5S Supply - Introduction to 5S - February 24 2010

3,415 views

Published on

This is the slide deck from our a free webinar presented on February 24, 2010 "Introduction to 5S" from 5S Supply.

Published in: Business, Technology
2 Comments
3 Likes
Statistics
Notes
No Downloads
Views
Total views
3,415
On SlideShare
0
From Embeds
0
Number of Embeds
14
Actions
Shares
0
Downloads
143
Comments
2
Likes
3
Embeds 0
No embeds

No notes for slide

5S Supply - Introduction to 5S - February 24 2010

  1. 1. 5S Supply Webinar Series Welcome to Introduction to 5S We will be starting shortly Please read Our formal presentation will run from 12:00 pm - 12:45 pm CDT. The final 15 minutes will be dedicated to your Questions & Answers. Please feel free to submit your questions at any time during our session. Submit them in writing (as the phone lines are muted) in the Questions section of your webinar control panel. If you have any technical issues during our event please call GoToWebinar at 800-263-6317 and be sure to give our Webinar ID 387-068-018 Be sure you have dialed in to the audio portion. Dial 866-941-8436 (International: 001-347-573-9605) and enter Pass Code 635785. Your telephone line will be muted to diminish any background noise. © 5S Supply 2010 Introduction to 5S Wednesday, February 24th, 2010 12:00 pm – 1:00 pm (CST) brought to you by 5S Supply www.5Ssupply.com 5S simplified. Everything you need… all in one place. © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 1
  2. 2. 5S Supply Webinar Series “Behind all Today’s Agenda workplace successes • What is 5S and failures are the • Philosophy of 5S 5S’s.” • Benefits of 5S From “5 Pillars of the • Explanation of each of the Visual Workplace: The Sourcebook for 5S S’s—Sort, Set-in-order, Implementation” by Hiroyuki Hirano Shine, Standardize, Sustain • Q&A © 5S Supply 2010 What is 5S? © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 2
  3. 3. 5S Supply Webinar Series What is 5S? • Five words that begin with the letter “S” • Meaning workplace organization and standardization • Foundational building block of Lean • Builds teamwork and discipline • It’s NOT JUST CLEANING! © 5S Supply 2010 Where did 5S Come From? • A fundamental part of the Toyota Production System (TPS) • Need for a safe working environment, respect for people • Quality, cost and delivery © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 3
  4. 4. 5S Supply Webinar Series Building Blocks of a Lean Enterprise Lean Enterprise TPM Cellular & Flow Pull System & Kanban Error-proofing Batch Size Reduction Quick Changeover V Standard Work Teams Layout POUS S M Problem Solving Kaizen Visual 5S Planning Leadership © 5S Supply 2010 Translation Japanese Translation Conversion *Other Seiri Organization Sort Sorting Simplifying Seiton Neatness Set in order access Seiso Cleaning Shine Sweeping Seiketsu Standardization Standardize Standardize Shitsuke Discipline Sustain Self-discipline * there are several other conversions © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 4
  5. 5. 5S Supply Webinar Series Other Names • 6S = 5S + safety • 5S is the most common • 7S = 5S + safety + term security • Using other terms may • 5Cs confuse people if they 1. Clear Out see or read other 2. Configure information about 5S 3. Clean & Check • If done correctly, safety 4. Conform is automatically part of 5. Custom & Practice 5S • Others © 5S Supply 2010 Garage Story • 5S is like cleaning out your garage • Clear everything out, make piles • Organize the things that you are going to keep • Clean top to bottom, fix or repair as needed • What happens 6 months later? © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 5
  6. 6. 5S Supply Webinar Series Philosophy of 5S Be a 5S learner, achiever and thinker © 5S Supply 2010 Why is 5S Necessary? • Companies are like living organisms, they must learn to adapt and be flexible to survive and thrive • Customers, suppliers, people, “5S is easy, processes, materials, technologies are continually getting changing people to • Deeply engrained processes, change is culture, and customs are not hard” easily changed © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 6
  7. 7. 5S Supply Webinar Series 5S Philosophy • 5S is not about the cleaning • 5S is not just the steps, it is how you go about your job – are you a Lean Thinker? • Think about the 5Ss as being attributes of the type of person you would want to hire © 5S Supply 2010 What do you think of this maintenance area? © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 7
