5S Workplace Organisation - Highways...
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5S Workplace Organisation Carl Hayward Lean Improvement Manager Area 9 Lean Team
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Transcript of 5S Workplace Organisation - Highways...
5S Workplace OrganisationCarl HaywardLean Improvement ManagerArea 9 Lean Team
5S Introduction
1. Amey 5S implementation
2. 5S origins
3. The 5S’s
4. Using the “5S” Approach to Organise the Workplace
Amey 5S Implementation
Area 9 MACHighways MaintenanceRoutine and Winter Maintenance OperationsIncident ManagementDesign and Deliver Road Renewals Schemes
TfLRoad / pavement repair and renewalsLighting / Drainage / SignageLandscapingWinter Maintenance
HerefordshireHighways MaintenanceSoft Estates / Street CleansingBuilding Maintenance / Building CleaningStreet Lighting
5S Origins
Lean Manufacturing
“Just in Time Production”
Hiroyuki Hirano
5S Origins
Further reading
5S Origins
Good Housekeeping?
Driving & Sustaining Improvement
Daily Management
Workplace organisation,
safety, cleanliness
The workplace is safe, orderly and clean
“Just in time”
Goods, services and
materials “flow” just in
time to customer demand
Built in Quality
“Right first time, every time” is built
into all processes
Visual management
At each step in the process
you can physically see if things are
right or wrong
Empowered teams
Front line staff are
empowered to make decisions
Continuousimprovement
Constant drive to eliminate
waste
The 5S’s
Japanese Western Meaning
Seiri Sort Clear
Seiton Set in OrderSimplifyStabiliseStraighten Out
Configure
Seiso Shine Clean and Check
Seiketsu Standardise Conformity
Shitsuke SustainSystemise
Consensus / Custom and Practice
Workplace Organisation
Cover with Focus Picture 1
Using the “5S” Approach to Organise the Workplace Amey Business Improvement Team
Driving & Sustaining Improvement
Daily Management
Workplace organisation,
safety, cleanliness
The workplace is safe, orderly and clean
“Just in time”
Goods, services and
materials “flow” just in
time to customer demand
Built in Quality
“Right first time, every time” is built
into all processes
Visual management
At each step in the process
you can physically see if things are
right or wrong
Empowered teams
Front line staff are
empowered to make decisions
Continuousimprovement
Constant drive to eliminate
waste
Workplace Organisation
How to get started:
Sort • Sort out required from non required items• Keep only the items you need todayStraighten / Set in Order• Place everything in order• Use colour coding, signage and floor markings to organise the workspaceSweep / Shine• Eliminate mess and junk Standardise / System• Set standards for inspections, cleaning and routine maintenance tasks• Assign clear ownership for every itemSustain• Embed the 5S discipline into the culture of the work force
Use the “5S” approach to bring order to a cluttered or badly laid out office or depot. See how much time you can save by getting rid of all the things you don’t need. An untidy workplace is an inefficient and unsafe workplace.
• Involve the whole team and appoint a champion who will drive any necessary actions through to completion
• Take before and after photos of the workplace / office / depot
• Add coloured tags to items you think you might no longer need. After an agreed period, if you haven’t used the items, remove them.
Before… After…
Strensham “5S” Exercise (1 of 3)Poor or missing markings
Potential health and safety issues
Untidy stores area
Lots of unneeded equipment &materials
Gradual decline over time
Business Problem:• Standards at the Strensham depot had gradually declined over
time. The layout was confused and many parts of the site were cluttered, inefficient and not very well organised. This was having an impact on our ability to manage resources effectively, in particular at the start and end of shifts.
Root cause analysis:• Lack of local ownership / lack of clear accountability• Depot organisation was not seen as a business priority
Information overload
Time wasted looking for missing forms
Strensham – Sort, Straighten, Sweep (2 of 3)
Action taken:• Photos taken of “as is” layout to highlight waste,
issues and inefficiencies• Rubbish cleared away• All unneeded items red-tagged for 30 days• Drew up an inventory of all red-tagged items• Action plan drawn up to address issues• Worked with operatives to design a new depot
layout and a new one-way system
Strensham – Standardise & Sustain (3 of 3)
Key Improvements:• Disposed of unneeded and damaged
materials to create more space• New layout designed with input from
operatives• Markings / signage being introduced to
ensure that all materials & vehicles are kept in the right place
• One way system designed to optimise vehicle movements and reduce need for reversing
• Team is now creating a simple audit plan to help maintain standards
Business Benefits:• Improved safety for operatives• Improved productivity at start / end of shift• Easier to find what you are looking for• Easier to access / manage materials• Quicker to load / unload vehicles
New depot layout is safer and more efficient
TfL “5S” Exercise Park Royal Depot
Workplace Organisation – Park Royal Redesign (1 of 2)
No markingsto show whatbelonged where
Potential health and safety issues
Old, damaged orunneeded materials
Broken barrierallowed uncontrolled access. Materialson view were atemptation tothieves
Materials stored in thewrong place and / ordifficult to access
Inefficient use of depot space
Old layout did notmake the bestuse of space
Business Problem:• The Park Royal depot was short on space and not very well organised.
This was having a significant impact on our ability to manage resources effectively, in particular at the start and end of shifts.
Root cause analysis:• Lack of local ownership / accountability• Depot organisation was not seen as a business priority
Limited space for parking vehicles over night
Park Royal “To be” Design (2 of 2)
Everything now has a designated place and thelayout reflects the needs of the overall operation.
Action taken:• Photos taken of “as is” layout to highlight waste,
issues and inefficiencies• Mapped out “as is” and “to be design layouts• Action plan drawn up to address issuesKey Improvements:• Disposed of unneeded and damaged materials to
create more space• New layout designed with input from operatives• Markings / signage being introduced to ensure that
all materials & vehicles are kept in the right place• One way system designed to optimise vehicle
movements• Simple audit plan to be developed to help maintain
standardsBusiness Benefits:• Improved productivity at start / end of shift• Easier to access / manage materials• Improved safety for operatives
New depot layout is helping to improve productivity
Workplace Organisation – Audit Plan
What we have done so far:
Workplace Organisation - Strensham Depot
What we have done so far:
Workplace Organisation - Strensham Depot
What we have done so far:
Workplace Organisation - Strensham Depot
What we have done so far:
Workplace Organisation - Strensham Depot
Workplace Organisation - Strensham Depot
Workplace Organisation - Strensham Depot
Workplace Organisation - Strensham Depot
Workplace Organisation - Strensham Depot
