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Manufacturing NZ

Implement the 5S workplace organisation method for efficiency. Learn how to Sort, Set in order, Shine, Standardise, and Sustain your workplace. Maximize productivity and morale.

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Manufacturing NZ

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  1. Manufacturing NZ 5S Introduction – Workplace Organisation

  2. Definition Workplace organisation is a visual and physical method of correctly organising the workplace. It ensures that only the required material and equipment is present, that it is in good condition, and that it is stored in a manner that aids the efficiency of the production facility or workplace.

  3. Step 1: SORT – clear out • Identify all items in the workplace which are not required to do the regular jobs, e.g. • Scrap material • Unused stillages • Unused Jigs and fixtures • Unnecessary tools • Obsolete components • Personal possessions • Etc. • These items should be immediately removed from the work area.

  4. Example of “Sort” on the factory floor • Many unnecessary items clutter the cell • All unnecessary items removed Obsolete parts Tables / benches Tools and fixtures A F A F Work in progress E E B B C F C F Scrap material Machines Containers of materials AFTER BEFORE

  5. Example of :sort” on the desk Things get hidden or lost In-Tray • Room to work • Easy to find things • Looks professional No room to work Looks unprofessional AFTER BEFORE

  6. Step 2: Set in order – create layout Properly identify, arrange and locate the material & equipment that is necessary to do the job. E.g. • Production components • Tooling and fixtures • Hand tools • Containers • Etc.

  7. Example of “Set in order” on the factory floor • Necessary item still with no home clutter up cell • All necessary items correctly located • Reduced congestion • Improved safety Tools and fixtures Tables / benches A F A F E B E B C F C F Containers of materials Work in progress AFTER BEFORE

  8. Example of “Set in order” in a storage area No easy visual idea of stock level Each item has a specific location can be colour coded No identification Store location identification is used Items stored randomly Diagonal strip indicates correct sequence Tool No 1234 Tool No 568 Material at a convenient height Part No. 356 Part No. 999

  9. Step 3: Shine • All tools and equipment associated with the process must be thoroughly cleaned and then checked for: • Leaks • Wear • Loose fittings • Incorrect settings • Etc. • “shine” must also be applied to the whole workplace, i.e. Floor and other factory fixtures and fitting including lights and heating. • Any concerns identified should be formally logged and followed up until resolved.

  10. Example of “shine” in equipment Poor equipment condition Dirt hides problems Problems become apparent Drives resolution of problems BEFORE AFTER

  11. Step 4: Standardise • The systemised approach of maintaining high standards of workplace organisation at all times by: • Recording requirements • Allocating responsibilities • Determining frequencies • Display of instructions and guidelines.

  12. Workplace organisation document Floor plan Team member Joe Bloggs Areas of responsibility: 1 Weld subassemblies 2 Machine centre 1 3 Work bench 1 Tasks to be completed Frequency Empty dustbins Daily Clean out swarf Daily Clear bench top Daily Empty metal scrap bin 2 Days Check machine maintenance monthly Example of “standardise” • Standard process sheet can be simple or detailed, openly displayed and include pictures to show requirements and standards WB 1 MC 1 Weld Subs

  13. Stap 5: Sustain – training and discipline • Workplace Organisation is an important part of any Best Practice system. • Everyone involved in operating the system must understand the principles and processes. • Formal structured training and on the job coaching is essential if good Workplace Organisation practice is to become part of “business as usual”. • Simple effective visual management methods should be used to assist the team members and team leaders to follow the processes and maintain standards. • All tasks, systems, locations and areas should be apparent and clear for strangers to be able to understand.

  14. Example of Training and discipline Workplace Organisation Monitor Board March Month _________ Team Members 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Work centres Fred Smith Mark Doyle Steven London David Connell Rear of card Front of card To be done Mark Black Completed Sam Davies Karen Jones

  15. Summary • Importance of Workplace organisation- 5S A workplace that is Well organised is • Safe to work in • High in productivity • High in Quality • Low in cost • Consistent in delivery • High in Morale Sustain Standardise Take all five steps to success! Shine Set in order Sort

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