5s a basic introduction

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This presentation is designed as a gentle intro to the concept of 5s and shows the benefits clearly.
It is designed to be followed by practical exercises on the shop floor / office

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5s a basic introduction

  1. 1. 5s An introduction
  2. 2. Objectives  To understand the importance of 5s to our Lean initiatives.  To know what the 5S’s are and know the key benefits of each.  To be able to participate in group and individual 5s activities.
  3. 3. What is 5s?
  4. 4. The Average Factory Environment
  5. 5. Sort • Everything at the workplace should be related to the work being done there. • Leave only what is needed, in the amounts needed. • Remove all items that are not needed for current / regular production.
  6. 6. Benefits of sort • Keeps the work area clean and clutter free. • Reduces the risk of accidents and near misses. • Creates extra work space where necessary items can be placed. • Reduces the time spent searching for tools and equipment. • Less clutter results in a more pleasant working environment.
  7. 7. • A method of identifying potentially unneeded items in the work area. • Ensures that no needed items are accidentally disposed of. • Allows us to evaluate the usefulness of an item by segregating it when we are unsure of it’s use. Red Tagging
  8. 8. • The three questions to ask - Is this item needed? - If it is needed, is it needed in this quantity? - If it is needed, is this the best location for it? • Holding areas - A safety net between questioning whether something is needed and getting rid of it. - Items are held for a set time (30 days?). - Notices are put out for unknown items so that they may be claimed by anybody who has a genuine need for them. After the allocated time, unwanted items are disposed of. Red Tagging
  9. 9. • Define the necessity of the item in order to perform the work required on a day to day basis. - If it isn’t needed it should be disposed of. • Determine the frequency with which the item is needed. - If it’s needed infrequently it can be stored away from the work area. • Decide the quantity of the item required to perform the regular work. - Excess items can be disposed or stored away. Red Tagging Aims
  10. 10. • Establish red tag holding area. - An area is set aside to store tagged items which need further evaluation • Red tag items. - the 5s team goes through the 5s area and red tags all items they believe can be removed from the area or disposed of. - Any items that we are unsure of are also red tagged. - All tagged items are listed on a log sheet with a location and description. - this log is circulated throughout the company so that anybody may claim an item if it is required. Red Tagging Steps
  11. 11. • Evaluate the red tagged items. - Decide if items should be disposed of, or kept for a period to determine their necessity. • Remove questionable items to the red tag holding area. - Assign responsibility of the area to the team. - Circulate item log. - After 30 days the items should be reviewed a final time. Log any items which have been removed back to the work area due to being required. - Dispose of, store away from the area, or sell any items left after the time period has passed. Red Tagging Steps
  12. 12. • Defective tools or inventory. • Obsolete tooling, jigs, inventory. • Worn out tools. • Broken equipment. • Outdated posters, signs & notices. • Excessive quantities of materials, tools, supplies. • Excessive personal items. Examples of Unneeded Items
  13. 13. After Sorting
  14. 14. • Everything that remains after Sort should have a place. • Arrange things so that they are easy to use, and label them so that anyone can find them and put them away. • Place frequently used items closer to you than those used less often. Set
  15. 15. • For every item in the workplace we will need to: - Identify it. - allocate a place to store it. - Determine how much / how many to store at the workplace. - Create a visual marker for it. Set
  16. 16. • Decide where to keep needed items. - Keep frequently used items at point of use. - Screwdrivers next to screws, order of use. • Organise items in a way that makes sense. - Make it easy for anyone to find them, use them and put them back after use. - Make it obvious when items are not in their correct place. - Use visual indicators such as area photos to show the area in it’s correct state. Set
  17. 17. • Safety is improved. - Ergonomic storage of tools and materials. - Clean, clutter free floors and walkways. • Tools and parts are stored properly so there’s less damage. • Less waste of motion – reduced searching for materials, tools & supplies. • Reduced inventory of materials, supplies, leaving more free space. • A more pleasant working environment. Benefits of Set