  8. 8. 5S Supply Webinar Series Do you think that 5S applies to office, common or support function areas? © 5S Supply 2010 5S Dreamland Fairies and robots do not come out in the middle of the night and do 5S for you. Who has to do it? © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 8
  9. 9. 5S Supply Webinar Series Benefits of 5S © 5S Supply 2010 Myths about 5S • 5S takes too much time. • There aren’t any benefits for doing 5S in the office. • 5S means to clean and I wasn’t hired to clean! • It doesn’t really matter how we store things. • I like the way my desk is. I can find everything I need so why does it matter how I have my things? • Doing 5S will take away from me doing my real work. © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 9
  10. 10. 5S Supply Webinar Series More Myths • We’re clean and neat already. • We have a cleaning crew so we don’t need to do 5S. • We’re not idiots, we know what we are doing. 5S will just get in the way of us doing our jobs. • We have so many problems here, why would you have us do 5S? • There is no benefit for us to spend time to this 5S stuff. © 5S Supply 2010 Benefits of 5S • Teamwork • Discipline • More organized workplace • Safer work environment • Reduces stress “Time is • Saves time money” • Saves money © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 10
  11. 11. 5S Supply Webinar Series Benefits of 5S • Impresses customers or auditors • Reduces waste • Better handle on true costs • More pleasant place to work and increase moral • Supports the other Building Blocks of Lean © 5S Supply 2010 Sort “When in doubt, move it out!” © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 11
  12. 12. 5S Supply Webinar Series Sort • The first thing to do is to clear the clutter out of the area • Perform as a team • Use the “30 day” rule • Use the Red Tag technique • Break the “just in case” mentality • “When in doubt, move it out!” © 5S Supply 2010 Sort • Clearly distinguish Will be used Keep between: – What is needed Red Tag May be used currently and should be kept – What is not needed Will not be used Discard and can be removed © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 12
  13. 13. 5S Supply Webinar Series Sort • Red Tags are visual signal that something may not belong in your target area • Attach Red Tags to items that don’t belong in the immediate area • Move the items to the Red Tag Holding Area • Use simple Red Tags • Have Red Tags easily available © 5S Supply 2010 Your 5S Red Tags Today’s date Name Name _______________ Date________ What the item is Item ____________________________ Why did you tag it? Use unknown, Reason for Tagging ________________ Obsolete, ________________________________ Not used here, etc. © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 13
  14. 14. 5S Supply Webinar Series Other Tag Issues • Some companies • Make sure you have use additional color wire, string or tape tags for to attach tags to the maintenance or item safety issues • Make sure everyone • Companies that use on the team has Red Tags for quality tags and a pen issues have to determine which color tag to use © 5S Supply 2010 Red Tag Area • The Red Tag Holding Area is a temporary holding area – meaning things can’t stay in there forever • If other people or groups need items, they are allowed to take things from the Red Tag Holding Area • Dispose of items periodically (rules will be setup during “Standardize”) © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 14
  15. 15. 5S Supply Webinar Series Notes on Red Tagging • Avoid the “Pack rat” mentality • Don’t worry about the “One thing”. Focus on the benefits of clearing things out of the immediate area. • Just because an item is tagged, it doesn’t necessarily mean that it is going to be thrown away. We will make the decision later if we need it or not. © 5S Supply 2010 5S and Dilbert © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 15
  16. 16. 5S Supply Webinar Series Benefits of Sort • Clears out the things that you didn’t need in your work area • Reclaim room and space • Reduces search time • Allows for other changes like moving items or changing the layout • Safer place to work • Let’s employees feel that they have control over their area, instead of the areas controlling them © 5S Supply 2010 Set-in-Order “A place for everything and everything in its place!” © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 16
  17. 17. 5S Supply Webinar Series Power of Set-in-order • Now that the area has been cleared out of unnecessary items, it is time to find a “home” for items that will remain • This is where fantastic results occur • Reduces: – Search time – Stress – Inventory and supplies © 5S Supply 2010 Everyday Examples • Kitchen • Parking lots • Highways • Broom racks & Shine Carts © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 17
