5S and visual factory and more detail example

5S and Visual Factory
5S and Visual Factory
Superfactory Manufacturing Excellence Series
Lean Overview
5S & Visual Factory
Cellular Manufacturing
Jidoka
Kaizen
Poka Yoke & Mistake Proofing
Quick Changeover & SMED
Production Preparation Process (3P)
Pull Manufacturing & Just In Time
Standard Work
Theory of Constraints
Total Productive Maintenance
Training Within Industry (TWI)
Value Streams

© 2007 Superfactory™. All Rights Reserved. 2
Contents
Contents
• Introduction
• Background and History
• Components and Implementation
• Knowledge Check

Introduction
Introduction
• 5S is a method to improve and sustain workplace
organization
• 5S represents 5 disciplines for maintaining a visual
workplace (visual controls and information systems).
• These are foundational to continual improvement and a
manufacturing strategy based on "Lean Manufacturing"
(waste removing) concepts.
• Reduces clutter
• Reduces the time it takes to look for tools and
equipment
• “A place for everything and everything in its place”
• Improves how the operation appears to customers –
always be “tour ready”
• Creates pride in the workplace
• Many companies have a standard that any tool
must be able to be found within 60 seconds.

Components and Implementation
Components and Implementation
• 5S and Lean Manufacturing
• Elements of 5S
– Sort
– Straighten
– Shine
– Standardize
– Sustain
– Safety
• Visual Factory
• Implementation plan

Elements of 5S
Elements of 5S
• Sort
– Remove all unnecessary materials and equipment
• Straighten
– Make it obvious where things belong
• Shine
– Clean everything, inside and out
• Standardize
– Establish policies and procedures to ensure 5S
• Sustain
– Training, daily activities
• Safety (often called “6S” or “5S + 1”)
– A safety commitment in all activities

The Good, Bad and the Ugly
The Good, Bad and the Ugly
• First the Bad and the Ugly - Life Without 5S

5S Examples – Sort and Straighten
5S Examples – Sort and Straighten
See the difference?
• Sort - All unneeded tools, parts and supplies are removed from the area
• Straighten - A place for everything and everything is in its place

5S Implementation
5S Implementation
1. Begin reviewing your areas for 5S
2. Discuss 5S with each of your groups (brief
group meeting)
3. Red tag sorting process (one time)
4. Brief, simple daily 5S individual activity (“just
look around”)
5. Brief 5S checklist or procedure for each area
6. Monthly 5S audit beginning __________
• Area Lead plus at least one person from outside that
area
• Post results (I will look for them!)
• Review results with your group
• Take corrective action

Red Tag Process
Red Tag Process
• One-time activity to remove or disposition
clutter
• To be started within two weeks of this training
1. Identify clutter, unused equipment, etc
2. Fill out and attach red tag
3. Note in red tag log
4. Red tags must be dispositioned within 30 days

5S and visual factory and more detail example

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