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  • 5S is the foundation, the building blocks, for a “Kaizen” approach to incremental improvement. 5S focuses on the elimination of wastes( Muda) in the work environment: to include the office environment as well as the manufacturing environment. In simplest terms , it is the cleaning up of all the wastes so that the work environment produces “what” it wants, at the “time” it is needed in the “correct quantities”.
  • 5S

    2. 2. Executive Overview Participant manual Tools Workbook Knowledge Breakthrough Lecture notes Lecture notes Performance Excellence Series Training Module Elements
    3. 3. Session 1.0 Introduction…….……...……………………. 3 Session 2.0 Waste Management ……………………….. 14 Session 3.0 5S Implementation…………………………. 20 Element 3.1 Systematic Organization…………………... 31 Element 3.1.1 Red Tag System……………………………. 47 Element 3.2 Sorting Visual Placement………………….. 33 Element 3.2.1 Visual Sign System………………………….. 66 Element 3.2.2 Visual Color System………………………... 76 Element 3.3 Scrubbing Clean……………………………. 40 Element 3.4 Standardizing Control……………………... 45 Element 3.5 Self Discipline Control……………………... 48 5s Table of Contents Knowledge Breakthrough
    4. 4. What is 5S ? <ul><li>An essential step required for Waste Elimination </li></ul><ul><li>An integral step in Kaizen </li></ul><ul><li>A required element to achieve Lean-site Manufacturing. </li></ul>Systematic Organization “ Seiri” Orderliness “ Seiton” Cleanliness “ Seiso” Cleanup “ Seiketsu” Cleanup “ Seiketsu” Standardization/Perseverance “ Shitsuke” 5s
    5. 5. 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
    6. 6. 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
    7. 7. 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
    8. 8. Expanding the Strategy <ul><li>6 Sigma </li></ul><ul><li>Disciplined Methodology </li></ul><ul><li>Technical Approach </li></ul><ul><ul><li>(Quantitative) </li></ul></ul><ul><li>Data Driven - Statistical </li></ul><ul><li>Customer Focus </li></ul><ul><li>Reduce Variation </li></ul><ul><li>Focus on Large Impact </li></ul><ul><li>Larger/Longer Projects </li></ul><ul><li>Kaizen </li></ul><ul><li>Philosophical Approach </li></ul><ul><li>Common Sense Approach </li></ul><ul><ul><li>(Qualitative) </li></ul></ul><ul><li>Data Driven - Observation </li></ul><ul><li>Operational Focus </li></ul><ul><li>Waste Elimination 5S </li></ul><ul><li>Incremental Change </li></ul><ul><li>Smaller/Shorter Projects </li></ul>Complimentary Tools Driving Continuous Improvement Performance Excellence 5s
    9. 9. Comparative Analysis <ul><li>Improvement Methodologies </li></ul><ul><li>Similar in Structure </li></ul><ul><li>Improvements measured against established process </li></ul><ul><li>Team oriented </li></ul><ul><li>Similar improvement tools </li></ul><ul><li>Measure effectiveness of improvements </li></ul><ul><li>Maintain new performance level </li></ul><ul><li>Standardize & Proceduralize </li></ul><ul><li>Results </li></ul><ul><li>More Efficient Processes </li></ul><ul><li>Comparison </li></ul><ul><li>Both are Effective Improvement Mechanisms </li></ul><ul><li>CPI/6s best applied to large complex problems </li></ul><ul><li>Kaizen/Lean best applied to achieve incremental changes and eliminate wastes. </li></ul>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
    10. 10. Why 5S <ul><li>To eliminate the wastes that result from </li></ul><ul><li>“ uncontrolled” processes. </li></ul><ul><li>To gain control on equipment, material & inventory placement and position. </li></ul><ul><li>Apply Control Techniques to Eliminate Erosion of Improvements. </li></ul><ul><li>Standardize Improvements for Maintenance of </li></ul><ul><li>Critical Process Parameters. </li></ul>Look Familiar ? 5s
    11. 11. <ul><li>Overproduction </li></ul><ul><li>Delays (waiting time) </li></ul><ul><li>Transportation </li></ul><ul><li>Process </li></ul><ul><li>Inventories </li></ul><ul><li>Motions </li></ul><ul><li>Defective products </li></ul><ul><li>Untapped Resources </li></ul><ul><li>Mis-used Resources </li></ul>9 Wastes The Nine types of wastes.
    12. 12. <ul><li>Overproduction ______________________________ </li></ul><ul><li>Delays (waiting time)__________________________ </li></ul><ul><li>Transportation _______________________________ </li></ul><ul><li>Process_____________________________________ </li></ul><ul><li>Inventories__________________________________ </li></ul><ul><li>Motions ____________________________________ </li></ul><ul><li>Defective products ____________________________ </li></ul><ul><li>Untapped Resources __________________________ </li></ul><ul><li>Mis-used Resources ___________________________ </li></ul>9 Wastes Give an example of each type of waste. The Nine types of wastes Think Break
    13. 13. Elimination of Waste
    14. 14. 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
    15. 15. <ul><li>Removing “ Red Tagged ” stuff </li></ul><ul><li>What Stuff would you “Red Tag” in these pictures ? </li></ul>Picture A__________________________________________________________ Picture B _________________________________________________________ Think Break
    16. 16. <ul><li>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). </li></ul><ul><li>___________________ ___________________ _________________ </li></ul><ul><li>___________________ ___________________ _________________ </li></ul><ul><li>___________________ ___________________ _________________ </li></ul><ul><li>___________________ ___________________ _________________ </li></ul>Everything has a useable place Think Break Finding Wastes
    17. 17. Some evidence of standardized work areas <ul><li>Clear, shiny aisle ways </li></ul><ul><li>Color coded areas </li></ul><ul><li>Slogans, banners </li></ul><ul><li>No work-in-process ( WIP ) </li></ul><ul><li>One-Piece Flow </li></ul><ul><li>Standardized Work Sheets </li></ul>
    18. 18. Visual Color System Implementation <ul><li>Develop a map identifying the “access ways”(aisles, entrances, walkways etc.) and the “action” areas. </li></ul><ul><li>Perform any necessary realignment of walkways, isles, entrances. </li></ul><ul><li>Assign an address to each of the major action areas. </li></ul><ul><li>Mark off the Walkways, Aisles & entrances from the action areas Table 1.0 </li></ul><ul><li>Apply flow-direction arrows to aisles & walkways Table 1.0 </li></ul><ul><li>Perform any necessary realignment of action areas. </li></ul><ul><li>Mark-off the inventory locations Table 1.0. </li></ul><ul><li>Mark-off equipment/machine locations Table 1.0 </li></ul><ul><li>Mark-off storage locations( Cabinets,shelves,tables) Table 1.0 </li></ul><ul><li>Color-code the floors and respective action areas per Table 1.0. </li></ul>
    19. 19. 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
    20. 20. Step 2: Allocation: Assign resources to the specific tasks required to make 3S a habit.
    21. 26. Waste Identification Map
    22. 28. The Nine Wastes Percentage of Waste