Lean in Action 5S System: Techniques for Efficient Workplace Organization

1. Lean in Action5S System: Techniques for Efficient Workplace Organization Management Meeting Month X, 20XX

2. What is 5S? • A visual method of workplace organization • 5S helps to: • Have needed material, tools, supplies, and documentation at hand, organized, and identified • Maintain a clean work area with tools and equipment in top condition • Standardize workplace organization • Maintain a occupationally-safe, ESD-safe, FOD-free workplace

3. Why employ 5S? • An organized, clean workplace: • Shortens Span Times • Reduces the non-value added work of searching for materials, tools, equipment and paperwork • Reduces Floor Space requirements • Prevents and detects errors and defects • Raises team pride and job satisfaction • Makes work easier to accomplish • In short, an organized workspace • enhances safety • improves quality • and reduces cost and cycle time

4. Elements of a 5S Program • Sort • Set in Order • Shine • Standardize • Sustain

5. 5S - Down to Basics SORT Remove all non-essential items from around the work area. Any essential items that do not fit or work, or are broken, are tagged for action. SET IN ORDER A place for everything and everything in its place. Arrange items so they can be found, retrieved and returned easily. SHINE Remove dust, dirt & debris. Cleaning will also highlight any previously unforeseen problems. Prioritize safety, quality and reliability issues. STANDARDIZE Spread through the work place. Checklists are made showing exactly where and when regular maintenance should take place. SUSTAIN Everyone who uses the work area is encouraged to adopt the new system. Eventually the new arrangements will become the culture. For 5S to be effective, everyone must take full responsibility for their own area of work, while supporting 5S throughout the shared workplace

6. Elements of a 5S Program • Sort • Eliminate the clutter “When in Doubt, Throw It Out!” • Create a place for everything and put everything in its place • Arrange needed items so that they are easy to use and label them so that “anyone” can find them and put them away • Use Visual Aids to aid understanding and minimize complexity • Shadow Boards • Labels (“Return addresses”) • Clearly marked places for items that are movable • Area Identification signs • Lines on the floor • Set in Order • Shine • Standardize • Sustain

7. Sort: Workstations What work is being Performed?

8. Sort: Workstations Before After

9. Sort: 5S Holding Area • If unsure whether or not to discard an item, a 5S Holding Area should be established • Items should remain in the area for a short period of time, reassessed, and either discarded or (if needed) placed back into the work area • All items should have a 5S Holding Tag for identification (next slide) • Items will be logged in a database and tracked

10. Date placed in Holding Area Individual that tagged the item Area item came from (stock, assembly, Test area etc.) Short description (include P/Ns if necessary) Reason why in Holding Area (obsolete, not needed, broken, etc.) Proposed next steps to take Used to track all items Sort: 5S Holding Tag (example) • Tag is used for tracking and maintaining items that are in the 5S Holding area that are to be reevaluated for either disposal or for placement back into appropriate area • 5S Holding Tag should be filled out completely and logged into database example

11. Sort Set in Order Organize and label, set boundaries and limits “A Place for Everything and Everything in its Place” Why:Makes things easy to locate, easy to put away, readily apparent if missing Results:No wasted time looking for tools or documents; they are identified and on hand when needed One-Step Rule:Nothing that is used daily is stored more than a step away. Improve economy of motion, save valuable seconds, and make the job less frustrating. 45 Degree Rule:Arrange the immediate work area layout to minimize twisting, especially applicable for bench work. If something weighs more than a few pounds, make sure it is beyond immediate reach so the lifter must reposition the body properly for lifting. Strike Zone Rule:Store things above the knees and below the chest. This will help to reduce the chance of back strain. Higher the Pounds - Closer to Knuckles:Locate heavy items to eliminate bending, stooping or unnecessary arm movements during lifting. Elements of a 5S Program

12. Set In Order: Tool Crib Before Organization

13. Set In Order: Tool Crib After Organization

14. Set In Order: Unorganized Toolbox

15. Set In Order: Organized Toolbox

16. Sort Set in Order Shine Clean everything, inside and out “Inspection Through Cleaning” Why: Nobody works well around a mess; FOD can ruin or delay a mission; a clean workplace promotes pride and demonstrates an interest in quality; cleaning allows us to find problems with equipment and tools in time to prevent delays Results:A bright, clean, organized, work area that promotes confidence, quality, and on time delivery Standardize Sustain Elements of a 5S Program

17. Shine: Before Cleaning

18. Shine: After Cleaning Recognize and Reward the Team !!

19. Sort Set in Order Shine Standardize Document the standard method for workplace organization so we always do things in the same way “Everything in a State of Readiness” Why:Standardizing the way we maintain a work area and perform our work promotes consistency in how work is approached and accomplished, and allows easier cross training and movement of personnel Results:Standardized presentation of work areas, material and tools for work Sustain Elements of a 5S Program

