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5s (Workplace Organization)Implementation

CONFIDENTIAL AND PROPRIETARY – © 2008 KELLOGG NA COMPANY

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Understanding the Kellogg Understanding the Kellogg approach to LEAN manufacturing & approach to LEAN manufacturing &

how it effect you.how it effect you.

One does not do 5-S or One does not do 5-S or LEAN, one must live it every LEAN, one must live it every

day; day in and day outday; day in and day out!!

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AgendaAgenda

What is 5_S?What is 5_S? 5_S History & Background.5_S History & Background. Why 5_S at Kellogg?Why 5_S at Kellogg? How it effects our WorkplaceHow it effects our Workplace 5-S Process5-S Process Examples at KelloggExamples at Kellogg ReviewReview

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What is 5 S?

SSort, ort, SSet, et, SShine, hine, SStandardize, & tandardize, & SSustainustain

It is a concept born from LEAN It is a concept born from LEAN manufacturingmanufacturing

It is a new developing culter at It is a new developing culter at KelloggKellogg

GMPs are its foundation.GMPs are its foundation.

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History

Henry Ford first perfected flow production in Henry Ford first perfected flow production in the early part of the 20the early part of the 20thth Century. Century.

Toyota improved Ford’s design in the 30s and Toyota improved Ford’s design in the 30s and 40s developing its LEAN production system 40s developing its LEAN production system to be more adaptive to needs and changes.to be more adaptive to needs and changes.

It is based on “order & structure” It is based on “order & structure” It was required to ensure the sustainability of It was required to ensure the sustainability of

the “Visual Factory” concept.the “Visual Factory” concept.

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Benefits It supports Kellogg SAFETY initiatives.It supports Kellogg SAFETY initiatives. People feel better about their work area People feel better about their work area

and take pride and ownership in the and take pride and ownership in the results. (Looks better, feels better)results. (Looks better, feels better)

Individuals have more control over their Individuals have more control over their workspace through identifying what, workspace through identifying what, where, and how much they need as well where, and how much they need as well as maintaining it in a visual atmosphere.as maintaining it in a visual atmosphere.

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5 S Kellogg Benefits

Supports Kellogg SAFETY initiatives. Promotes & supports discipline in the

work place. Supports & enhances GMPs. Provides visual organization. Sets the foundation for consistent &

sustainable processes.

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Eliminates the waste resulting from disorganization.

Helps to eliminate duplication of unwanted/un-needed materials.

Kellogg sees this as a catalyst for Continuous Improvement.

5 S Kellogg Benefits cont.

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5S Workplace Organization

Key Items for Implementation & SuccessKey Items for Implementation & Success Identify a Plant Resource to become the Identify a Plant Resource to become the

subject matter expert.subject matter expert. Identify a Pilot Area, and educate everyone Identify a Pilot Area, and educate everyone

working in that area on 5S. Take “before” working in that area on 5S. Take “before” pictures. (Recommend only 1 area at a time.)pictures. (Recommend only 1 area at a time.)

5S initiative must support existing Safety, 5S initiative must support existing Safety, Quality, Ergonomics and Company Quality, Ergonomics and Company Objectives.Objectives.

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5S Workplace Organization

Key Items for Implementation & SuccessKey Items for Implementation & Success People must “let go” of personal preferences.People must “let go” of personal preferences. Make the facility “VISUAL”.Make the facility “VISUAL”. Make the workplace “Easy to Use”.Make the workplace “Easy to Use”. Think of new methods to make work easy Think of new methods to make work easy

(don’t criticize methods that fail).(don’t criticize methods that fail). Think outside the box & don’t accept excuses Think outside the box & don’t accept excuses

for “why it has to be that way”.for “why it has to be that way”.

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5S Workplace Organization

Key Items for Implementation & SuccessKey Items for Implementation & Success Continually improve – it won’t be perfect in Continually improve – it won’t be perfect in

an instant.an instant. Everyone owns an area (even common areas).Everyone owns an area (even common areas). Correct mistakes immediately – never ignore Correct mistakes immediately – never ignore

out of standard.out of standard. Ask Why? Five times to find the root cause.Ask Why? Five times to find the root cause.

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5S Workplace Organization

Key Items for Implementation & SuccessKey Items for Implementation & Success To change the current state you must change To change the current state you must change

the culture.the culture. EveryoneEveryone must “buy-in”. must “buy-in”. Live 5S on a daily basis.Live 5S on a daily basis. Lead by example not by exception.Lead by example not by exception.

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The 5 S Process

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SORT Definition: Involves the sorting of the

contents in an area and removing unnecessary items.

Why: Problems are reduced & it improves work flow & communication.

Problems avoided: Clutter in the workplace. (i.e. Time wasted searching for tools and/or parts. Un-needed inventory such as parts and/or material.)

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SET IN ORDER DefinitionDefinition: Involves the arrangement of : Involves the arrangement of

the necessary items for easy and the necessary items for easy and efficient access and keeping them in efficient access and keeping them in that order.that order.

