Veritiv Facility Solutions: Have you Leaned your cleaning?
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The application of lean principles is spreading to nearly every type of business and industry. There is literally no place, function, or operation that could not benefit from Lean Enterprise.
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Veritiv Facility Solutions: Have you Leaned your cleaning?
- 1. Welcome Michael Parks, Six Sigma, Lean, AMS, CIMS Director of Marketing Veritiv, Facility Solutions
- 2. LEAN Principles can be applied to any industry
- 3. Have you LEANed your CLEANing?
- 4. When it comes to Cleaning, does your company have a “Housekeeping” Mentality? Do you view cleaning as a necessary evil? Is it assigned less importance? Not given enough focus? Shortcuts taken?
- 5. WHAT IS THE RESULT? Waste and an overall facility that suffers
- 6. Are you delaying costs and taking shortcuts? LESS ENGAGED EMPLOYEES WITH LOW MORALE HUGE EXPENDITURES FOR REPAIR AND REPLACEMENT DETERIORATION OF THE ENVIRONMENT DELAYED COSTS and CLEANING SHORTCUTS
- 7. The High Cost of Employee Disengagement 32.7% Decrease in Operating Income Average of 3% Lower Earnings Per Share
- 8. The Benefits of Engaged Employees 3X More Creativity And Ideas 20% Better Performance On Average
- 9. Workplace Environment and Employee Emotional Health WHAT IS THE BENEFIT OF LEAN? Empowerment Higher Morale Engagement
- 10. *Based on Gallup study greater likelihood of success when companies do all the right things, make sure employees feel appreciated, and have the tools to do their jobs* *Based on Gallup study
- 11. The “Clean” application of 5S sort set in order shine standardize sustain sweep, sanitize or scrub an environment elimination of unnecessary materials to make an environment less cluttered organizing things in their right place to make an environment more orderly work rules, visuals, instructions, signoff ensuring lean changes stick
- 12. Another way to view 100% Value Added W O R K I N G8 HOUR STANDARD SHIFT Non-Value Added Time
- 13. Another way to view 100% Value Added W O R K I N G8 HOUR STANDARD SHIFT Non-Value Added Time • Getting ready to work • Looking for tools, equipment, supplies • Waiting for other departments • Working inefficiently • Rework loops • Retracing steps • Putting things away Leaving an un- organized space, work undone, unresolved issues, frustrated employees
- 14. The Un-Lean Reality Floors still dirty after cleaning Ineffective products; too many; not diluted properly Ineffective cleaning; wasted time and effort
- 15. Better Practices through 5S: SORT | SET in ORDER | SHINE
- 16. Better Practices: Equipment Storage Organized floor space with location addresses Result: Savings of up to 15 minutes per employee, per shift in locating tools and equipment
- 17. Better Practices: Tool Walls Dedicated storage space throughout plant Result: Reduced transportation and time waste
- 18. Lean Concepts for Janitorial Closets/Store Rooms
- 19. • Disorganized • Lost or Missing items • Wasted Time and Effort • Potential Safety Issues • Lost Productivity Typical issues regarding janitorial closets/Store Rooms From Executives • Lack of Standardization • Inconsistency in performance • Compliance Issues • Complex or lack of training program • Operational Spend From Employees • Frustrated with how things are laid out • Dislike cumbersome tools • Know they are wasting time • Creates feelings of distrust Feedback we have received:
- 20. Typical Conditions • Congested; creates lost productivity • Items mishandled; causing damage • Disorganized; leads to wasted time • Product lost/waste, too much product
- 21. Typical Conditions • Product proliferation follows • Lack of standardization • Holding more inventory than needed • Employees cannot quickly find or get the tools, materials, and products they need • Non-Compliance issues arise
- 22. Typical Conditions • Tools left in improper condition • No clear “place” or address to park items • Lost productivity for all • Frustration • Out-dated tools remain in use • Cleaning suffers
- 23. 5S Lean Improvements • Non essential items removed: frees up space, saves time • All items put in a specific location, and labeled so they remain: • Visual tools help employees stay organized- take self control • Work rules ensure cleaning processes are correct Easy to Find Easy to Get East to Put-away Every client’s environment is unique, these are only example and not specific recommendations
- 24. 5S Lean Improvements • All items given a permanent home • Clearly labeled to ensure: • More professional appearance Easy to Find Easy to Get East to Put-away
- 25. Have you Leaned your CLEANing? Eliminate variety of wastes that “Housekeeping” mentality generates EVERY company can benefit from applying Lean principles Realize the positive strategic effects of 5Y
- 26. 1. Increased productivity 2. Enhanced company image 3. Improved morale & engagement 4. Making every dollar count 5. Protection of valuable assets Embrace 5Y! The 5Y’s of why you should apply Lean to your cleaning function
Editor's Notes
- 0:30 seconds
- 0:10 seconds As this audience knows, the application of lean principles is spreading to nearly every type of business and industry. There is literally no place, function, or operation that could not benefit from Lean Enterprise.
