1 / 38

5S Techniques

[To download this presentation, visit: https://www.oeconsulting.com.sg/training-presentations]

oeconsulting
Download Presentation

5S Techniques

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Standardize Sort Sustain Shine Set In Order © Operational Excellence Consulting. All rights reserved.

  2. NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg Learning Objectives 1. Understand the benefits of working in a clean and neat environment 2. Define the 5S principles, and identify visual tools 3. Explain how to apply the 5S principles and visual tools to enhance workplace organization 4. Learn how to kick start and launch a 5S initiative 5. Define the critical success factors for 5S implementation 2 © Operational Excellence Consulting. All rights reserved.

  3. Outline 1. Introduction to 5S 2. The 5S Principles – Step by Step 3. How to Conduct a Red-tag Sort Event 4. The Visual Workplace 5. 5S for the Operations 6. 5S for the Office 7. Implementing 5S 8. Sustaining 5S 3 © Operational Excellence Consulting. All rights reserved.

  4. Introduction to 5S § 5S is a structured program to implement workplace organization and standardization Standardize Sort § 5S represents five disciplines for maintaining a visual workplace Sustain Shine Set In Order § 5S is a foundation to Kaizen and Lean implementation, e.g. TPM 4 © Operational Excellence Consulting. All rights reserved.

  5. 5S Lays the Foundation for a Lean Enterprise Goals: highest quality, lowest cost, shortest lead times Just-In-Time • Continuous flow • Takt time • Pull system • Flexible workforce Jidoka Involvement Productivity • Separate man & machine work •Abnormality Identification • Poka yoke •Visual Control Heijunka Standardized Work Kaizen 5S 5 © Operational Excellence Consulting. All rights reserved.

  6. 5S Establishes a Baseline for Kaizen Activities Kaizen A P D Standardize Act Plan Kaizen C Check Do Standardize Kaizen Kaizen (改 Continuous Improvement 善) = 改 善 Standardize 6 © Operational Excellence Consulting. All rights reserved.

  7. 5S is a Cornerstone of Employee Engagement 5S Continuous Improvement Teams Suggestion System 7 © Operational Excellence Consulting. All rights reserved.

  8. 5S Can Be Integrated With Other Continuous Improvement Initiatives Business Excellence • Customer Orientation • QC Circles • Suggestion System • 5S • TPM • Automation • Robotics • TQC • Quality Improvement • Just-In-Time • Kanban • Zero Defects • Small Group Activities • Cooperative Labor- Management Relations • Productivity Improvement • New Product Development 8 © Operational Excellence Consulting. All rights reserved.

  9. 5S Helps to Eliminate Waste Over-production Producing more than what the customer needs Waiting Intellect Employees waiting for another process or a machine/tool Not using employees full intellectual contribution Over-processing Adding excess value when the customer does not require it Motion Extra physical/mental motion that doesn’t add value Waste Rework Reprocessing, or correcting work Transportation Moving product from one place to another Inventory Building and storing extra services/products the customer has not ordered 9 © Operational Excellence Consulting. All rights reserved.

  10. "A company that cannot successfully implement the 5S's cannot expect to effectively integrate JIT, re-engineering, or any other large-scale change. Good workplaces develop beginning with the 5S's. Bad workplaces fall apart beginning with the 5S's.” Dr. Hiroyuki Hirano © Operational Excellence Consulting. All rights reserved. 10

  11. The 5S Seiri Seiton Seiso Seiketsu Shitsuke The 5 Japanese words that start with S 11 © Operational Excellence Consulting. All rights reserved.

  12. What is 5S? Principles General Description Remove what is not needed and keep what is needed 1S Sort Arrange essential items in order for easy access 2S Set in Order Keep things clean and tidy; no trash or dirt in the workplace 3S Shine Establish standards and guidelines to maintain a clean workplace 4S Standardize Make 5S a habit and teach others to adhere to established standards 5S Sustain 12 © Operational Excellence Consulting. All rights reserved.

  13. What is the purpose of 5S? Immediately make problems visible 13 © Operational Excellence Consulting. All rights reserved.

  14. What 5S Is NOT § 5S is applicable only to manufacturing environments § A thorough spring cleaning § A program to impress visitors and customers § 5S is another “extra-curricula activities” § 5S has little or no impact on efficiency and customer satisfaction 14 © Operational Excellence Consulting. All rights reserved.

  15. Benefits of 5S § 5S makes our workplace more pleasant § 5S improves work efficiency § 5S and safety go hand-in-hand § 5S leads to better customer satisfaction and higher productivity 15 © Operational Excellence Consulting. All rights reserved.

  16. 1S : Sort § Principle • Stratification management • Dealing with the causes § Meaning • Distinguish between the necessary and unnecessary • Get rid of what you do not need • “When in doubt, move it out” 16 © Operational Excellence Consulting. All rights reserved.

  17. Attach Red Tags § Fill in everything except disposition B01 005 § Perform tagging swiftly § Place tags on all items in question Dot Matrix Printer 3 06/13/2007 § Move “tagged items” to a holding area Not in Use 17 © Operational Excellence Consulting. All rights reserved.

  18. Identifying Red-tag Targets Raw materials, procured parts, processing parts, in-process inventory, assembly parts, Semi-finished products, finished products Inventory Types of Items Machines, equipment, jigs, tools, cutting bits, gauges, measuring instruments, dies, carts, conveyance tools, worktables, cabinets, desks, chairs, supplies Red-tag Equipment Targets Floors, walkways, operation areas, walls, ceilings, lightings, shelves, storage areas, warehouses Physical Areas Source: 5S for Operators, Productivity Press 18 © Operational Excellence Consulting. All rights reserved.

