5S training material power point slide 2.ppt

1
© 2004 Superfactory™. All Rights Reserved.
5S and Visual Control
Superfactory Excellence Program™
Superfactory Excellence Program™
www.superfactory.com
www.superfactory.com

2
Disclaimer and Approved use
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
 5 Elements of 5S
5 Elements of 5S
 Why 5S?
Why 5S?
 Waste
Waste
 Workplace observation
Workplace observation
 S
Sort
ort
 S
Straighten
traighten
 S
Shine
hine
 S
Standardize
tandardize
 S
Sustain
ustain
 Visual Factory
Visual Factory
 Summary
Summary

4
5 Elements of 5S
5 Elements of 5S
 Sort
Sort
 Straighten
Straighten
 Shine
Shine
 Standardize
Standardize
 Sustain
Sustain

5
Why 5S?
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
Types of Waste
Types of Waste
 Overproduction
Overproduction
 Delays (waiting)
Delays (waiting)
 Transportation
Transportation
 Process
Process
 Inventories
Inventories
 Motions
Motions
 Defective Products
Defective Products
 Untapped Resources
Untapped Resources
 Misused Resources
Misused Resources

7
Elimination of Waste
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
Waste Identification
 What waste can be identified in the following photos?
What waste can be identified in the following photos?

9
 What waste can be identified in the following photos?
What waste can be identified in the following photos?

10
After 5S
After 5S
 Clear, shiny aisles
Clear, shiny aisles
 Color-coded areas
Color-coded areas
 Slogans & banners
Slogans & banners
 No work in process
No work in process

11
Workplace Observation
Workplace Observation
 Clearly define target area
Clearly define target area
 Identify purpose and function of target area
Identify purpose and function of target area
 Develop area map
Develop area map
 Show material, people, equipment flow
Show material, people, equipment flow
 Perform scan diagnostic
Perform scan diagnostic
 Photograph problem areas
Photograph problem areas
 Develop a project display board (area)
Develop a project display board (area)

12
Target Area Vision
Target Area Vision
Safety
Safety
Current Condition
Current Condition Desired Conditions
Desired Conditions

13
Target Area Vision
Target Area Vision
Product Quality
Product Quality
Current Condition
Desired Conditions

14
Target Area Vision
Target Area Vision
Equipment Maintenance
Equipment Maintenance
Current Condition
Desired Conditions

15
Target Area Vision
Target Area Vision
Work Efficiency
Work Efficiency
Current Condition
Desired Conditions

16
Target Area Vision
Target Area Vision
Inventory Levels
Inventory Levels
Current Condition
Desired Conditions

17
Target Area Vision
Target Area Vision
Information Flow
Information Flow
Current Condition
Desired Conditions

18
Sketch of the Current Work Area
Sketch of the Current Work Area
Show flow of people, equipment, and materials with arrows
Show flow of people, equipment, and materials with arrows

19
Workplace Scan Checklist
Workplace Scan Checklist
Date
Step Item
De te rmine w ha t is a nd is not ne e de d
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 pla ce for e ve rything…
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
Cle a ning a nd looking for w a ys to ke e p it cle a n
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
Ma inta in a nd m onitor the first thre e ca tegorie s
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 rule s
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
Num ber of proble m s found+D13 Ra ting
None 5
1 4
2 3
3-4 2
5 or more 1
Sustain
Sort
Straighten
Shine
Standardize

20
Waste Radar Chart
Waste Radar Chart
% of Waste Before 5S
% of Waste After 5S
0
D e fe c t iv e P r o d u c t
T r a n s p o r ta tio n
D e la y s
R e s o u r c e s
M is - u s e d
P r o c e s s
1 0
M o t io n
In v e n t o r y
U n ta p p e d
R e s o u r c e s
9 0
7 0
2 0
3 0
4 0
5 0
6 0
8 0
1 0 0
O v e r p r o d u c t io n

21
Sort
Sort
 When in doubt, move it out
When in doubt, move it out
 Prepare red tags
Prepare red tags
 Attach red tags to unneeded items
Attach red tags to unneeded items
 Remove red-tagged items to “dinosaur burial ground”
Remove red-tagged items to “dinosaur burial ground”
 Evaluate / disposition of red-tagged items
Evaluate / disposition of red-tagged items

22
Red Tag Inspection Sheet
Red Tag Inspection Sheet
Search
Search
 Floors
Floors
 Aisles
Aisles
 Operation areas
Operation areas
 Workstations
Workstations
 Corners, under equipment
Corners, under equipment
 Small rooms
Small rooms
 Offices
Offices
 Loading docks
Loading docks
 Inside cabinets
Inside cabinets
Look for unneeded equipment
Look for unneeded equipment
 Machines, small tools
Machines, small tools
 Dies, jigs, bits,
Dies, jigs, bits,
 Conveyance equipment
Conveyance equipment
 Plumbing, electrical parts
Plumbing, electrical parts
Look for unneeded furniture
Look for unneeded furniture
 Cabinets
Cabinets
 Benches, tables
Benches, tables
 Chairs
Chairs
 Carts
Carts
Search these storage places
Search these storage places
 Shelves
Shelves
 Racks
Racks
 Closets
Closets
 Sheds
Sheds
Search the walls
Search the walls
 Items hung up
Items hung up
 Old bulletin boards
Old bulletin boards
 Signs
Signs
 Other _________
Other _________
Look for unneeded materials
Look for unneeded materials
 Raw material
Raw material
 Supplies
Supplies
 Parts
Parts
 Work in process
Work in process
 Finished goods
Finished goods
 Shipping materials
Shipping materials
Look for other unneeded items
Look for other unneeded items
 Work clothes
Work clothes
 Helmets
Helmets
 Work shoes
Work shoes
 Trash cans
Trash cans
 Other
Other