- 0:10 seconds Today, I will explore one area that may be an undiscovered opportunity to apply Lean Principles based on our research and activities. That is the holistic cleaning function in a facility.
- 0:20 seconds In fact, many companies still view cleaning as a “Housekeeping” function, almost as a necessary evil. As such, not enough focus is applied, shortcuts are taken, and the overall facility suffers. The focus might be on getting by as cheaply as possible, unaware of the waste that is being created – which far outpaces any dollars saved on the front end. What are the real issues, waste created, by this lack of focus?
- 0:10 seconds
- 0:60 seconds The same is true for a manufacturing plant, office, or any other work environment, or even your home; the longer you wait to make needed repairs and improvements the more expensive it will be in the long run. And, the longer you take to maintain something properly the faster it will deteriorate. Reminds me of that time I did not pay attention to some squeaky breaks and an $85 brake pad replacement ended up costing me $500. You see it happening, the carpet is stained and begins to fray, concrete is breaking up, equipment is running slow and oils are leaking more and more. And yet, no real action is taken. Cleaning is often times not given proper priority or resources. Short cuts are taken, things are overlooked. The cost to replace carpeting can be in the $1000s, and other types of flooring in the $10,000s. Replacing other materials can be equally expensive. Often times, we also see a cleaning staff disconnected from the rest of the business. They operate almost autonomously, often untrained or using “tribal knowledge” to do their jobs. The challenge is, when you short cut cleaning you accelerate deterioration of the environment, putting pressure on the need to spend huge dollars to repair or replace. Another huge factor with poor cleaning practices is employee morale and engagement. Cleaning has a direct link to this, yet many companies short cut or ignores the cleaning process all together.
- 0:20 seconds Look at these statistics! The cost of disengagement is Huge. [point out 2 points]
- 0:20 seconds And the benefits of high engagement are significant. [point out 2 points]
- 0:60 seconds It is said that the implementation of Lean Enterprise also improves morale. What are the factors contributing to this? Empowerment is certainly a strong contributor. In William Byham’s 1988 book, Zapp! The lightning of Empowerment, he pointed out that empowerment is the feeling of job ownership and commitment brought about by the ability to make decisions, be responsible, be measured by results, and recognized as a mindful contributor to overall company goals, versus just hands doing a task directed by someone else. Lean provides the means for job ownership, measurement, feeling of self determination and so on. It’s clear it’s easy to support the case that Lean contributes to higher levels of morale and engagement. And we know thanks to the Gallup organization that engaged employees are key to success. Gallup’s studies showed that companies doing all the right things, making sure employees feel appreciated, have the tools to do their job, ECT. have a 70% more likelihood of success. Empowerment – and therefore Higher Morale and Engagement – also relies on employees taking personal pleasure or satisfaction in the work they do and the environment they work in. This brings me back to my central question, have you leaned your cleaning? Or have you put it off to the side, reduced the resources available to the cleaning function, or not given it appropriate attention.
