5S for Teammates

8/14/2019 5S for Teammates

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WelcomeWelcomeWorkplace Organization & Housekeeping 101

Kurt Fink

Corporate Manager Marketing & Public Rel.

15 years of Lean & Six Sigma experience

Workplace Organization & Housekeeping 101

Kurt Fink

Corporate Manager Marketing & Public Rel.

15 years of Lean & Six Sigma experience


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ObjectivesObjectives

Present the 5S history & methodology

What is in it for the MFG Teammates

Define what the Teammates role will be

Learn to SEE

Begin the process!

Present the 5S history & methodology

What is in it for the MFG Teammates

Define what the Teammates role will be

Learn to SEE

Begin the process!


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The Challenges

In order to become a Profitable company,

MFG needs to do three things well, all at

the same time!Reduce

CostImproveQuality

CompetitiveFaster

ReduceLead Time

Better


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These Challenges can only be

met, through a continuous war onWaste


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Waste

Waste is an activity which, from the

customer point of view,

is Not needed!


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7 Types of WASTE

Transportation

Defects

Unnecessary

Inventory

Over-Production

Processing

Motion

Wait time


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Over-production - Waste

Definition: Producing more than

needed by the customer orfaster than the customercan take it.

Process 1 Process 2

Extra

ProcessingDefects Inventory

Waiting

Time

Motion

Correc

tion

WHO IS YOUR CUSTOMER???


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Waiting Time - Waste

Definition:

Cycle Time That Is Too Long

Due To Insufficient Organization

Operator Wait Time Ex: Waiting on a machine to be fixed

Machine Wait Time Ex: Waiting on materials from the

previous process


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Transportation - Waste

Definition

Any Material Movement That

Does Not Directly Support a

Lean Manufacturing System

Parts temporarily on racks

Multiple handling

Excessive travel


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Processing - Waste

Definition:

The use of the wrong set of

tools or wrong procedures,which will take longer than

required!

Parts


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Unnecessary

Inventory -

Waste

Definition:

Any Supply in

Excess of Process

Requirements

Parts

Parts

Parts

Parts

Parts

Parts

Parts

Parts

Parts

Parts

Parts

The Evils of Inventory

Takes up Space

Hides Problems Could damage products or wind up

being obsolete


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Motion - Waste

Definition:

Any Movement of

Teammates Which Does

Not Contribute Added

Value To The Product, such

as: too much walking,

stretching, bending,reaching.


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Defects - Waste

Definition:

Repair of a Product

in order to deliver

the right quality Rework

Repair Re-inspect


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War On Waste starts withimproving the Workplace

organization & Housekeeping

or

Implementing

War On Waste starts withimproving the Workplace

organization & Housekeeping

or

Implementing

In order for MFG to become aWorld Class Company, we must

initiate a War on Waste

In order for MFG to become aWorld Class Company, we must

initiate a War on Waste


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History of 5SHistory of 5S

Started by Toyota Motor Company in the 1950s

Total Productive Maintenance Program

Eliminate unnecessary equipment downtime (Line Pulls)

Increase life of capital equipment investments

Improve Safety for associates

Improve Quality of parts produced

A place for everything and everything in its place.

Started by Toyota Motor Company in the 1950s

Total Productive Maintenance Program

Eliminate unnecessary equipment downtime (Line Pulls)

Increase life of capital equipment investments

Improve Safety for associates

Improve Quality of parts produced

A place for everything and everything in its place.


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Where did Toyota get the idea???Where did Toyota get the idea???


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Good house keeping

A barometerof how well the business is being run

A method to reduce Waste

A method to improve Safety

The foundation to become a World Class Company

A way of life Culture within the organization

Good house keeping

A barometerof how well the business is being run

A method to reduce Waste

A method to improve Safety

The foundation to become a World Class Company

A way of life Culture within the organization


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MFG Entity

RED TAG EVENT


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Sort - Separate, red tag, remove from the workplace anyitem that is not immediately needed

Set In Order Orderliness: arrange items so that they

are identified and easy to reach

Shine Cleanliness: sweep the floors, wipe off

equipment, paint walls and equipment

Standardize - Formalize activities, frequencies, and

responsibilities

Sustain - Discipline, practice, audit, and repeat these

procedures so they become a way of life

Sort - Separate, red tag, remove from the workplace any

item that is not immediately needed

Set In Order Orderliness: arrange items so that they

are identified and easy to reach

Shine Cleanliness: sweep the floors, wipe offequipment, paint walls and equipment

Standardize - Formalize activities, frequencies, and

responsibilities

Sustain - Discipline, practice, audit, and repeat these

procedures so they become a way of life


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If in doubt, move it out!


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Red Tag Procedure:

Identify unneeded items in an area

Ask, what is this? Do we need it? Keep it? If yes, How Many?

Store it?

Dispose it?

Red tag staging area - for final review

One time event only!


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Red Tag Labeling: When in doubt, put a red tag on it!!!

Common places to find clutter:

Shelves and lockers

Aisles and corners

Tool and gauge cribs

Odd corners, under tables, behind

machines,...


