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5S: A Lean Transformation Tool

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5S is one of the basic tools in lean, six sigma, continuous improvement and operational excellence. It works everywhere and applies to all kinds of industries. This presentation is one of many presentations that we are working on. These will be helpful for any organization looking to leverage its resources and taking the journey of operational excellence.

Published in: Leadership & Management
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  • DOWNLOAD FULL BOOKS, INTO AVAILABLE FORMAT ......................................................................................................................... ......................................................................................................................... ,DOWNLOAD FULL. PDF EBOOK here { https://tinyurl.com/yyxo9sk7 } ......................................................................................................................... ,DOWNLOAD FULL. EPUB Ebook here { https://tinyurl.com/yyxo9sk7 } ......................................................................................................................... ,DOWNLOAD FULL. doc Ebook here { https://tinyurl.com/yyxo9sk7 } ......................................................................................................................... ,DOWNLOAD FULL. PDF EBOOK here { https://tinyurl.com/yyxo9sk7 } ......................................................................................................................... ,DOWNLOAD FULL. EPUB Ebook here { https://tinyurl.com/yyxo9sk7 } ......................................................................................................................... ,DOWNLOAD FULL. doc Ebook here { https://tinyurl.com/yyxo9sk7 } ......................................................................................................................... ......................................................................................................................... ......................................................................................................................... .............. Browse by Genre Available eBooks ......................................................................................................................... Art, Biography, Business, Chick Lit, Children's, Christian, Classics, Comics, Contemporary, Cookbooks, Crime, Ebooks, Fantasy, Fiction, Graphic Novels, Historical Fiction, History, Horror, Humor And Comedy, Manga, Memoir, Music, Mystery, Non Fiction, Paranormal, Philosophy, Poetry, Psychology, Religion, Romance, Science, Science Fiction, Self Help, Suspense, Spirituality, Sports, Thriller, Travel, Young Adult,
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  • Good Eye Opener and starter for Lean, Thanks!!!
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5S: A Lean Transformation Tool

  1. 1. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Zulfa Management Consulting To get closer … www.zulfadev.com @zulfa.team @zulfateam support@zulfadev.com+966 59 084 2622 Hussain Yasin Al-Ahmed Management Consultant @hussain_alahmed @hyahmed hussain@zulfadev.com
  2. 2. Imagine: A fire fighter with a broken water hose! 2
  3. 3. … or a surgeon with dirty instruments! 3
  4. 4. … or an astronaut who forgot the hand tools on earth! 4
  5. 5. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Image It makes the place organized and always ready for client or executives visits 5S Overview and Benefits •  A method to improve and sustain workplace organization. •  One of the basic stones for successful lean transformation. •  It applies to every industry and every job function. Time It saves precious time looking for material, tools, equipment or information and increases overall efficiency Pride It makes employees proud of their workplace and willing to show it to others HSE A clean and ergonomically organized workplace is more healthier and much safer for employees and visitors 5
  6. 6. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. 5S Workplace Organization Sort Clearly distinguish what is needed, what should be kept and what should be thrown out. “When in doubt, move it out” Set in Order Organize the necessary things making it easier for anynone to find and use them. “A place for everthing and everthing in its place” Shine Clean equipment and workplace requrlay. Paint them as needed and inspect them while cleaning. “A clean place is safer and more productive” Standardize Develop standards for sorting, setting in order and shining. Enforce them and follow up. “The seceret of success is consistency of purpose” Sustain Make it a daily habit and a way of life through discipline, auditing and recognition. “Motivation is what gets you started, habit is what keeps you going” 6