  18. 18. 5S Supply Webinar Series Set-in-order • Now that you have used Sort, decide where the items that you will keep belong • Decide how many and how to replenish • Make it visual and obvious if something is out of place © 5S Supply 2010 Decide Where Things Belong Guidelines • If it is used often, keep close at hand • Designated location & label • Use systems like the “2-label” system • Shadows, lines, color-coding • Easy to get & put away (ergonomic and safe) • Get items off the floor & top shelves © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 18
  19. 19. 5S Supply Webinar Series Other Set-in-order Issues • Make it easy for everyone to find and use them – “30 second” rule • Use “recoil”, getting items back to where • Make items easy to they belong get and easy to put away • Make it obvious when they are not in there correct place © 5S Supply 2010 Benefits of Set-in-Order • No guessing at where items belong and how many • No excess items • Items are easy to find and put away • Everyone passes the 30-second test “A place for everything and everything in its place!” © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 19
  20. 20. 5S Supply Webinar Series Shine ”To clean and inspect.” © 5S Supply 2010 Shine • Shine = clean + inspect • Perform as a team • Must plan Shine • Have the necessary items easily available • 5S is not just cleaning! © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 20
  21. 21. 5S Supply Webinar Series Why Shine? • Can prevent accidents or safety incidents • People feel better when they work in a clean environment, this actually helps morale • Working together helps build team work • Impresses customers on tours • Can spot potential problems with equipment before they occur © 5S Supply 2010 Make it Fit Your Organization • Even if you have a cleaning crew or service, do they know exactly what you want and what is expected of them? Is it followed? • Wiping and cleaning common areas helps reduce the spread of germs thus improving sick-time related absenteeism • Make it quick and simple - or better yet, think of ways to prevent dirt from accumulating in the first place! © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 21
  22. 22. 5S Supply Webinar Series Initial Cleaning and Inspection • Have to have a plan • Start at the top and work down • Clean and inspect major items first • Be thorough, restore to “like new” condition • Clean floors and aisle ways last • Everyone has to participate • Schedule it • Take it Serious © 5S Supply 2010 Planning Shine Supplies Area Team Needed Determine • Task Supplies • Location Common Areas • Who Files/Storage • When • Cleaning materials Equipment needed Desks © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 22
  23. 23. 5S Supply Webinar Series Additional Ideas for Shine • Prevent dirt in the first place or at least contain it • Low cost solution versus breakdowns • Plan ahead • Everyone participates as a team • Make it quick (and fun!) • Have the right tools & supplies ready © 5S Supply 2010 Benefits of Shine • A more pleasant place to work • Promotes a professional atmosphere • People actually have the tactile sensation by touching their equipment, machines and work areas • You are able to find small problems before they become BIG problems • Safer and cleaner workplace © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 23
  24. 24. 5S Supply Webinar Series Standardize “Make up the rules and follow and enforce them!” © 5S Supply 2010 Standardize • Standardize means to set up the rules for Sort, Set-in-order and Shine • Have the 5S teams and 5S Design Teams set the standards • Standards must be simple and easy to follow • Use audits to help maintain the standards © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 24
  25. 25. 5S Supply Webinar Series Standards for Sort One-point Lesson Red Tag Rules Description: How to fill-out a Red Tag • When to Red Tag W rite in your name 1 Fill-in date tagged 2 • How to Red Tag 5S Red Tag 3 Name ______________ Date __________ • What’s go on the Red W rite in the Item ______________________________ name or Tag description of the item __________________________________ Reason for Tagging __________________ • more… __________________________________ 4 Rules for the Red Tag W rite in the reason for tagging (obsolete, needs repair, not Holding Area needed, scrap, use unkown, etc.) 5 Attach tag using • When to clear out wire, tape, string, or other method • How to dispose of items 6 Move item to the Red Tag Holding Area • more… © 5S Supply 2010 Standards for Set-in-Order • Which items, where, how many • Who replenishes • Return all items… and What to do when items are missing • Visual standards – signs, lines, labels and color coding © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 25
