1
XYZ Company
Lean Building Blocks
Continuous Improvement
Pull/Kanban
Plant Layout
5S System
Cellular/Flow
Quick Changeover
Batch Reduction
Standardized Work
Visual
Systems
Teams/Employee Involvement
Quality at Source
TPM
POUS
Value
Stream
Mapping
2
XYZ Company
Source: The MEP Lean Network
Visual Factory
“Ability to understand the status of a
production area in 5 minutes or less
by simple observation without use
of computers or speaking to anyone.”
3
XYZ Company
5S
Method for
creating and maintaining
an organized and clean
workplace.
4
XYZ Company
5
XYZ Company
1S - Sort - Seri
Separate and Discard
6
XYZ Company
1S - Sort - Seri
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Identify all necessary and unnecessary items.
Move unnecessary items from workplace to a
designated area or “throw it out”.
Remove all excess items from working areas –
work pieces, personal items etc.
Organize all remaining necessary items.
Designate a team to “hunt down unnecessary
items”.
7
XYZ Company
2S - Stabilize - Seiton
Set – in – Order
Straighten
Arrange and identify for ease of use
8
XYZ Company
2S - Stabilize - Seiton
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Locate materials and tools at POINT- OF- USE
(POUS).
Store items needed by most people in a common
storage area.
Make items easily identifiable and easy to obtain.
Label all containers, totes, supplies etc.
Storage areas, work areas, containers should have
floor marking and identifying labels.
Place Maintenance/Operator instructions close to
the point of use.
Use special device (carts/shelves/racks) to organize
tools and fixtures.
Performance boards – daily/weekly production,
scrap/rework rate chart….
9
XYZ Company
2S – Visual Controls
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Label – Containers, Cabinets, Supplies, Inventory,
Machines, Tools, Scrap, Rework,……..
Color – Parts container, floor markings, safety, work
areas, trash cans,..
 Green – Shipping, Yellow – Work in process, Blue –
Storage/Trash.
 Checkered – Aisles.
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Footprints – Anything that is movable.
Tool Boards – Shadow board, Peg board.
Performance Boards – Hour by hour, 5S Measurement,…
Standard Work visible.
Re-order points, Inventory levels.
Material Flow indicators within, into, out of your cell.
Equipment related information.
Documents on safety, quality,…
10
XYZ Company
3S - Shine - Seiso
Clean – up
Scrub
XYZ Company
11
3S - Shine - Seiso
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Use dust collecting devices to prevent possible dirt.
Ensure that electrical and other cords are not a
hindrance to all personnel.
Operators should clean their work area and
equipment and perform preventive maintenance.
Keep everything clean for constant state of
readiness.
A Clean Workplace enhances
QUALITY, SAFETY, and PRIDE.
12
XYZ Company
4S - Standardize - Seiketsu
Keep Clean
13
XYZ Company
4S - Standardize - Seiketsu
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Implement a plan to keep the
workplace clean all the time
No – unnecessary items, mess,
dirt
Who?
When?
How?
DO
PLAN
DEMING
CYCLE
ACT
CHECK
14
XYZ Company
5S Schedule
5S Job Cycle Chart
Name:
Dept:
1
2
3
4
5
6
7
8
9
Red-Tag (company wide)
Red-tag (cells / lines)
Inventory check
Tool check
Wipe area
Vacuum area
Machine Clean Inspection (Ops)
Degrease work area
etc
XYZ Company
MONTHLY
WEEKLY
DAILY(PM)
DAILY(AM)
CONTINUOUSLY
Sustain
Shine
Set
5S Job
Sort
No
Standardise
Date:
15
5S - Sustain - Shitsuke
Motivate
16
XYZ Company
5S - Sustain - Shitsuke
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Commitment
Adherence
Cell meets 5S principles at the end of each shift
5S Daily Checklist
17
XYZ Company
5 Minute 5S
Five Minute 5S
Area:
Contact:
Sort
Remove unwanted tooling
(red tag to holding area)
Set
Mark out product variants
(floor tape from Joe)
Shine
Degrease banjo press
(gloves, solvent from Joe)
Standardise
Why is banjo press greasy,
Why are variants mixed
Sustain
Who is/are responsible for press
18
XYZ Company