  7. 7. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Sort Red tagging Define a “Red Tag Team” and a leader and train them on 5S Seperate the unneeded items from the needed ones Attach a red tag to the uneeded items Move them to a temporary holding area Set the time to hold in temporary area Review the items after the defined time Give away, sell or throw the remaining items 1 2 3 4 5 6 7 Red Tag Temporary Holding Areas Red Tags 7
  8. 8. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. How often is it used? What to do with it? Never Give, sell or throw away Once or twice a year Store in a distant place Once a month Store near your work area Once a week Store near the the workstation Once a day or more Keep near you or your workstation Sort If in doubt, throw it out No Unused X No Duplicates X No Uncessary !No Just-in-Case 8
  9. 9. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Set in Order A simple exercise Focus on the next slide for 5 seconds 9
  10. 10. 12345
  11. 11. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Set in Order A simple exercise Now on the next slide, tell us what was removed? 11
  12. 12. 12
  13. 13. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Set in Order A place for everything, and everything in its place What’s missing from this tool kit? 13
  14. 14. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Set in Order If it moves, it needs a home Organize what’s left after sorting. Physically reconfigure the area. Make it visual and self explanatory. Make everything easy to find and return. Label and mark locations of movable items. Color-code items based on location or use. Build racks, shelves or shadow boards. Try new ideas and be creative. 14
  15. 15. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Shine A clean place is safer and more productive Promotes Safety Detecting and removing sources of danger such as liquid spills, tripping hazards, and biological infections. Quality Inspection Helps in checking for non standard conditions such as leaks, cracks and wear. Reputation Customers will trust people who keep thier workplace clean and organized more than those who don’t. Improves Moral Team members become happier in a clean workplace and closer to managment when managers are involved in 5S. 15
  16. 16. Before 5S Photo Credit: Hussain Al-Ahmed 16
  17. 17. After 5S Photo Credit: Hussain Al-Ahmed 17
  18. 18. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Shine Guidelines Together clean the entire area Assign roles and responsibilities Repair leaks Tag what you can’t repair Plan proper collection method Dispose correctly Paint or retouch Provide proper cleaning tools Think of ideas to minimize dirt 18
  19. 19. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Standardize The key to success is consistency of purpose Sorting Setting in Order Shining Visual Management Making the place self-explenatory through signs, labels, colors and marks. Continuous Improvement Keeping the ball of improvement rolling and keep changing for better. Utilizing Talent When there is a standard, it becomes easier to choose non critical things such as colors, material, brand, etc. Sustaining Clear and simple instructions help making it easier for members to keep the place organized and tidy. Training New members will learn faster and will get invloved immidately. Best Practices Recognition and knowledge sharing helps in finding best practices and adopting them. 19
  20. 20. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Check this …! and this … then that …! CHECKLIST 1 2 3 Do this …! and this … then that …! PROCEDURE PROCESS Which Color? What should be done and why? When should it be done and how often? How should it be done and who should do it? Colors, fonts, sizes, shapes, templates, etc. Develop checklists, procedures and processes. Remember; the first idea may not be the best one. Material, brand, model, etc. Find the best practice and make it a standard. Standardize Be consistent but not constant Try, experiment, explore and innovate. 20
  21. 21. Be consistent, not constant Photo Credit: Hussain Al-Ahmed Photo Credit: Hussain Al-Ahmed
  22. 22. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Sustain How to keep the improvement ball rolling? 22 Promote 5S Get people buy-in by getting them involved in shaping the improvement path and recognizing individual efforts and rewarding for teamwork. Focus Management team must lead the 5S efforts, learn the techniques, and participate in practical activities. Simplify Wining Celebrate simple improvements and avoid comparisons between individuals or teams. Develop Metrics Establish KPIs and visually display them to create pride through positive competition and a sense of achievement. Walk The Talk Go to the workplace and observe what’s happening and help before giving constructive feedback. Conduct Audits and Reviews Regularly conduct assessments for the current state and create and improvement plan.
