it-465ch4

Chapter 45S

IT-465 Lean Manufacturing

What are the 5Ss?They are the keys to workplace organization, housekeeping, and visual management.Simple and produces:Increase in qualityIncrease in productivityCleaner workplace which produces a safer workplaceEarlier i.d. of abnormal business situations


WasteWaste is anything other than the MINIMUM amount of people, time, equipment, material, parts, and space required to ADD VALUE to the product.

The 5Ss apply everywhere.


The 8 General Types of WasteScrap/Rework/RemakeTransportationMotionWaiting TimeInventoryOverproductionOverprocessingUnderutilized Human Resources


The 5SsSortProper arrangementStraighten (Store)OrderlinessSweep (Shine)CleanlinessSchedule (Standardize)Cleaned up, standardized.SustainDiscipline, practice and repeat.


The Origin of 5S


Lack of 5SHides safety problemCreates wasteLimits a companys ability to satisfy their customers.You never get a second chance to make a first impression.World class facilities develop beginning with the 5Ss, and facilities that fall, fall apart beginning with the 5Ss (Hiroyuki Hirano)


Implementing 5S5S Implementation Steps OutlinePrelaunchStep #1.Form, train, & develop 5S teams.Step #2.Develop the 5S model

LaunchStep #3.AnnouncementStep #4.Train the plant in 5S


Implementing 5SStep #1. Form, Train, and Develop 5S Grading/Recognition Teams.

Rule #1:Leaders must lead. Everyone must be involved. Applies to the office and the shop floor.

Rule #2:Everyone must be trained in 5S


Implementing 5SStep #2. Develop the 5S Models: The Islands of Excellence Using the Grading/Recognition Teams.


Implementing 5SStep #3. Kick Off the 5S Implementation: Tell Your Entire Team About the Importance, Goals, and Vision of 5S.ImportanceEstablish plant wide discipline & org baseline that supports all improvement activities.GoalsImprove safety & pride in the work place. Improve quality and productivity.VisionIslands of Excellence, World Class Enterprise.


Implementing 5SStep #4. Train the Entire Plant in 5S.Sorting, proper arrangement.Improved safetyImproved communication between team membersSmoother work flowImproved quality and productivityClearly distinguish between what is needed and what is not needed.When in doubt, move it outRule #3. Facility environmental, health, and safety procedures must be followed at all times in the cleaning, moving, and disposal of equipment and material.


Implementing 5SStep #4 Continued.Sorting using the Red Tag systemA method used to i.d. items that are found in the work area, but their use and need are unknown.Red Tag ProcedureDedicate a red tag storage siteLook at all items critically, then place tagsRecord all tags on log sheetGive all users and shifts 48 hours to reviewMove items to red tag storage siteManagement review in one weekMake a list of tools that are required, but not available.Rule #4. The Red Tag System is for one-time use only; it is not an ongoing crutch for future clean-ups.


Implementing 5SStep #4 Continued.Straighten, orderliness. (Store)Improved safetyImproved qualityImproved productivityA place for everything, and everything in its place.Rule #6. Use a ceiling-down strategy. The first straighten and sweep begins with the ceilings, walls, and floor.


Implementing 5SStep #4 Continued.Straighten, orderliness. (Store)Organize everything that remainsMake locations visible and self-explanatory.Designate storage locations for everythingToolsGaugesCleaning suppliesJob aides, information sheets, etc.Keys to organizationVisual controlsImmediate retrievalImmediate return


Implementing 5SStep #4 Continued.Sweep, cleanliness. (Shine)Improved safetyImproved team morale and ownershipImproved qualityReduced equipment downtimeSweep the floors, wipe off equipment, paint if necessary, and make sure everything stays clean.


Implementing 5SStep #4 Continued.Sweep, cleanliness. (Shine)Three Phases of ShineDaily cleanlinessCleanliness inspectionsCleanliness MaintenanceAttach a maintenance card (or TPM Card) to identify the problem.Keys to CleanlinessMust be done on a regular basisCleaning tools and supplies available at point od usageAssign specific individuals to tasksDesignate specific cleaning time


Implementing 5SStep 4 Continued:Schedule, Cleaned up. (Standardize)Improved safetyImproved team morale and ownershipPave the path to step #5, Sustain.Standardize and maintain the use of sort, straighten, and sweep.Develop 5S activity checklists for all mfg and office areas.Rule #7. Have regular inspections.Rule #8. Have recognition and reward programs


Implementing 5SStep 4 Continued:Schedule, Cleaned up. (Standardize)Develop and implement best practicesUse a 5S checklist to i.d. what will be done, who is responsible and when the task is to be done.Visual Workplace Color-coded ZonesRed Inventory too low, re-orderGreen Inventory level okYellow Inventory too high, stop productionVisual StandardsQuality board to record problemsPictures representing types of defectsEveryone can easily identify defects


Implementing 5SStep #4 Continued.Sustain, DisciplineImproved safety through better housekeepingImproved team morale and ownershipReduced overhead costs.Practice and repeat these procedures until they become a way of life throughout the entire company.Sustain is the discipline or rope that ties the other 4Ss together.Rule #9. 5S has to be self sustaining.


Implementing 5SStep 4 Continued:Sustain, DisciplineContinue to sort, store, shine, standardize, and sustain the work area.Companywide promotion of disciplineMake properly maintaining correct procedures a habit:Use inspections/audits by top managers to evaluate each workstation and to provide feedback.Chart the audit scores on a visual display board to show progress/deterioration


Implementing 5SChart production schedules and team improvements5S BenefitsEliminates excess equipment & inventoryReduced absenteeismFewer equipment breakdowns & longer lifeBetter understanding of equipment conditionsFewer defects and higher qualityDefects are made obviousEfficient and effective organizationSaves time, cost, and makes workplace easier to maintainImproves production schedulesMotion and waste reductions


Implementing 5SSummaryImprove VisualsBrainstorm better visualsPhotograph completed areaCreate a to do listConduct final 5S Audit using scorecardAssign ownership of completed area


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