  26. 26. 5S Supply Webinar Series Standards for Shine • Clean and Inspect (C&I) Schedule • Show the task, person responsible, items needed, frequency, the time element and the desired state • Where to keep cleaning supplies, how to replenish © 5S Supply 2010 5S Clean and Inspect Schedule Item: ID: Key: Clean & Inspect activity required Cleaning activity completed Frequency of C&I Team Time No Task Requirement MON TUE WED THUR FRI Min Member 1 Technician Wipe down equipment Cleaner & Wipes 1 Cleaner, rags, 2 Operator Clean or replace filter filter (if required) 3 3 Helper Sweep floor Broom 2 4 Supervisor Inspect safety guards Visual 1 Complete Diagnostic Post results on 5S 5 Manager Checklist Display Board 5 6 All 5S Weekly Meeting Agenda, ½ hour max 30 7 8 9 10 Total 42 © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 26
  27. 27. 5S Supply Webinar Series Key for Standardize • Make the rules, then follow and enforce them • People usually think 5S fails at Sustain, but it typically fails at enforcing the rules • Policies drive behaviors • Make the rules simple and easy to follow • Use immediate correction • Lead by example • Do not allow 5S to take a backseat to other things © 5S Supply 2010 Benefits of Standardize • Everyone knows the rules • Easy to understand and to follow • You have to have a standard in order to know that you have improvement • Sets the foundation for successful 5S implementation and Sustain • Allows you move on to “Sustain” © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 27
  28. 28. 5S Supply Webinar Series Sustain “Make 5S part of everyday life.” © 5S Supply 2010 5S Discipline • Management’s support – without this 5S will never work! • 5S is not something extra, it’s part of everyday work • Get everyone involved – teamwork • Helps set the base for other Lean efforts • Creative ways to prevent Standardize from deteriorating © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 28
  29. 29. 5S Supply Webinar Series Ways to Make 5S a Habit • On-going • Lead by example communication – • 5S promotions newsletters, communication boards, posters, short meetings • Field trips, benchmarking • Reward and recognition • Use immediate correction © 5S Supply 2010 More Ways to Make 5S a Habit • Training and additional • Continued 5S Audits “Booster” training once • Contests or twice per year • 6-week photos • Brainstorm problems • “Extreme 5S Makeover” and solutions video • Study groups • 5S Campaign boards • Capture Lessons 5S Campaign Week of XX/XX 5S Item Team Learned, share Best Sort Check Red Tags Jim, Bob Practices Set-in-Order Check missing items Jennifer, Ralph Shine Check lights Homer, Marge Standardize Update audit schedule Eileen, George Sustain New Contest All © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 29
  30. 30. 5S Supply Webinar Series Additional Information for Success • Everyone has to participate • Promote participation • Keep at it, even when it isn’t easy • Make sure everyone understands what 5S is and why it’s needed • Remember, 5S is a low cost solution • 5S is essential for Lean © 5S Supply 2010 Q&A Please submit your questions at this time © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 30
  31. 31. 5S Supply Webinar Series Developer Anthony Manos • Tony Manos is a Professional Business Advisor with expertise in Lean. Trained and certified by the Department of Commerce, National Institute of Standards and Technology (NIST) in Lean principles and as a trainer in Lean courses. He is an international trainer and speaker on Lean topics. • Mr. Manos is a Senior Member of ASQ, SME and AME and is a Shingo Prize examiner © 5S Supply 2010 5S Garage: An Recommended Introduction to 5S and Lean Resources Principles “5S Pillars of the Visual Workplace: The Sourcebook for 5S Implementation” by Hiroyuki Hirano “5S for Operators: 5 Pillars of the Visual Workplace” by Productivity Press © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 31
  32. 32. 5S Supply Webinar Series Additional Resources Group 5S Supply © 5S Supply 2010 Q&A If we don’t get a chance to answer your question today, please send it to: webinar@5Ssupply.com © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 32
  33. 33. 5S Supply Webinar Series Upcoming Events • March 2010 – 5S for the Office Don’t forget to visit us at www.5Ssupply.com 888 4 LEAN 5S © 5S Supply 2010 Thank you for attending Your opinion is important to us A short survey will be sent to you You may sign-off now © 5S Supply 2010www.5Ssupply.com © 5S Supply 2010 33

×