Improvement Standardize - Standardize / Leverage - SPC - Update Procedures Evaluate - Baseline Process Performance - Establish Target Decide -Compare solutions - Choose Act -Communicate - Implement improvement - Control Measure - Validate improvement - Standardize - Update Procedures Focus - Reduce Process Variation - Identify Critical Cause and Focus Resources for Maximum Impact Focus - Eliminate Waste 5S - Seek Incremental Process Changes Kaizen/Lean 6 Summary - Technical Approach based on Statistical Analysis - Requires Significant Data Collection - Best applied to Manufacturing Processes - Typical Projects 1-3 Months Summary - Common Sense Approach based on Observation - Applicable to all types of processes - Defined improvement strategy - Typical Projects 1 week 5s
To eliminate the wastes that result from
“ uncontrolled” processes.
To gain control on equipment, material & inventory placement and position.
Apply Control Techniques to Eliminate Erosion of Improvements.
Standardize Improvements for Maintenance of
Critical Process Parameters.
Look Familiar ? 5s
Delays (waiting time)
9 Wastes The Nine types of wastes.
Delays (waiting time)__________________________
Defective products ____________________________
Untapped Resources __________________________
Mis-used Resources ___________________________
9 Wastes Give an example of each type of waste. The Nine types of wastes Think Break
Elimination of Waste
Systematic Organization Cleanliness Visual Placement Standardization 5 S Implementation Plan Progressive Enhancements Step 1 Establish 5 S Implementation Team Step 2 Develop Specific Implementation Plan Step 3 Develop Communication Plan Step 4 Develop 5 S Training Plan Step 5 Implement 5 S Step 6 Verification of Effectiveness
Removing “ Red Tagged ” stuff
What Stuff would you “Red Tag” in these pictures ?
Picture A__________________________________________________________ Picture B _________________________________________________________ Think Break
In the following pictures, identify some of the “finding wastes “ ( assume you work in a distribution center and you have to fill an order with product located in the following pictures).
Color-code the floors and respective action areas per Table 1.0.
Cleanliness involves cleaning every aspect of the Organization and the removal of dirt, dust,oil, scraps on the floor, & garbage. Key Deliverables A clean Systematic Organization results in increased safety and efficiency . Increased Safety Increased Efficiency
Step 2: Allocation: Assign resources to the specific tasks required to make 3S a habit.