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Location CriteriaPRIORITY FREQUENCY OF USE HOW TO STORE

Low Less than once a yearA few times a year Distant storage

Medium Once every 2-6 months In the plant

Once a month Near the use point

Once a week Within eyesight

High Few times a week At point of use

One or more times a day


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A Place For Everything

and

Everything In Its Place


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Observe how Teammates get things inand out

Study variables:

Distance to parts Distance to tools

Frequency of use

Time required to take out and

put away objectsNote: Time values for each variable might be

small but think of the cumulative effect, andimpact on productivity


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Designate Storage Locations

Containers, boxes, cabinets,

shelves, and racks must be

identified

Materials and tools should be

waist to shoulder high

Frequently used tools should

be kept at point of use Use shadow boards where

practical Good Visual Management Tool!


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Clean and paint, walls, floors, and equipment

Divide area in small manageable sectors

Define Who is the owner/responsible for cleaning

Define what are the cleaning rules Set time frequencies for cleaning

Be aware of:

Clean equipment is much more easier to read

Quality issues or cause of problems become more evident


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Implement working procedures forcleaningUse pictures! A picture is Worth a Thousand

Words

Specify responsibilities

Indicate frequencies, and specific times forcleaning

Borders on the floor for: pallets, WIP, endproduct

Visualize good and out of rangeparameters

Red Light warnings for equipment failures

Preventive Maintenance indicators


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Do not let the daily problems take your focus away from 5S!

Post 5S bulletin boards in each area

Post before and after pictures on bulletin board to show the

improvements

Keep 5S rankings and progress reports visible

Active management involvement AT ALL LEVELS

Perform frequent (monthly) formal 5S audits


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Frequent audits indicate the level ofproficiency

What are we looking for?


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Sort

Unneeded items have been completely disposed of

All unneeded items are stored away from work place(awaiting disposition)

It is easy to distinguish between needed and unneeded items

Unneeded items do not reappear in the area

5S Audit System



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Set In Order

All tools and gauges are identified and placed in their properlocation. Supplies and raw materials are clearly marked and intheir proper location.

Color-coding, outlining or other methods are used to facilitateplacement of tools, gauges, supplies and materials.

Location and item indicators are clearly used for tools, gauges,supplies and raw materials. Aisles are clearly marked.

5S Audit System



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Shine

Cleaning tasks include dirt preventing methods for Floors, Walls,Tools, Fixtures, and Gauges.

Cleaning tasks have been established, documented, and postedon a checklist.

The work area is cleaned according to the checklist.

The work area is cleaned on the proper frequency.

5S Audit System



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Sustain

A disciplined system of control and maintenance is in place toassure the 4 previous steps of 5S are maintained at the highestpossible level.

All Teammates have been educated on the principles of 5S and Waste.

5S practices and audits are in place throughout the facility.Improvements are identified and implemented.

5S Audit System



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Before After


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After


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Before After


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BeforeAfter


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E i 30 i t


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Exercise: 30 minutes

Take a look at your current area

Identify and write down things you

would improve

Discuss findings with the group

Pictures from the areas


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AfterBefore


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What did you see?

Overproduction ______________________________

Delays (waiting time)__________________________

Transportation _______________________________

Process_____________________________________

Inventories__________________________________

Motions ____________________________________

Defective products ____________________________ Untapped Resources __________________________


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What is in for YOU!

5S Aims on


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5S Aims on

Teammate Participation

100% Teammate5S education

Teammates will be involved in Sorting, Set In Order,Shining, and Sustaining

Teammates will be the main source for improvement ideas

Teammates will help determine individual responsibilities for

each area

5S will be included in the job descriptions


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5S Means Teamwork

5S can only work if all Teammates act as a Team

Each shift will have to maintain the 5Ss

Each Teammate will have clear responsibilities

Roles and Responsibilities


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You the Leader/Trainer:

Learn as much as you can about 5S

Educate co-workers

Be enthusiastic and promote 5S

Take initiative by implementing 5S in your area

Ask manager for support and resources

Participate in implementing and promoting 5S

Bring your 5S ideas to your manager

Lead by example

Roles and Responsibilities

5S Benefits for the


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5S Benefits for the

Teammates Better and safer workplace

Eliminates the search time for tools and

materials, these will always be at the work cell

Teammates will have more fun and less stress

Preserve our investment in MFG, and improve

long term employment, contribute to profit sharing
http://www.hands.com.br/mod_modulos.asp?id=59


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5S will be as important as Qualityand

Productivityand Attendance

5S will be included in the Teammate

evaluations

Will be an important part of the

MFG work routine!

Clean-up and organize your work area every day so thateach new day is easier and safer than the day before

Share your input with your leaders so that the tools you

need will be available to you, increasing your efficiency.

I l ti 5S


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Lets get started!

Meet Tomorrow @ 7:00 am

Be prepared to think outside the

norm!

Implementing 5S


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Determine the area which will be part of the scope

Define the boundary limits

Take before pictures of the area

Establish a red tag holding area (COMPLETED)

Come to an agreement who will be responsible for each area

Steps for the 5S Team

Next Steps for the 5S Team


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Make an initial audit through this area and look for

everything that needs improvement

Write down the required improvements (always think

how can we create a better work environment!)

Be very specific.

Indicate what, where, who, and when.

p

(continuation)


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Summarizing!


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MFG Entity


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Points to Remember

1. Take responsibility for your work

environment

2. A place for everything, and everything

in its place If in doubt, move it out!

3. Develop habits you wont forget


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Documents

5S for Teammates