Creating World Class Organization Through 5S and Visual Management @ 3rd Annual Lean Conference, 2015 @ AMA Ahmedabad
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The document discusses the implementation of 5S and visual management techniques to create world-class organizations. It describes the 5S methodology as a 5-step process to reduce waste, including sorting, systematic arrangement, spic and span, standardization, and self-discipline. The steps involve organizing the workspace and establishing visual controls. Implementing 5S provides benefits such as improved productivity, quality and safety. It also reduces costs and waste. The presentation provides examples of implementing 5S and recommends defining the implementation scope, collecting baseline data, and using data to guide the process.
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Creating World Class Organization Through 5S and Visual Management @ 3rd Annual Lean Conference, 2015 @ AMA Ahmedabad
- 1. Presentation Title: Creating World Class Organization through 5S & Visual Management Presented on 2nd Feb 2015 @ 3rd Annual Lean Conference, AMA, Ahmedabad
- 2. Creating World Class Organizations Through 5S & Visual Management
- 3. 5S is a set of steps to create a more productive workshop
- 4. 5 Step to reduce or eliminate waste • Searching • Waiting • Wandering • Wondering • Delays • Extras • Waste/Scrap 8 Type of Waste Transportation Motion Waiting Inventory Over processing Rejection Over production Human Potential
- 5. × Cleaning and janitorial work to satisfy management. × Imposing standards at workplace. × Silver bullet to productivity gains. Foundation to achieve employee engagement , waste reduction, improve workflow, and safety. Empower workforce. There will not be immediate influx of ROI when you implement 5S, but it trickles down slowly, in different forms & ways. “There is not an end, it’s a journey”
- 6. 5S Pictures
- 7. 5S Pictures
- 8. 5S Pictures
- 9. s 1st S - SEIRI Sorting Out
- 10. 1. Touch everything 2. Evaluate everything with a standard set of decision making rules 3. Tag it 4. Set tagged items in tag area 5. Record all items in a Red tag Register Remove all unessential items from the workplace
- 11. Tools Red Tag Red Tag Register Red Tag Area
- 13. • Identify a home for everything that will be easy to find and put away (PEEP) • List everything that’s left from sorting step • Create a master list of everything include as much in formation on it as possible • Agree on a location for these items, 1. How to keep them, 2. How many to keep, 3. Use Visuals to locate them 2nd S: Set in Order
- 15. s 3rd S - SEISO Spic and Span
- 16. • Keep everything in top condition. So, when someone need something, it's ready • Designate areas of space to different person • Remove unnecessary items • Sweep & wipe down with tools Shine
- 17. Example of Seiso
- 19. • Take the pictures • Create a map of that locates where everything is stored • 5S team maintains a job list and schedule 5S activities Establish Visuals for everyone to maintain the condition
- 22. • Clear deliverables & communication • Score Keeping • Continuous improvement with cyclic mini-5S events Tools: • Training and Awareness of 5S • Dedicated 5S team • Clear 5S Map and Responsibilities/Ownership You are setting the standards to what you must live by
- 23. 5S Benefits to Customer & Employees Customer • Win customer confidence by bringing them to factory • Delight the Customer • Customers always expect lower price. 5S is one way to make it possible • Faster Response to queries/ requests • Improves on time delivery • Higher demands are met Employees • Improve employee involvement • Lower Absenteeism • Build Employee pride • Working smarter not harder • Higher employee Satisfaction
- 24. 5S Benefits – Improves, Reduces Improves • Productivity • Quality • Process Reliability • Work Standardization • Work Culture • Daily & Shift Start Times • Simplified work Environment • Profitability & Efficiency by reducing time wasted looking for tools and Equipment • Safety Reduces • Transportations • Cost • Machine Down time • Changeover Time • Lead Time • Waste • Inventory • Rejects/ Rework • Breakdowns • Waste in materials, Space & Time
- 25. How to implement 5S Define Scope • Where?-Identify where exactly boundary starts and ends • Who?- Define the 5S team and participants with the visuals
- 26. • What?- Define the 5S job responsibility with required resources? • When?-Settle down a plan for 5S activities with targetdates and checklist for routine How to implement 5S Define Scope
- 27. How to implement 5S ? Collect Baseline Data • Use pictures of Before and After (Inside - outside, Above-under)
- 28. • Time Study • Cost & Quality of Inventory How to implement 5S Spaghetti Diagram Floor Plan Usage Use Data
- 29. 5S - SEITON
- 30. 5S-SEITON
- 31. 5S - SEITON
- 32. Thank You