  18. 18. • Standardisation - Creating a consistent method of carrying out tasks and procedures. • Visual controls - Used to identify standards. - Examples; • Where items belong and how many belong there. • Standard procedures. • Area photographs. • Colour coding • Restock markers Keys to Set
  19. 19. • Used for identifying locations on floors and walkways. • Segregate working areas from walkways. • May show: - Flow direction. - Storage location. - Hazards or safety devices. - Areas to be kept clear. Painting / Marking
  20. 20. • Colour coding - Shows which parts, tools etc are used for which purpose, or which items are used together. - Used for storage containers. - Used to set items to a specific work area. • Outlining - Shows what parts and tools go where. - Shadow boards. • Cross hatching - Areas to be kept clear. Painting / Marking
  21. 21. Examples of Set
  22. 22. After Set
  23. 23. • Clean the area - Remove all dust, dirt - Floors clean - Work surfaces clean - Inside all cupboards, drawers etc clean - All tools clean • A clean workplace suggests quality work! Shine
  24. 24. • Safety - No debris, fluids or materials on floor to cause slips, trips or falls • Morale - Dirty workplaces are unpleasant to work in. - Clean workplaces foster pride in what we do. • Customer service / satisfaction - Customers touring a clean and organised factory are more likely to see us as a quality driven business and want to work with us. Benefits of Shine
  25. 25. • Machine reliability - Easier to identify issues on clean machines, meaning they can be addressed sooner. - Cleaning is a form of inspection. • Equipment / Tools - Clean equipment functions more effectively. - Easier to spot damage or wear on clean equipment and tools than on dirty ones. Benefits of Shine
  26. 26. After Shine
  27. 27. • All procedures, practices and activities established with the first 3s’s occur consistently and at regular intervals. - There is no point in going through Sort, Set or Shine if we are going to let things go back to the way they were. • Makes implementing Sort, Set and Shine a daily habit so that conditions are maintained at the desired level. Standardise
  28. 28. • Safety - Walkways and floors are kept clear and hazard free. • Efficiency - Storage areas remain organised. - Materials, tools and equipment remain organised and cared for. • We maintain all the benefits gained from Sort, Set and Shine. • We have a template for expanding the 5s area across the whole plant. Benefits of Standardising
  29. 29. • Decide who is responsible for each activity / area. - Activity charts, Checklists, Schedules. • Integrate 5s into daily work activities. - 5 minute 5s, daily cleaning / inspection. • Ensure 5s conditions are being maintained. - 5s audits, 5s walk rounds. Establishing the Habits
  30. 30. After Standardise
  31. 31. • 5s Audits. - Checking the level of effectiveness of the first 3s’s. - Use traffic light system, green, amber, red, to display current state of area. - To be conducted routinely by operators, managers and directors. • 5s Walk rounds. - Weekly tours by managers / directors to note improvements made and to encourage any further improvements that can be made. Monitoring
  32. 32. • Having the discipline to maintain the correct standards over time. • Creating conditions, and an atmosphere that encourages the constant practice of good habits, and the elimination of bad ones. • Creating a culture which constantly looks for improvement opportunities. Sustain
  33. 33. • A workforce that is trained and aware of the benefits of 5s. • Time allowed to practice and maintain. • Organised, focussed effort. • Management support and drive. • Efforts that are recognised, and appreciated. • All improvements need to be beneficial and purposeful. Keys to Success
  34. 34. After Sustain
  35. 35. Recap
  36. 36. • Sort – To put things in order. - Remove what is not needed. • Set – Arrange for ease of use. - Place things in a way that they are easily accessible whenever they are needed. • Shine – Clean. - Keep area clean and free from rubbish. • Standardise. - Best practices to be used throughout. • Sustain – Commitment and self discipline. - Develop a culture of 5s and improvement. The 5S’s
  37. 37. • Reduced set-up times. • Reduced searching times. • Increased floor space. • More pleasant working area. • Employees enabled to lead improvements. • Less frustration. • Less wasted labour. • Better equipment reliability. • Higher quality. • Lower cost. • Safer working area. • & many, many other benefits. Benefits
  38. 38. • Challenge traditional ideas. • Find ways to make the impossible possible. • Don’t accept excuses. • Go for the simple solution, don’t overcomplicate things. • Correct mistakes right away. • Involve everybody. • Improvement never ends! Keys to Success
  39. 39. Questions?

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