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5S.ppt
1.
1 © 2004 Superfactory™.
All Rights Reserved. 5S and Visual Control Superfactory Excellence Program™ www.superfactory.com
2.
2 © 2004 Superfactory™.
All Rights Reserved. Disclaimer and Approved use Disclaimer The files in the Superfactory Excellence Program by Superfactory Ventures LLC (“Superfactory”) are intended for use in training individuals within an organization. The handouts, tools, and presentations may be customized for each application. THE FILES AND PRESENTATIONS ARE DISTRIBUTED ON AN "AS IS" BASIS WITHOUT WARRANTIES OF ANY KIND, EITHER EXPRESSED OR IMPLIED. Copyright All files in the Superfactory Excellence Program have been created by Superfactory and there are no known copyright issues. Please contact Superfactory immediately if copyright issues become apparent. Approved Use Each copy of the Superfactory Excellence Program can be used throughout a single Customer location, such as a manufacturing plant. Multiple copies may reside on computers within that location, or on the intranet for that location. Contact Superfactory for authorization to use the Superfactory Excellence Program at multiple locations. The presentations and files may be customized to satisfy the customer’s application. The presentations and files, or portions or modifications thereof, may not be re-sold or re-distributed without express written permission from Superfactory. Current contact information can be found at: www.superfactory.com
3.
3 © 2004 Superfactory™.
All Rights Reserved. 5S and Visual Control 5 Elements of 5S Why 5S? Waste Workplace observation Sort Straighten Shine Standardize Sustain Visual Factory Summary
4.
4 © 2004 Superfactory™.
All Rights Reserved. 5 Elements of 5S Sort Straighten Shine Standardize Sustain
5.
5 © 2004 Superfactory™.
All Rights Reserved. Why 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.
6.
6 © 2004 Superfactory™.
All Rights Reserved. Types of Waste Overproduction Delays (waiting) Transportation Process Inventories Motions Defective Products Untapped Resources Misused Resources
7.
7 © 2004 Superfactory™.
All Rights Reserved. Elimination of Waste 5 S Element Waste/ Improvement Item Deliverable Systematic Organization Elimination of finding. Reduction of part selection errors. Reduced Costs Improved Quality Increased Product Options Sorting-Visual Placement Elimination of finding. Elimination of nonconformances. Elimination of motion. Reduction of part selection errors. Reduced Costs Increased Safety Improved Quality Increased Product Options. Scrubbing Clean Increased safety. Preventive maintenance. Increased equipment knowledge. Increased Safety Improved Quality Standardization Control Increased equipment life. Higher morale. Clean environment. Increased visibility of nonconformances. Improved Quality Consistent Delivery Improved Safety
8.
8 © 2004 Superfactory™.
All Rights Reserved. Waste Identification What waste can be identified in the following photos?
9.
9 © 2004 Superfactory™.
All Rights Reserved. Waste Identification What waste can be identified in the following photos?
10.
10 © 2004 Superfactory™.
All Rights Reserved. After 5S Clear, shiny aisles Color-coded areas Slogans & banners No work in process
11.
11 © 2004 Superfactory™.
All Rights Reserved. Workplace Observation Clearly define target area Identify purpose and function of target area Develop area map Show material, people, equipment flow Perform scan diagnostic Photograph problem areas Develop a project display board (area)
12.
12 © 2004 Superfactory™.
All Rights Reserved. Target Area Vision Safety Current Condition Desired Conditions
13.
13 © 2004 Superfactory™.
All Rights Reserved. Target Area Vision Product Quality Current Condition Desired Conditions
14.
14 © 2004 Superfactory™.
All Rights Reserved. Target Area Vision Equipment Maintenance Current Condition Desired Conditions
15.
15 © 2004 Superfactory™.
All Rights Reserved. Target Area Vision Work Efficiency Current Condition Desired Conditions
16.
16 © 2004 Superfactory™.
All Rights Reserved. Target Area Vision Inventory Levels Current Condition Desired Conditions
17.
17 © 2004 Superfactory™.
All Rights Reserved. Target Area Vision Information Flow Current Condition Desired Conditions
18.
18 © 2004 Superfactory™.
All Rights Reserved. Sketch of the Current Work Area Show flow of people, equipment, and materials with arrows
19.
19 © 2004 Superfactory™.
All Rights Reserved. Workplace Scan Checklist Date Step Item Determine what is and is not needed Unneeded equipment, tools, etc. ...are present Unneeded items are on walls (bulletin boards etc.) Items are present in aisleways, stairways, corners, etc. Unneeded inventory, supplies, parts, materials are present Safety hazards (water, oil, chemicals) exist A place for everything… Correct places for items are not obvious Items are not in their correct places Aisleways and equipment locations are not identified Items are not put away immediately after use Height and quantity limits are not obvious Cleaning and looking for ways to keep it clean Floors, surfaces, and walls are not free from dirt Equipment is not kept free from dirt, oil, and grease Cleaning materials are not easily accessible Lines, labels, and signs are not clean Other cleaning problems are present Maintain and monitor the first three categories Necessary information is not visible All standards are not known and visible Checklists don't exist for all cleaning and maintenance jobs All quantities and limits are not easily recognizable How many items can't be located in 30 seconds or less Stick to the rules How many workers have not had 5-S training How many times last week was daily 5-S not performed Number of times that personal belongings were not stored Number of times job aids are not available or up to date Number of times last week 5-S inspections were not done Total Number of problems found+D13 Rating None 5 1 4 2 3 3-4 2 5 or more 1 Sustain Sort Straighten Shine Standardize
20.