  19. Sort: Disposal Methods Treatment Description Dispose of as scrap or incinerate items that are useless or unneeded for any purpose Throw it away Sell off to other companies items that are useless or unneeded for any purpose Sell Return Return items to the supply company Lend items to other sections of the company that can use them on a temporary basis Lend out Distribute items to another part of the company on a permanent basis Distribute Central red-tag area Send items to the central red-tag holding area for redistribution, storage or disposal Source: 5S for Operators, Productivity Press 19 © Operational Excellence Consulting. All rights reserved.

  20. 2S : Set In Order § Principle • Functional storage • Search elimination § Meaning • Arrange essential items in order for easy access • A place for everything • Everything in its place after use 20 © Operational Excellence Consulting. All rights reserved.

  21. 2S : Set In Order - Examples 21 © Operational Excellence Consulting. All rights reserved.

  22. 2S : Set in Order - Office Desk After Before An office desk before and after conducting 5S Sort, Set In Order and Shine. Clutter and unused items have been removed leaving only what is needed. 22 © Operational Excellence Consulting. All rights reserved.

  23. 3-Step Approach to Cleaning Common areas, walls, ceilings, lights, storage areas, toilets, “junk yards”, shelves, filing cabinets, etc. Macro Individual workstations, chairs, drawers, computers, cabinets, shelves, etc. Clear away things underneath your table! Individual Measuring instruments, e.g. micrometer, gauges, vernier calipers, contact surfaces, etc. Micro 23 © Operational Excellence Consulting. All rights reserved.

  24. Standardization is the Way to Sustain the Gains Improvement Without standardization, all my improvements will roll back with time… Future state Present state STANDARDIZATION Standardization is a tool that will ensure your improvements will be sustained. 24 © Operational Excellence Consulting. All rights reserved.

  25. 5S Audit Checklist & Results 25 © Operational Excellence Consulting. All rights reserved.

  26. 5S Radar Chart Sort 5 4.4 4 3 2 Sustain Set In Order 1 3.7 2.2 0 Standardize Shine 1.9 2.7 26 © Operational Excellence Consulting. All rights reserved.

  27. Everyday Visual Management 27 © Operational Excellence Consulting. All rights reserved.

  28. 3 Types of Visual Management • Label to make it perfectly clear where things belong and what the procedures are Visual Display • Quantify the path to targets for success • Graphs and Pareto charts Visual Metrics • Create an error-proofed environment to promote easy adherence to standards Visual Controls 28 © Operational Excellence Consulting. All rights reserved.

  29. Example of Visual Metrics Cycle Time Reduction WIP Backlog On Time 100% Product Profitability Internal Quality Rework Revenue Customer Complaints Process Costs 29 © Operational Excellence Consulting. All rights reserved.

  30. Measures should be integral and visible to a Continuous Improvement Process MEASURES TEAM MEETINGS IDENTIFY Lead time Quality Costs PROBLEM PRIORITY Innovation Flexibility Service THE IMPROVEMENT PROCESS IMPLEMENTATION ANALYZE FLOW CHART PLAN SOLUTION ANALYSE PROBLEM SCHEDULE OF ACTIVITY TASK RESP’Y TIMEFRAME MEASURE 1 2 3 4 5 6 30 © Operational Excellence Consulting. All rights reserved.

  31. Andon § A visual control device in a production area ANDON BOARD ANDON BOARD • Typically a lighted overhead display #2 #2 #3 #3 #4 #4 #1 • Gives the current status of the production system • Alerts team members to emerging problems § Serves as warning system to signal and identify problems in the process 31 © Operational Excellence Consulting. All rights reserved.

  32. Warning Sensors § Warning sensors signal the operator that there is a problem. These sensors use colors, alarms, lights to get the workers attention! § These sensors may be used in conjunction with a contact or energy sensor to get the operators attention. Color Code Lights connected to Micro switches & timers Lights 32 © Operational Excellence Consulting. All rights reserved.

  33. The 8 Steps of 5S Implementation 1 Establish a 5S Steering Committee Review & Improve 8 2 Conduct 5S Audits Define a 5S Implementation Plan 5S 7 IMPLEMENTATION PROCESS 3 Launch Mass Rollout Communications Campaign 6 Provide 5S Training & Education Start 5S Pilots 4 5 33 © Operational Excellence Consulting. All rights reserved.

  34. Launching a 5S Day 1 § Set aside half a day for this event • Best on Fridays or before a festive season or public holiday • Everyone in casual attire, e.g. T-shirts § Prepare sufficient cleaning equipment, detergents, paints, etc. § Speech by CEO on importance of 5S to all staff 34 © Operational Excellence Consulting. All rights reserved.

  35. 5S Launch Day in a Company Getting rid of things that are not needed 35 © Operational Excellence Consulting. All rights reserved.

  36. Example: 5S Improvement Project type: 5S Area: Sales & Marketing Office Team Leader: John Smith Before After Reasons project chosen: • Difficult to move around a cluttered office • Difficult to find information and supplies Tools used on project: • Cleaning equipment and tools • 5S principles Results: • Unwanted materials were discarded • Less waste – e.g. transportation, motion, waiting, etc. • Improved staff morale Next steps: • Conduct monthly 5S audits • 5S for other common areas 36 © Operational Excellence Consulting. All rights reserved.

  37. About Operational Excellence Consulting § Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. § The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions. § OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg 37 © Operational Excellence Consulting. All rights reserved.

  38. Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg 38 © Operational Excellence Consulting. All rights reserved.

More Related