Training - 5S+1

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LT6
5S + 1
CONTINUOUS IMPROVEMENT
OFFICE
1
Session Agenda
• Introduction
• Background and History
• Components and Implementation
2
Introduction
• 5S + 1 is a method to improve and sustain workplace
organization
• Represents 6 disciplines for maintaining a visual workplace
(visual controls and information systems).
• These are foundational to continual improvement and a
manufacturing strategy based on "Lean Manufacturing"
(waste removing) concepts.
• Reduces clutter
• Reduces the time it takes to look for tools and equipment
• “A place for everything and everything in its place”
• Improves how the operation appears to customers – always
be “tour ready”
• Creates pride in the workplace
• Many companies have a standard that any tool must
be able to be found within 60 seconds.
3
Background and History
• Taiichi Ohno created the original “4S” concept of
workplace organization and visual control at Toyota
during the early 1950’s.
• The concept was further refined into “5S” during
the 1960’s and 1970’s.
• U.S. manufacturers added a sixth “S” for “safety”
during the 1990’s.
• The 5S+1 tools were recently modified by
Gwendolyn Galsworth to include “Visual
Workplace” disciplines.
4
Elements of 5S + 1 and Visual Workplace
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5
Sort
Scrub/Shine
Secure Safety
Select Locations
Set Locations
Sustain
Elements of 5S +1 & Visual Workplace
• Sort
– Remove all unnecessary materials and equipment
• Scrub/Shine
– Clean everything, inside and out
• Secure Safety (often called “6S” or “5S + 1”)
– A safety commitment in all activities
• Select locations
– Decide where everything remaining should be
• Set locations
– Put remaining items in place, provide “anchors”
• Sustain
6
– Establish policies and procedures to ensure 5S
– Training, daily activities, audits
Types of Waste
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Defects
Over-Production
Waiting
Non-Utilized Talent
Transportation
Inventory
Motion
Extra Processing
• Other Wastes:
– Inappropriate Systems
– Wasted Utility Resources
– Wasted Materials
7
The Good, Bad and the Ugly
• First the Bad and the Ugly - Life Without 5S
8
The Good – After 5S + 1
9
After 5S + 1
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•
•
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Clear, shiny aisles
Color-coded areas
Posted processes, metrics and other current information
Always “customer tour ready”
10
5S + 1 Examples
Before 5S
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After 5S - Cleaned, organized
and drawers labeled (less
time and frustration hunting)
Sort
• Identify clutter and disposition
• When in doubt, move it out
• Red tag exercise (more later)
12
Scrub/Shine
• Clean everything, inside and out
• Prevent dirt and contamination from reoccurring
• Remove outdated material (like old posted charts,
news, and metrics!)
• Results in
– Fewer breakdowns
– Greater safety
– Product quality
– More satisfying work environment
13
Shine Check Sheet
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•
•
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•
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Ceilings
Aisles
Workstations
Corners, under equipment
Loading docks
Walls
Doors
Pillars, posts
14
•
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•
•
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Floors
Machines
Conveyance equipment
Plumbing, sinks
Cabinets, shelves, racks
Carts, Racks
Drawers, storage bins
Fixtures, power boxes
5S Examples - Shine
• The area is cleaned as the work is performed (best) and\or
there is a routine to keep the work area clean.
15
Safety
• Does not replace the existing site safety plan
• During 5S audits also review all areas for safety
16
Select Locations
• Make it obvious where things belong
– Lines
• Divider lines
• Outlines
• Limit lines (height, minimum/maximum)
• Arrows show direction
– Labels
• Color coding
• Item location
– Signs
• Equipment related information
• Show location, type, quantity, etc.
• Consider your “Value Field”
17
Select Locations Check Sheet
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Equipment
Machines
Small tools
Dies
Jigs
Bits
Conveyance equipment
Cleaning equipment
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Materials
Raw material
Supplies
Parts
Work-in-process
Finished goods
Shipping materials
Cleaning supplies
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•
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Furniture
Cabinets
Benches, tables
Chairs
Carts
Shelves
Racks
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•
•
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•
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Other items
Charts, graphs, bulletin boards
Pens, pencils
Work clothes
Helmets
Work shoes
Trash cans
18
5S Examples
See the difference?
•
•
•
Sort - All unneeded tools, parts and supplies are removed from the area
Scrub/Shine – Cleaned/Painted
Select & Set Locations - A place for everything and everything is in its place
19
Set Locations & Standards
• Establish guidelines for the team 5-S conditions
• Make the standards and 5-S guidelines visual
• Maintain and monitor those conditions
20
Typical Team Standards
• Sort
– Amount of inventory
– Tools that belong in the area
– How often to remove scrap
• Straighten
– Location of aisleways
– Location of tools, equipment
• Shine
– Cleaning schedule
– Maintenance tasks
– Checklist of what to look for as cleaning is
performed
21
Sustain
• Determine the methods your team will use to
maintain adherence to the standards
• 5-S concept training
• Before and after photos
• Checklists, standards and procedures
• Daily 5-minute 5-S activities
• Monthly 5S Audit
22
5S Implementation
1. Begin reviewing your areas for 5S
2. Discuss 5S with each of your groups (brief group
meeting)
3. Red tag sorting process (one time)
4. Brief, simple daily 5S individual activity (“just look
around”)
5. Brief 5S checklist or procedure for each area
6. Monthly 5S audit beginning __________
•
•
•
•
23
Area Lead plus at least one person from outside that area
Post results (I will look for them!)
Review results with your group
Take corrective action
© 2007 Superfactory™. All Rights Reserved.
Red Tag Process
• One-time activity to remove or disposition clutter
• To be started within two weeks of this training
1. Identify clutter, unused equipment, etc
2. Fill out and attach red tag
3. Note in red tag log
4. Must disposition Red Tags within (XX) days
24
Red Tag Example
Item Tagged by: ________________________
Name of Item: __________________________
Date: _________________________________
Location of Item: ________________________
Reason for Red tagging
(Check One)
Obsolete
Used once/day
Defective
Used once/week
Scrap
Used < once/month
Trash
Seldom Used
Unneeded
Use Unknown
For Office Use Only:
Item No. ___________________________
Disposition:_________________________
__________________________________
25
Red Tag Hints
• Search
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26
Floors
Aisles
Operation areas
Workstations
Corners, under equipment
Small rooms
Offices
Loading docks
Inside cabinets
Red Tag Hints
• Look for unneeded equipment
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–
–
–
27
Machines, small tools
Dies, jigs, bits,
Conveyance equipment
Plumbing, electrical parts
Red Tag Hints
• Look for unneeded furniture
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28
Cabinets
Benches, tables
Chairs
Carts
Red Tag Hints
• Search these storage places
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29
Shelves
Racks
Closets
Sheds
Search the walls
Items hung up
Old bulletin boards
Signs
Red Tag Hints
• Look for other unneeded items
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30
Work clothes
Helmets
Work shoes
Trash cans
Other
Red Tag Hints
• Look for unneeded materials
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31
Raw material
Supplies
Parts
Work in process
Finished goods
Shipping materials
Visual Factory
• Mark-off the inventory locations
• Mark-off equipment/machine locations
• Mark-off storage locations (cabinets, shelves,
tables)
• Visually indicate amount of allowed inventory
• Keep metrics, wall charts, and other information
current
• Label all cabinets, shelves, etc with their contents
• Posted production status, upcoming jobs
32
WASTE WALK
then
Return and discuss
33
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