  23. 23. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Sustain Tools for sustaining: Metrics 23 You Can’t Manage What You Can’t Measure Focus on the important goals only. Not all goals are as important. Establish lead measures (KPIs) that you can act on to achieve the goals. Lead measures should be directly related to the members of the team. Have people develop their own lead measures to create accountability. Show the measures and the progress publicly and present them visually. Simplify or automate the measurement and data collection process. Photo Credit: Hussain Al-Ahmed
  24. 24. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Sustain Tools for sustaining: Zone Charting 24 Divide the shop floor or office to areas and assign people to them. Clearly show photos of assigned people in the area. Members should audit their areas regularly and allow others to do so. Managers should plan to visit different areas randomly and give feedback. Show photos of good work publicly in displays or meetings. Don’t take disciplinary actions for bad scores, but reward good ones. Everyone is Accountable Photo Credit: Hussain Al-Ahmed
  25. 25. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Sustain Tools for sustaining: Recognition 25 Reward teams for small and continuous improvements. Simple and continuous recognitions can boost motivation. You don’t have to spend money. An applause or a thank you note will do. Supporting new ideas and allowing trial and error is a form of recognition Educate employees in new skills and provide necessary resources. Encourage friendly competition and fun challenges.
  26. 26. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Sustain Tools for sustaining: Visual Displays 26 Show progress visually. It can be manual or digital. Spend more time analyzing and planning for improvements than collecting data. You don’t have to spend money. A simple white board and a marker will do. Updating the display must be simple an easy and done in at least in daily basis Discuss accountabilities in short quick, routine meetings next to the display. Be flexible with the format. The team should put what really matters to them.
  27. 27. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. Sustain Tools for sustaining: Auditing 27 Consistently review progress using different audit tools. Preform 5S self assessments and audits at least weekly by different people. Simplify audits and translate to local languages. Auditing should be an opportunity to discuss barriers to improvement. Visually present audit results and post them in the Primary Visual Display (PVD) Encourage knowledge sharing and cooperation between teams. 0 1 2 3 4 5 Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 5S Weekly Score 0 1 2 3 4 5 Sort Set in Order ShineStandardize Sustain Current 5S Audit Score Sort 3.5 Set in Order 2.5 Shine 3 Standardize 4 Sustain 2
  28. 28. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. 5S Tips for successful implementation: Take photos 28 •  A picure worth a thousand words. •  Before and afetr pictures help convey the message. •  Great tool for reporting progress and training people. Why Take Photos? •  Get a good camera and learn how to use it. •  Smartphones good for social media and quick sharing, but not for quality photos. •  Make sure it’s charged and memory is cleared. •  Make a home for it. Remember “Set in Order”. How To Take Photos? •  Take before and after photos from the same angle and use the same camera if possible. •  Capture good practices and lessons learned. •  Record activities and use them on event •  Store the photos in a common place. What To Capture?
  29. 29. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. 5S Tips for successful implementation: Leverage teamwork 29 •  It divides the work and doubles the success. •  Helps generating different ideas. •  Effective problem solving tool. •  The whole is greater than the sum of the parts. Why Teams? •  Effective communication and collaboration. •  Embracing and encouraging differences. •  Doesn’t matter who gets the credit. •  Understanding the stages of team development. What is Teamwork? •  A Group of people working together to achieve a common goal in sports, life or at work. •  It can be formal or informal. What is a Team? 1. Forming 2. Storming 3. Norming 4. Performing
  30. 30. www.zulfadev.com © 2015 Zulfa Managment Consulting. All Rights Reserved. 5S Can you recall them? Sort Set in OrderShineStandardize Sustain 30
  31. 31. “ Coming together is a beginning, keeping together is progress, working together is success ” - Henry Ford Photo Credit: Hussain Al-Ahmed
  32. 32. We hope you liked the presentation… Please share, leave a comment and like. Our goal is to help you achieve your goals. We strongly believe in supporting local communities and charities. We are committed to providing help anyway we can. Zulfa Management Consulting www.zulfadev.com @zulfa.team @zulfateam support@zulfadev.com+966 59 084 2622 Let us hear from you …

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