Phuong phap trien khai 5S trong doanh nghiep

1. 5S / Visual Factory

2. 2
IPI Vision
A meaningful work opportunity for
every offender

3. 3
Continuous Improvement (CI) CI - Supporting Tools
CI
Purpose of CI Tools
• Standardize the system
• Return the system to standard
• Improve the standard
Just
In
Time
PI
VMM
S
Visual
Managed
Metrics
People
Involvement
Standardization
CI
Continuous Improvement
• Standardization
– 5S
– Standard Work
– Total Productive Maintenance
• VMM
– Visual management
– CI boards
– Layered process audits
– Smart Goals
• Continuous Improvement
– Process Problem Solving
– Kaizen
– VSM
– Go See

4. Why did we do the 5S event?
FOR
OUR
What was the
????

5. WE ACCOMPLISHED……
• Discovered roughly 400 square feet of
space that we can now use exclusively
for chemical production!

7. CHEMICAL AREA
BEFORE AFTER

8. What did we accomplish?
• Discovered roughly 400 square feet of space!
• Redesigned the RAM table area to
eliminate wasted motion.

10. Ram table area
BEFORE AFTER

11. What did we accomplish?
• Discovered roughly 400 square feet of space!
• Redesigned the RAM table area to eliminate
wasted motion.
• Combined the 2 GUI computers onto 1
desk to free up space and standardize
the location.

13. GUI STATION
BEFORE AFTER
X 2!!

14. What did we accomplish?
• Discovered roughly 400 square feet of space!
• Redesigned the RAM table area to eliminate
wasted motion.
• Combined the 2 GUI computers onto 1 desk to
free up space and standardize the location.
• Developed a plan to relocate the
apprentice clerk and training materials
to a better location

15. CLERK OFFICE
BEFORE AFTER

16. What did we accomplish?
• Gained approval to utilize the space in
front of the overhead door for soap
production!

18. OVERHEAD DOOR AREA
BEFORE AFTER

19. What did we accomplish?
• Gained approval to utilize the space in front of
the overhead door for soap production!
• Reduced the space for the staff desk on
the floor by roughly 50 square feet!

21. STAFF SHOP DESK
BEFORE AFTER

22. What did we accomplish?
• Gained approval to utilize the space in front of
the overhead door for soap production!
• Reduced the space for the staff desk on the
floor by roughly 50 square feet!
• Relocated a saw to improve safety and
reduce motion!

24. TABLE SAW AREA
BEFORE AFTER

25. What did we accomplish?
• Gained approval to utilize the space in front of
the overhead door for soap production!
• Reduced the space for the staff desk on the
floor by roughly 50 square feet!
• Relocated a saw to improve safety and reduce
motion!
• Removed 6 trailer loads of non-value
added items from the shop and old
soap!

27. • Developed a standard for Floor markings for
all IPI shops!
What did we accomplish?

28. IPI Floor marking standard

29. • Developed a standard for Floor markings for all IPI shops!
• Started applying floor marking tape
What did we accomplish?

30. Floors

31. Standard Floor Markings

32. • Developed a standard for Floor markings for
all IPI shops!
• Started applying floor marking tape
• Developed a standard for shop signage!
What did we accomplish?

33. STANDARD SIGNS
IPI DARK BLUE
WITH WHITE
BOARDERS.

34. Standard Signs

35. • Developed a standard for Floor markings for all IPI
shops!
• Started applying floor marking tape
• Developed a standard for shop signage!
• Established Visual metrics for the team!
What did we accomplish?

36. METRICS
Zero
RECORDABLES
Zero DEFECTS
PASSED ON
5 DAYS ORDER
TO DOCK
NO EXTRA
HELP NEEDED
STANDARD
WORK WRITTEN

37. LEAN THINKING is….
• Understand the differences between value
add and waste.
– What is the customer willing to pay for?
– Understanding what adds value to the product.
IF IT DOESN’T ADD VALUE ITS WASTE!
It might be necessary but it’s still waste.
37

38. WASTE
38
What does this monster we call waste look like?

39. 39
•Why is Lean important?
TIMWOOD = WASTE
Anything that does not add value to the
product for the customer is waste!

40. 40
•Why is Lean important?
Transportation
Transportation WASTE

41. 41
•Why is Lean important?
Inventory
Inventory WASTE

42. 42
•Why is Lean important?
Motion
Motion WASTE

43. 43
•Why is Lean important?
Waiting WASTE
Waiting

44. 44
•Why is Lean important?
Over Production WASTE
Over production

45. 45
•Why is Lean important?
Over Processing WASTE
Over processing

46. 46
•Why is Lean important?
Defect WASTE
Defects

47. What’s next?
• 5S audit schedule
• 5S task cards
• Zone maps
• Install visual metrics board
• COUNTER MEASURE SHEET reviews
SUSTAINMENT MUST DO’s!

48. What’s next?
• Floor repairs
• Walls painted
• Finish taping the floors
• Staff desk in office
• Platform for staff desk on floor
• Overhead door removal
• Enclosed dock proposal

49. FEEDBACK
• Was it worth the time?
• What went well from your perspective?
• What would you do differently (if anything)
knowing what you know now?

50. Thank you!
• Great
participation
• Support
• Resources