5S Workplace Organization Northland Community & Technical College Presented by: Tim Bergerson, Robbi Brateng, Mitch Ostrom, Jesse Adkins, Bob Gooden, Barb Noel, Don Brown, Dave Olsen

Target Area  EGF Maintenance Shop  Maintenance Shop and Receiving Area  Creating a neat and orderly shop area using the 5S Program

Target Area Storage, shipping and receiving Storage, shipping and receiving To serve as an area to receive and store maintenance products To serve as an area to receive and store maintenance products

Area Map

Workplace Scan Diagnostic Checklist Date: Sort Sort (Organization) (Organization) Distinguish between what is needed and not needed Distinguish between what is needed and not needed Number of Problems Rating Level  5 or more  3 -4  2  1  None  Level 0  Level 1  Level 2  Level 3  Level 4 Unneeded equipment, tools, furniture, etc. are present 32 Unneeded items are on walls, bulletin boards, etc. 44 Items are presents in aisles ways, stairways, corners, etc. 34 Unneeded inventory, supplies, materials are present. 24 Safety hazards exist. 24

Workplace Scan Diagnostic Checklist Set in Order Set in Order (Orderliness) (Orderliness) A place for everything and everything in its place. A place for everything and everything in its place. Number of Problems Rating Level  5 or more  3 -4  2  1  None  Level 0  Level 1  Level 2  Level 3  Level 4 Correct places for items are not obvious. 04 Items are not in their correct places. 03 Aisle ways, workstations, equipment locations are not identified. 04 Items are not put away immediately after use. 04 Height and quantity limits are not obvious. 03

Workplace Scan Diagnostic Checklist Shine Shine (Cleanliness) (Cleanliness) Cleaning and looking for ways to keep it clean and organized Cleaning and looking for ways to keep it clean and organized Number of Problems Rating Level  5 or more  3 -4  2  1  None  Level 0  Level 1  Level 2  Level 3  Level 4 Shelves, floors, walls, stairs, and surfaces are not free of obvious dirt and dust 44 There is chipped paint, ceiling and/or floor tiles broken or stained. 44 Equipment is not kept clean and free of dirt and dust. 44 Cleaning materials are not easily accessible. 34 Lines, labels, signs, etc are not clean and unbroken 24

Workplace Scan Diagnostic Checklist Standardize Standardize (Adherence) (Adherence) Maintain and monitor the first three categories. Maintain and monitor the first three categories. Number of Problems Rating Level  5 or more  3 -4  2  1  None  Level 0  Level 1  Level 2  Level 3  Level 4 Necessary information is not visible. 04 All standards are not known and visible. 03 Checklists don’t exist for all cleaning and equipment maintenance. 02 All quantities and limits are not easily recognizable. 03 How many items can’t be located in 30 seconds? 24

Workplace Scan Diagnostic Checklist Sustain Sustain (Self-discipline) (Self-discipline) Stick to the rules! Stick to the rules! Number of Problems Rating Level  5 or more  3 -4  2  1  None  Level 0  Level 1  Level 2  Level 3  Level 4 How many workers have not had 5S training? 04 How many times, in the last week, was daily 5S not performed? 03 Number of times that supplies (room contents) not neatly stored? 04 Number of times job aids are not available or up to date? 34 Number of times, in the last week, daily 5S inspections not performed? 03

Workplace Scan Diagnostic Checklist Totals Totals (Category Totals) (Category Totals) Benchmark your 5S journey. Benchmark your 5S journey. Number of Problems Rating Level  5 or more  3 -4  2  1  None  Level 0  Level 1  Level 2  Level 3  Level 4 Sort Set in Order Shine Standardize Sustain

Target Area Photos Insert Target Area Photos Slides Insert Target Area Photos Slides Before Photos Before Photos Cluttered spaces, inadequate orderliness Cluttered spaces, inadequate orderliness Causes behind quality problems Causes behind quality problems Excess inventory or supplies Excess inventory or supplies