23
Red Tagged Items Log
Red Tagged Items Log
Needless Items
(describe)
# of
items
Date Reason for
Tagging
Notes /
Disposition

24
Disposition List
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
Straighten
Straighten
 Make it obvious where things belong
Make it obvious where things belong
 Lines
Lines
 Divider lines
Divider lines
 Outlines
Outlines
 Limit lines (height, minimum/maximum)
Limit lines (height, minimum/maximum)
 Arrows show direction
Arrows show direction
 Labels
Labels
 Color coding
Color coding
 Item location
Item location
 Signs
Signs
 Equipment related information
Equipment related information
 Show location, type, quantity, etc.
Show location, type, quantity, etc.

26
Straighten Check Sheet
Straighten Check Sheet
Equipment
Equipment
 Machines
Machines
 Small tools
Small tools
 Dies
Dies
 Jigs
Jigs
 Bits
Bits
 Cleaning equipment
Cleaning equipment
Furniture
Furniture
 Cabinets
Cabinets
 Benches, tables
Benches, tables
 Chairs
Chairs
 Carts
Carts
 Shelves
Shelves
 Racks
Racks
Materials
Materials
 Raw material
Raw material
 Supplies
Supplies
 Parts
Parts
 Work-in-process
Work-in-process
 Finished goods
Finished goods
 Shipping materials
Shipping materials
 Cleaning supplies
Cleaning supplies
Other items
Other items
 Charts, graphs, bulletin boards
Charts, graphs, bulletin boards
 Pens, pencils
Pens, pencils
 Work clothes
Work clothes
 Helmets
Helmets
 Work shoes
Work shoes
 Trash cans
Trash cans

27
Shine
Shine
 Clean everything, inside and out
Clean everything, inside and out
 Inspect through cleaning
Inspect through cleaning
 Prevent dirt and contamination from reoccurring
Prevent dirt and contamination from reoccurring
 Results in
Results in
 Fewer breakdowns
Fewer breakdowns
 Greater safety
Greater safety
 Product quality
Product quality
 More satisfying work environment
More satisfying work environment

28
Shine Check Sheet
Shine Check Sheet
 Ceilings
Ceilings
 Aisles
Aisles
 Workstations
Workstations
 Corners, under equipment
Corners, under equipment
 Loading docks
Loading docks
 Walls
Walls
 Doors
Doors
 Pillars, posts
Pillars, posts
 Floors
Floors
 Machines
Machines
 Plumbing, sinks
Plumbing, sinks
 Cabinets, shelves, racks
Cabinets, shelves, racks
 Carts, Racks
Carts, Racks
 Drawers, storage bins
Drawers, storage bins
 Fixtures, power boxes
Fixtures, power boxes

29
Shine Cleaning Plan
Shine Cleaning Plan
Task Location Who When Materials/ tools
needed

30
Standardize
Standardize
 Establish guidelines for the team 5-S conditions
Establish guidelines for the team 5-S conditions
 Make the standards and 5-S guidelines visual
Make the standards and 5-S guidelines visual
 Maintain and monitor those conditions
Maintain and monitor those conditions

31
Typical Team Standards
Typical Team Standards
 Sort
Sort
 Amount of inventory
Amount of inventory
 Tools that belong in the area
Tools that belong in the area
 How often to remove scrap
How often to remove scrap
 Straighten
Straighten
 Location of aisleways
Location of aisleways
 Location of tools, equipment
Location of tools, equipment
 Shine
Shine
 Cleaning schedule
Cleaning schedule
 Maintenance tasks
Maintenance tasks
 Checklist of what to look for as cleaning is performed
Checklist of what to look for as cleaning is performed

32
Sustain
Sustain
Determine the methods your team will use to
Determine the methods your team will use to
maintain adherence to the standards
maintain adherence to the standards
 5-S concept training
5-S concept training
 5-S communication board
5-S communication board
 Before and after photos
Before and after photos
 One point lesson
One point lesson
 Visual standards and procedures
Visual standards and procedures
 Daily 5-minute 5-S activities
Daily 5-minute 5-S activities
 Weekly 5-S application
Weekly 5-S application

33
Visual Factory Implementation
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
Review and Summary
Review and Summary
 List each of the 5-S steps.
List each of the 5-S steps.
 Describe the “30-second test”.
Describe the “30-second test”.
 Why is total employee involvement so important?
Why is total employee involvement so important?
 What is management’s role?
What is management’s role?
 Briefly describe each step in the 5-S system.
Briefly describe each step in the 5-S system.
 How do you intend to use this information?
How do you intend to use this information?

5S training material power point slide 2.ppt

More Related Content

Similar to 5S training material power point slide 2.ppt

Recently uploaded

5S training material power point slide 2.ppt