5S Presentation Manufacturing NZ

8/8/2019 5S Presentation Manufacturing NZ

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www.ManufacturingNZ.co.nz

Successful implementation of 5s into manufacturing processes (or businessprocesses) has many advantages.

5S demonstrates that management has a commitment to change andimprovement.

5S gets everyone involved in doing something.

5S is a starting block and integral part of many other lean initiatives, such asTPM, Kaizen and SMED.

5S increases motivation of staff as it improves the working environment.

Costs are saved through efficiency and productivity improvements, freeing upspace and reducing wasted time and resources.

5S creates a better impression with customers and suppliers or any external

people.

5S can create funds by releasing unnecessary equipment that can be sold.

5S improves the safety of the workplace.

5S is a low cost, high impact activity to demonstrate the results that can beachieved through lean.

5S establishes a set of new practices and attitudes in the organisationworkforce that will be needed to successfully implement a Lean culture.

1Beth Smith Manufacturing Consulting 2009


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5S can be applied to a manufacturing cell, a production line, a support area suchas maintenance, or administrative areas.



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Sometimes the 5Cs is used

Clear out

Configure

Clean and Check

Conform

Custom and practice

It is important that all Five disciplines are implemented as they are allinterdependent upon each other.



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It is best if this exercise is carried out by the operators who work in the areaalong with their team leader.

The standardised work documentation should specify exactly what material andequipment is required to do the job. Anything else should not be in the work area

The team should compare the actual condition with that specified and removeany surplus.

A red tag campaign is often used, where any item that is not required isindividually marked and removed to a quarantine are for a period before beingscrapped or disposed of.

Use photos to record the before and after and display the after so all know thenew required standard.

Two areas should be set up: one for the collection of unused items and one foritems that are frequently used.



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This exercise has removed the unnecessary material. It is easier to see what isgoing on!

The sort or clear out should only leave the material and equipment necessaryto do the current and common jobs.

This is only the first of 5 steps, DONT STOP!



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Cleaning the desk is now possible.

Things are easy to find

Important items cannot get missed.

With the completion of the first S you will instantly see three main results:

1.increased productivity The purpose of individual work areas will be more

, .

2.Workers will be more satisfied with their environment. Emplotee morale willincrease as junk itmes or materials that are potetntil health hazards are identified

and removed.

3.Much more full attention can be paid to production. Employees will no longer

need to focus on tangential tasks such as locating tools and implementing theirown organisation systems.



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All material and equipment required for the job should located as close spossible to the point of use

All material and equipment should have a clearly amrked and visual homepositions , which make them easy to find and makes obvious any missing items.



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The workplace was much tidier after the sort step but efficient working wasstill obstructed by the inappropriate location of material and equipment.

The application of the set in order step has placed all the necessary material inthe most appropriate locations which are close to the point of use, but not inpositions which impedes the movement of production material or operators.

Cleaning and maintenance will now be much easier

The risk of accidents and mistakes will be reduced



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Make sure there is a place for everything

All items to be put where it is easy to find them and access them

Frequently used items should be stored in the most convenient locations foreasy and rapid retrieval.

Every location must have an identification label

Colour coding can be used to speed up identification

To improve access look at raising shelves or removing doors

Stock reorder level can be marked on location



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Where concerns logged an identification alert tag should be adde to theequipment. Regular reviews should pick up where action is not being taken.

Everyone in the work team should be involved in the shineEach work team member should be responsible for activity in their own area.

All areas must eventually have a shine owner



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Orderly cleaning will often identify problems in the production process.

Fluid leaks are often difficult to pin point on dirty machines

Particles such as swarff and filings get onto work areas and often damageproducts and equipment.

Dirty filters often lead to early failure and quality problems

Clogging cn occur when using dirty coolant.

Safety first. Untidy areas are not safe and create fire hazards.



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Standardisation is necessary to make sure Workplace organisation becomes away of life.

Standardisation must be applied to the following elemenets: Sort, set in orderand shine

Details of the individual tasks, responsibilities for those tasks, the requiredfrequency and the circumstances under which each task should be carried outmust be recorded within standard documents and displayed.

Basic posters reminding people of what is expected, help.



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The tasks involved in maintaining Workplace Organisation standards are just asimportant as those for the production process.

All Workplace organisation tasks should be captured on the normal workinstruction charts type documentation

Visual management methods help team members and team leaders maintainworkplace organisation standards

The use of good quality notice boards displaying colourful diagrams, tables,photographs and other messages will help provide effective communication

Visual aids must be placed where the team members find them easy to use andread, not just where visitors can see them!

Display and explanation of more infrequent tasks can help ensure continuity



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Workplace organisation supports the operation of the whole Best Practicesystem

Poor workplace organisation will inhibit the effective operation of the systemWorkplace organisation must be part of the overall training and induction plan

On the job training and coaching by team leaders forms an important part of thisplan

Visual management methods can help to make good workplace organisation away of life

All production management must understand the importance of good workplaceorganisation and must immediately challenge any examples of poor discipline.

Train people to devise and implement their own solutions

Use team meetings to highlight success.



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The use of a workplace organisation monitor is invaluable as method of visualmanagement.

A simple visual system can help the whole team become accustomed to therequirements of the system,

Such a system can provide an instantly obvious status of the workplaceorganisation process

Regular audits should also be carried out by team members.



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The five disciplines of Workplace organisation are well-recognised method ofimproving the working environment that is used extensively around the world.

Workplace organisationDefines workplace standards

Defines organisation processes

Defines roles and responsibilities

Workplace organisation helps to:-

Reduce stress

Reduce absenteeism

Improve qualityImprove interpersonal relations

Better use the equipment available.

5S Presentation Manufacturing NZ

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