WhyWhy:: Eliminates many kinds of waste. Eliminates many kinds of waste. (i.e. Scrap, time, lost opportunity.)(i.e. Scrap, time, lost opportunity.)

Problems avoidedProblems avoided: Waste in motion, : Waste in motion, searching, human energy, excess searching, human energy, excess inventory, & defective products.inventory, & defective products.

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SHINE DefinitionDefinition:: Involves the cleaning of Involves the cleaning of

everything in the work area and keeping everything in the work area and keeping it clean.it clean.

WhyWhy: Use cleaning as a way to ensure : Use cleaning as a way to ensure that the area & equipment are that the area & equipment are maintained as they should be “ in like maintained as they should be “ in like new condition”.new condition”.

Problems avoidedProblems avoided: Low moral, safety : Low moral, safety issues, & hidden defects.issues, & hidden defects.

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STANDARDIZE Definition: Involves creating or

updating SOPS (KSAT – Level of Detail) for keeping the area organized, orderly, clean and make the workplace more visual and obvious.

Why: Integrates first 3 Ss into a unified structure.

Problems avoided: helps to prevent regression.

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SUSTAIN DefinitionDefinition: Involves education, : Involves education,

communication, and supervisory and communication, and supervisory and management engagement to ensure management engagement to ensure that everyone adheres to the standards that everyone adheres to the standards developed for workplace organization.developed for workplace organization.

WhyWhy: Benefits of doing it exceed the : Benefits of doing it exceed the excuses of not doing it.excuses of not doing it.

Problems avoidedProblems avoided: Clutter, chaos, & : Clutter, chaos, & bad communications.bad communications.

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The 1st “S” Sort

UN-NEEDEDUN-NEEDED(Red Tag)(Red Tag) meansmeans:: Unsafe/ DefectiveUnsafe/ Defective ObsoleteObsolete Hoarded junkHoarded junk Too manyToo many Rarely used parts & Rarely used parts &

equipmentequipment UnknownUnknown

NEEDEDNEEDED(Green Tag) (Green Tag) means:means: Used for daily workUsed for daily work Used periodically Used periodically

(changeovers)(changeovers) Used by someone in the Used by someone in the

areaarea

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The 1st “S” Sort

Basic Rules for Red Tagging Any item w/ a fixed asset number must go

through a special disposition process. Any parts such as motors, gearboxes,

bearings, belts, etc. will be referred to Maintenance & Stores for final disposition.

Chemicals will be referred to Safety Mgr. & Quality Mgr. for disposition directions.

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The 1st “S” Sort

Basic Rules for Red Tagging Team will establish a deadline for initial

disposition. (Usually 24-48 hrs.) Team to define a “Red Tag Area” to hold

items awaiting disposition. Raw materials are reviewed from a “visual

inventory” standpoint.

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The 1st “S” Sort

Basic Rules for Red Tagging Disposition for all items should be recorded

listing the item description, picture if applicable, & final disposition i.e. scrap, return to stores, etc.

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The 2nd “S” Set In Order Analyze the situation for the designated area. Target issues & areas to improve. Decide where things belong, how they should be

kept and agree upon the best location and method to address these concerns.

Make it obvious - “Visual Controls”. Labels & color coding (shows ownership, optimal

set-points). Signboards (metrics, component names, etc).

Make certain there is adherence to GMPs!

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The 3rd “S” Shine Inspect the work area and equipment, with an

emphasis on health and safety. Begin eliminating obvious defects on the shop floor

and on equipment. Identify areas needing attention such oil leaks,

frayed belts, excess grease, peeling paint. Itemize required materials such as cleaners,

degreasers, paint, etc. All material must be approved for use in a food facility.

Itemize work required & develop schedule.

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The 4th “S” Standardize Review & incorporate GMPs as required. Establish operations SOPs & maintenance work

instructions for the visual workplace. (KSAT-SAP) Create schedules and checklists that define

required activities and responsibilities. (SAP) Establish “visual controls” (sign-boarding). Establish procedures for maintaining & sustaining

3rd S –Shine.

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The 5th “S” Sustain Establish & promote routine audits to sustain

GMPs. Managers, Supervisors, and Team Leads must be

committed to establishing & maintaining the 5 Ss Adhere to first 4 S categories. Set practical goals and giving adequate feedback to

all. Implement a discipline for culture change to

maintain the 5 S concepts.

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Examples of 5_S Silverware organizers Library/Bookstores Traffic Signs & Maps Parking Lots Department, Building Supply, & Grocery

Stores Airports Fire Stations & Engines Fast food restaurants

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Areas In Need Of 5 S

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5 S in Action

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5-S Work Floors

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5-S Work Floors

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Organized Work Areas

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Review 5-S is a systematic organizational approach

to manufacturing Developed in its current form by Toyota SSort, ort, SSet, et, SShine, hine, SStandardize, & tandardize, & SSustainustain A new culture developing at KelloggA new culture developing at Kellogg A method we live EVERY day – NOT a one A method we live EVERY day – NOT a one

time occurancetime occurance 5-S is here to stay – let’s all get on board!5-S is here to stay – let’s all get on board!