20. Standardize: Best Practices for Organization Old way New Standard

21. Standardize: Best Practices for Organization Old way New Standard

22. Standardize: Shadow Part Kits

23. Sort Set in Order Shine Standardize Sustain Maintain discipline through systems and a supportive culture “Launching quality with persistence.” Why:Without sustaining the first 4 Ss, they will die; promotes a continuous improvement environment Results:Ever improving quality, cycle times, on time commitments; high motivation, recognition for excellence Elements of a 5S Program

24. Sustain: Teams set Standards to meet Customer Demand • Communications Board in the area shows the Continuous Improvement List, Current Schedules and Metrics • White board is for anyone to post any issue to be put on the Continuous Improvement List

25. Sustain: Teams set Standards to meet Customer Demand – Show progress Publicity !

26. Sustain: Standard Assessment Score (spider web chart)

27. Getting Started • Form 5S Teams: • All players who regularly work in the work are/ center • If you use tools, hook up & use test equipment, handle parts, or regularly handle travelers, drawings or Work Procedures in the area, we want you on the team • Conduct 5S Kaizen event: • Learn what a 5S workplace looks like • Only needed things present • Clean; dustless • All things organized, arranged and identified • Visuals help tell at-a-glance the state of the workplace (signs, posters, arrows, charts, schedules, etc.)

28. Getting Started • Plan for Success: • Set team 5S goals • Appoint 5S champion(s) • First Steps: • Post 5S team roster with leader, champions, and backups for calibration, shelf life, job supplies • Create a 5S holding area • Sort unneeded items and move them to the 5S holding area • Conduct monthly 5S Assessments • Using Standard 5S Assessment

29. Monthly 5S Scoring -- example only --

30. SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN Work place checks are Necessary and Tools, supplies and Work/break areas and Work place methods are not randomly performed and LEVEL 1 unnecessary items are materials are randomly machinery are dirty and consistently followed and are there is no visual Just Beginning mixed together in the located. disorganized. not documented. measurement of 5S work area. performance. Work/break areas and A recognizable effort has Necessary and Designated location machinery are cleaned on Methods are being improved, LEVEL 2 been made to improve the unnecessary items are established for all items a regularly scheduled but changes have not been Focus on Basics condition of the separated. as needed. basis. Key items documented. workplace. identified. Working environment changes Designated locations are Visual Controls are in are documented and 5S schedules and safety All unnecessary items marked to make LEVEL 3 place for labeling and performed the same by all practices have been have been removed organization more visible Make It Visual quantity levels. Machines employees. Visual Controls are developed and are from the work area. (color, outlines, labels, are cleaned daily. in place for labeling and utilized. numbers, etc). quantity levels. A dependable, Documented method of 5S techniques are LEVEL 4 documented method visual sweep to identify Substantial process Follow through with 5S understood and practiced Focus On has been established to items out of place or documentation is available and schedules and safety continually. 5S schedules keep the work area free exceeding quantity followed. practices is evident. Consistency are posted and followed. of unnecessary items. limits. Waste is immediately There is a general Dependable, documented Everyone is continually seeking LEVEL 5 visible and triggers a Defined process to appearance of a confident method of preventative the elimination of waste with Focus on planned response with evaluate and improve understanding of, and cleaning and changes documented and root cause analysis and movement and motion. adherence to, the 5S Prevention maintenance. information shared. corrective action. principles. Levels of Achievement What Level is Your Work Area?

31. Let’s Go ! • Designate and identify location(s) for cleaning gear • Tape aisle ways and perimeter of work areas • Shadow box all needed tools; hang large tools on outline boards • Sweep/ shine floors; post a cleaning schedule w/ names & assignments • Clean in corners, around I-beams & columns; wipe off wire molds, vents, equipment, cabinets so that there is no dirt, dust, paper clips, loose pens, loose papers, sticky notes, throw away or put away ANYTHING laying around • Remove things from the top of cabinets, consoles, tables, chairs, etc.

32. Let’s Go ! • ANYTHING that HAS to be stacked is stacked neatly (90°) in a designated location • Implement visual helps to indicate where things go, including cleaning and safety gear • Conscientiously conduct FOD and ESD surveillance • Perform TPM on equipment • Keep aisles clear; limit extension cords; no tripping or tipping hazards; call attention to safety equipment locations • Visually highlight equipment safety features (emergency stops, stay out areas, etc.)

33. Let’s Go ! • Post evacuation routes near exits • ID chemical storage cabinet locations and check frequently • ID and Wear protective equipment • Have MSDS sheets in a clearly marked area • Find a place for EVERYTHING; mark its perimeter and identify it • Maintain the 5S bulletin board • Evidence “clean-as-you-go” throughout the day • Assess the area monthly; discuss and act on results • Post results in 5S display area • Hang posters, signs, etc. to sustain 5S

34. Lean in Action5S System: Techniques for Efficient Workplace Organization Management Meeting Month X, 20XX