- 0:30 Seconds
- 2 Minutes Why do I say Holistic? Certainly, when we look at the 5S principles we do see that cleaning is represented. The 3rd S is shine or Sieso after all. When companies conduct or implement a Lean event they go through several steps that have cleaning activities embedded; Sorting is the elimination of materials that are not needed, this certainly “cleans” up an environment, makes it look less cluttered. Setting in Order is about organization and keeping things in their right place, which contributes to a clean and orderly environment. And Shining, the act of cleaning can also be interpreted as: Sweeping, Sanitizing or Scrubbing Cleaning the workspace Use cleaning as a form of inspection Prevent machinery and equipment from deterioration Keeping the workplace safe Keep the workplace clean and pleasing to work in The issue we have uncovered many times is that when 5S activities are conducted, they are often focused on one area or subject matter, not the entire facility, and not the overall cleaning function. So one area or function might see improvement but the overall facility might still need help. We also have seen that many companies that have embraced Lean have not applied those principles to the cleaning process.
- 0:90 seconds
- 2 Minutes That’s it! Simple. Yet so valuable because its about what customers really value. Do they honestly value any product we sell? That they might pour down a drain, or replace everyday, or have to expense regularly? What they really value is the end result. A business running efficiently in all aspects, no deterioration, improving employee engagement
- 2 minutes From the waist up this facility looked great. Remember that first picture I showed you? But when we looked down it was a different story. The floors were dirty – not filthy-in-your-face dirty, but stains and spots throughout. The company employs 3 people to do nothing but ‘Clean” their manufacturing environments all day long. They threw resources at cleaning for sure. Perhaps the outdated cleaning schedules and SOPS were part of the waste created, but also, too, was the fact that employees were never trained how to clean. The result was dirty floors, the use of ineffective products, wasted time and wasted effort.
- 2 Minutes Let me close with some quick examples of how the application of Lean and the 5S principles helped this 3rd class environment. This is a great example of how SORT- SET IN ORDER- and SHINE combined to improve the cleaning impact at this facility. As for morale, which environment makes you feel better?
- 1Minutes Now, all equipment is addressed and assigned a specific location. This saved up to 15 minutes per employee per shift change just in locating their tools and equipment.
- 0:30 seconds Some tools are now addressed and located throughout the plant, reducing transportation and time waste.
- 0:20 seconds
- 0:90 seconds
- 1 Minutes
- 1 Minutes
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- 2 Minutes
- 2 Minutes
- 3 Minutes My intent today was to expose a potential new or undiscovered area where companies can apply lean principles that our research shows go overlooked more often than not. Even companies fully implementing lean could benefit. Lean will certainly eliminate any number of types of waste that a “Housekeeping Mentality” will generate, but it will also have these positive effects:
- 3 Minutes I call them the 5 y’s or why’s of why you should apply lean to your cleaning function. First WHY: It increases the productivity of your cleaning teams, they will spend more time doing the value-added activity of cleaning and less of the non-value added time of getting ready to clean or moving things unnecessarily around. Second WHY: Enhancing the company image. How well a facility is maintained directly reflects the image and culture of a company. Third WHY: Improves morale & engagement. Every human wants to work in a clean, safe, well organized environment – and when they do they give more! And when they don’t they give less. Fourth WHY: Make every dollar count. Why spend even $1 for cleaning if the end result is a less than a clean environment? And why spend any dollars for an environment that is declining and leading to unnecessary future replacement costs? Fifth WHY: Protection of Valuable Assets. Effective cleaning and maintenance of equipment is known to extend the life and maintain a higher level of performance, and effective cleaning and maintenance of the facility overall can avoid the need for those costly replacements and repairs. Instead of ignoring the obvious to avoid the expense, companies can keep their facilities and all the materials within in good condition for years longer than if they don’t Lean their Cleaning.
- Thank you. If we have time and there any questions I would be happy to field those.