1. 5S Accessories Team
01-13 Jan 2012
Jimmy Holmes – Director of Quality, Perry Henry -5S
Manager,Lorena Magdalena – Accessories, Sam Mendez –
Lamination, Bobby Castillo – Rough Mill, Usbaldo Sanchez – Paint
Line, Jason Vargas – Assembly, Juan Lopez –Prep, Cruz Galvan -
Housekeeping
2. 5S Paradigm Pioneers – Team 1
From l-r Jimmy Holmes, Jason Vargas, Lorena Magdalena , Perry Henry , Usbaldo Sanchez, Juan Lopez
Back row: Cruz Galvan, Sam Mendez, Bobby Castillo
3. Event objectives
• Sort – Go through the department and determine
what needs to stay for processing and real work, and
red tag anything that may not be needed.
• Set in order – Begin setting up the workstations in
a manner that makes more sense for smart
operations.
• Shine – Cleaned up the entire area to remove all
dirt, dust, sawdust, and additional trash that was
contributing to clutter.
• Standardize – Began setting up operations,
procedures, and WIP locations to provide order and
routine.
• Sustain – Met with the entire department and got a
commitment for sustainment from all operators and
leadership.
4. General Observations
• At the outset, the first impression we got from
the area and the operators is that with the
amount of materials processed and their current
work area layout, they are victims of production
and the clutter, and they cannot do anything
about it.
• We very quickly changed that when we went into
(Set in order mode) and discussed with them
their ideas for smarter operations could be
implemented as part of this team.
6. The sugar biscuit
• The point of mentioning this pastry is that
it symbolizes the mindset that most people
have about the cleanliness of our factory.
That pastry was on the floor near
accessories and the door to the break
room for almost an entire week before we
finally pointed it out and picked it up in our
clean.
7. Safety Assessment
• Fire extinguishers relabeled where needed
• Plastic strapping removed where needed
• Closed 2 open junction boxes
• Labeled Hot Glue Machines clearly
• Lights out over some work stations – Under review from maintenance
• MSDS locations identified
• Emergency Air Shut off out of reach
• Anti-Stress mats under tables instead of positioned for use
• No Safety reminders posted anywhere
• Lots of debris, sawdust, and trash posing tripping/slipping hazards
• Air hoses positioned posed tripping hazards
• One fire extinguisher was hidden by some type of tarp
• Air vent (Louvers) broken, need to be replaced for temperature control – reported to maintenance
• Carts and materials positioned all over the area posed blocking hazards due to line of sight issues
• Igloo coolers (2) being used as chairs – removed from the area
• Broken or damaged racking fixed
• Medical equipment box not accessible by anyone on the Accessories team
• Emergency exits blocked by materials
• Extra half broken chairs in the work area used for break
• Table Saw Apron hidden on a shelf
• Staple guns laying sideways out in the open posing misfire hazard
• Eyewash was moved from in front of the forklift for better access
8. 5s Level 1 Findings
• Old materials (Molding) not being used
• Coolers being used for chairs
• Break areas at every work station with microwaves under tables
• Pantry for food and cleaning supplies in the same area
• Lots of small cabinets being used for junk hoarding
• Lots of unlabeled carts all over the place
• Boxes full of cardboard even though they practice cardboard recycling
• Lots of extra pallets on the racks in wrong locations or not needed at all
• Extra large fans positioned in the area but in the way of normal activity (Not used during Winter)
needs to be stored somewhere
• Broken radio and hot glue machines under the tables needed to be removed
• Extra staple guns, drills etc. in a cardboard box removed
• Several cabinets being used for work stations with extra drawers being used for storing and
hoarding stuff
• Area had not been swept in a while – they did not have any brooms or dustpans – we got them
some and a 5S station for this
• Table on the other side of build table being used for general junk storage in the work area
• Un-labeled templates
• Fake trash cans (Cardboard boxes) being used for trash everwhere
• Red tagging happened at this stage and all materials pulled during red tagging was moved out
into a holding area near
9. 5S Level 2 Findings
• Safety issues addressed
• Kanban racks and materials being moved and sent back if needed
to create order in accessories racking resulting in removal of an
entire rack which also created a work area for Lorena getting her out
of the isle where she previously worked
• Workstations organized for smart operations and labeled properly
• Labeled Trash containers replaced cardboard boxes and placed in
designated locations with marking
• Drop zones identified and labeled
• Obsolete spec books and training guides for doors were in use
• Break area designated with new microwave cabinet and picnic table
taking this out of the general work area
• Created designated tables for storage and staging for glue
machines and staple guns
10. Before pictures
• Accessories large panel processing – Lots
of trash and clutter.
Strapping, sawdust
And plastic wrap
Creating tripping
And slipping
Hazards
11. Table saw – sawdust, clutter, and
large tripping hazard
Repositioned to avoid tripping
57. After pictures
• The remaining pictures are from the after
Sort, Standardize, Shine efforts had taken
place. Consider these the after pictures
with improvements and sustainment in the
works…..
58. Cleaning up and moving an area
freed up space for break time
• This also created a place for lockers
which we got from the paint line. Now the
operators have a place for their stuff.
72. General Observations
• The first day of Training and general work center visits and observations is critical to the learning
and success going forward
• The Standardization and Shine steps require a lot work that need to be planned out better – One
example already floated was the idea of coming in for this part extra early so that it can be done
without interrupting production
• The work centers must be briefed properly in order for this to be a success in the area we visit or
we will have additional unnecessary challenges when we get there
• Work centers have to understand what we are trying to do when it comes to standardization and
process improvement/ergonomics etc.
• The Red tagging process can generate a lot of waste and areas need to be prepared with an
area for this and a process for addressing it ASAP or it will create other problems where it sits
• Standard work did not appear to be a consideration at any of the stations prior to our visit
• General supplies like marking tape, cleaning supplies like brooms, push brooms, dust pans etc.
need to be ordered ASAP in order to be put to use right away
• It would help to have help and there are plenty of people interested
• There are already a few people asking to be on the next team
• Excitement around this is building as people see what we did
• This is actually pretty fun once you get going!!!!!
• A standardization checklist needs to be developed for sustainment compliance
73. Special thanks goes out to
• The Accessories Production Team for
putting up with us and helping out with all
the things we needed from them
• Adam Yarbro for his help with the supplies
and direction needed for station building
and his efforts to get the pallets under
control
• Maintenance-Ernie, Russel, Casey, and
the rack removal crew for all their help