Worksheet for Creating a 5S Vision Current Condition Categories Desired Condition Current Condition Categories Desired Condition Eyewash hard to get to, not marked Fire Extinguishers not labeled Safety Clear pathway and signage Label Fire Extingusher Good Product Quality Good Good Equipment Maintenance Daily forklift check list Checklish for the two lifts Good Levels Need an inventory list Inventory Levels More Organization Inventory List Calendar Bulliten Board Information Sharing Facility Master Plan

Team Charter Today’s Date: February 6, 2007 Today’s Date: February 6, 2007 Target Area: Shipping & Receiving/Maintenace Target Area: Shipping & Receiving/Maintenace 5S Project Sponsor: 5S Project Sponsor: Target Area Manager: Bob Gooden Target Area Manager: Bob Gooden Facilitator: Bob Gooden Recorder: Barb Noel Recorder: Barb Noel Reporter: Jesse Adkins and Dave Olsen Reporter: Jesse Adkins and Dave Olsen Team Member: Robbi Brateng Team Member: Robbi Brateng Team Member: Don Brown Team Member: Don Brown Team Member: Tim Bergerson Team Member: Tim Bergerson Team Member: Mitch Ostrom Team Member: Mitch Ostrom Team Member: Team Member:

Measurables Record as many of the 7 deadly wastes identified Record as many of the 7 deadly wastes identified Assign a value to the eliminated wastes identified Assign a value to the eliminated wastes identified

Sort Red Tagged Items: Fan, Old Shelving, Unused Filing Cabinets, Fume Hoods, Fire Extinguisher, Tables and Chairs. Red Tagged Items: Fan, Old Shelving, Unused Filing Cabinets, Fume Hoods, Fire Extinguisher, Tables and Chairs.

Where did red tag items go Where did red tag items go Trash and cold storage. Trash and cold storage.

Were items added to the room because they were not available to serve functions of the room: Were items added to the room because they were not available to serve functions of the room: Yes, we added some shelving and cabinets

Red Tagged Items

After red tagging, did the pictures reveal extra space. Yes After red tagging, did the pictures reveal extra space. Yes

Did you do another process flow to analyze the space after the red tagging event? Yes Did you do another process flow to analyze the space after the red tagging event? Yes

Set In Order How did you utilize labels: How did you utilize labels: Labeled all inventory Labeled all inventory Lines: Lines: Indicated walkways and storage spaces Indicated walkways and storage spaces Signboards: Indicate equipment spaces Signboards: Indicate equipment spaces

What type of education did you do with your employees in this area? All employees in area were involved in the organization of the area. What type of education did you do with your employees in this area? All employees in area were involved in the organization of the area.

After Pictures

Shine Plans to keep this room clean: Return tools and equipment to their properly labeled area. Plans to keep this room clean: Return tools and equipment to their properly labeled area. What type of cleaning did you do:Dust, sweep, vacuum and scrub floors. What type of cleaning did you do:Dust, sweep, vacuum and scrub floors.

Who will maintain it: All maintenance employees Who will maintain it: All maintenance employees Who will monitor it: Bob Gooden Who will monitor it: Bob Gooden

What types of things did you find during the inspection and how was it corrected: Clutter, not organized, not labeled. Clutter removed, labels added and equipment organized. What types of things did you find during the inspection and how was it corrected: Clutter, not organized, not labeled. Clutter removed, labels added and equipment organized. Did you develop a shine cart: All shine carts are located in this area. Did you develop a shine cart: All shine carts are located in this area.

Why is it important to shine: Why is it important to shine: A clean shop is a happy shop. A clean shop is a happy shop.

Standardize What areas were standardized practices between campuses: Organizing and labeling What areas were standardized practices between campuses: Organizing and labeling What areas were standardized in your target areas What areas were standardized in your target areas Supply and storage area Supply and storage area How are you going to make these standards visible and what are your training plans for other employee: Labeling of supplies, maintain organization How are you going to make these standards visible and what are your training plans for other employee: Labeling of supplies, maintain organization

Sustain How will you make 5S a part of daily work? Tools returned to their proper place. How will you make 5S a part of daily work? Tools returned to their proper place. How will you involve all employees: Departmental meetings How will you involve all employees: Departmental meetings Which of the tools you received will help you sustain your target areas? Labels, tool box, shelving, sign boards. Which of the tools you received will help you sustain your target areas? Labels, tool box, shelving, sign boards.