20 © 2004 Superfactory™.
All Rights Reserved. Waste Radar Chart % of Waste Before 5S % of Waste After 5S 0 De f ec ti veP r oduc t T r anspo rt a ti on De l ays Resou rces M i s- used P r ocess 10 M o ti on I nven t o ry Un t apped Resou rces 90 70 20 30 40 50 60 80 100 O ve rp r oduc ti on
21.
21 © 2004 Superfactory™.
All Rights Reserved. Sort When in doubt, move it out Prepare red tags Attach red tags to unneeded items Remove red-tagged items to “dinosaur burial ground” Evaluate / disposition of red-tagged items
22.
22 © 2004 Superfactory™.
All Rights Reserved. Red Tag Inspection Sheet Search Floors Aisles Operation areas Workstations Corners, under equipment Small rooms Offices Loading docks Inside cabinets Look for unneeded equipment Machines, small tools Dies, jigs, bits, Conveyance equipment Plumbing, electrical parts Look for unneeded furniture Cabinets Benches, tables Chairs Carts Search these storage places Shelves Racks Closets Sheds Search the walls Items hung up Old bulletin boards Signs Other _________ Look for unneeded materials Raw material Supplies Parts Work in process Finished goods Shipping materials Look for other unneeded items Work clothes Helmets Work shoes Trash cans Other
23.
23 © 2004 Superfactory™.
All Rights Reserved. Red Tagged Items Log Needless Items (describe) # of items Date Reason for Tagging Notes / Disposition
24.
24 © 2004 Superfactory™.
All Rights Reserved. Disposition List Category Action Obsolete Sell Hold for depreciation Give away Throw away Defective Return to supplier Throw away Used about once per week Store in area Used less than once per month Store where accessible in plant Seldom used Store offsite (or in distant place) Sell Give or throw away Use unknown Store until information is found
25.
25 © 2004 Superfactory™.
All Rights Reserved. Straighten Make it obvious where things belong Lines Divider lines Outlines Limit lines (height, minimum/maximum) Arrows show direction Labels Color coding Item location Signs Equipment related information Show location, type, quantity, etc.
26.
26 © 2004 Superfactory™.
All Rights Reserved. Straighten Check Sheet Equipment Machines Small tools Dies Jigs Bits Conveyance equipment Cleaning equipment Furniture Cabinets Benches, tables Chairs Carts Shelves Racks Materials Raw material Supplies Parts Work-in-process Finished goods Shipping materials Cleaning supplies Other items Charts, graphs, bulletin boards Pens, pencils Work clothes Helmets Work shoes Trash cans
27.
27 © 2004 Superfactory™.
All Rights Reserved. Shine Clean everything, inside and out Inspect through cleaning Prevent dirt and contamination from reoccurring Results in Fewer breakdowns Greater safety Product quality More satisfying work environment
28.
28 © 2004 Superfactory™.
All Rights Reserved. Shine Check Sheet Ceilings Aisles Workstations Corners, under equipment Loading docks Walls Doors Pillars, posts Floors Machines Conveyance equipment Plumbing, sinks Cabinets, shelves, racks Carts, Racks Drawers, storage bins Fixtures, power boxes
29.
29 © 2004 Superfactory™.
All Rights Reserved. Shine Cleaning Plan Task Location Who When Materials/ tools needed
30.
30 © 2004 Superfactory™.
All Rights Reserved. Standardize Establish guidelines for the team 5-S conditions Make the standards and 5-S guidelines visual Maintain and monitor those conditions
31.
31 © 2004 Superfactory™.
All Rights Reserved. Typical Team Standards Sort Amount of inventory Tools that belong in the area How often to remove scrap Straighten Location of aisleways Location of tools, equipment Shine Cleaning schedule Maintenance tasks Checklist of what to look for as cleaning is performed
32.
32 © 2004 Superfactory™.
All Rights Reserved. Sustain Determine the methods your team will use to maintain adherence to the standards 5-S concept training 5-S communication board Before and after photos One point lesson Visual standards and procedures Daily 5-minute 5-S activities Weekly 5-S application
33.
33 © 2004 Superfactory™.
All Rights Reserved. Visual Factory Implementation Develop a map identifying the “access ways”(aisles, entrances, walkways etc.) and the “action” areas. Perform any necessary realignment of walkways, aisles, entrances. Assign an address to each of the major action areas. Mark off the walkways, aisles & entrances from the action areas Apply flow-direction arrows to aisles & walkways Perform any necessary realignment of action areas. Mark-off the inventory locations Mark-off equipment/machine locations Mark-off storage locations (cabinets, shelves, tables) Color-code the floors and respective action areas
34.
34 © 2004 Superfactory™.
All Rights Reserved. Review and Summary List each of the 5-S steps. Describe the “30-second test”. Why is total employee involvement so important? What is management’s role? Briefly describe each step in the 5-S system. How do you intend to use this information?
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