The toyota production system 5S Applied in Summer internship The toyota production system 5S Applied in

ABOUT THE COMPANY World’s largest airline caterer Headqaurtered in Zurich, Switzerland and Reston Virginia Clients include Delta, United, British Airways and Renfe (Spain Rail Network) Part of the GATEGROUP network including sister company GATESAFE (security), DeSTER (utensil manufacturer), POUSHIN (food supplier)

I was at Gategourmet Honolulu……ALOHA!

What are the 5s? Sorting Staighten Shine (Sanitize for Food Industry) Standardize Sustain -> 5S is set to reduce the key 8Waste:Transport; Inventory; Motion; Waiting; Over Production; Rework; Skills; over processing.

Sorting BEFORE KAIZEN AFTER KAIZEN LEFT: Items in boxes, unsorted, undecanted RIGHT: Items in Ergonomic bins, with PAR levels KAIZEN: Japanese term for “improve”

Sorting BEFORE KAIZEN AFTER KAIZEN LEFT: Undefined work area RIGHT: Work area defined with clear drop zones and passage way. Drop zone helps the delivery system to become more efficient.

International Vs Domestic SORTING Aisle vs Work area International Vs Domestic

Straighten

Straighten(Have a place for everything)

VISUAL MANAGEMENT (STATIC DISPLAY

WHY 5S? Minimizes time by not wasting time looking for items when processing (increase productivity defined as MHPF-Man Hour Per Flight) The one arm rule policy to reduce walking (one of the 8 waste). Ergonomic bins for easy access PAR Levels to control material cost Dropzones for efficient delivery System

Shine(keep the area clean)

Standardize (COMBINATION WORK FLOW)

Continued: Standardized Map of Cell Layout

Sustain(maintain the system and continue to improve it)

Continued: Sustain Daily Tracking Tool

Conclusion 5S contributes to productivity which is related to labour cost savings. It also aims to control material cost by reducing waste, and increase quality Statistically, it takes an hour for an operator to set up a station. Assuming there are 100 employees. That would have been a 100 hour opportunity in savings. (Do the math: 50 X $8.5 per hour X 20 days a month X 12 months = $204,000. If this was in overtime dollars, it would be $102K X 1.5 = $306,000 excludes benefits and insurance the company have to pay for employees) 5S such as Visual Management simplifies process that is useful for new hires as it reduces the complexities of training. Also useful for cross training, increasing skills (where under-utilization of skills is one of the 8 Waste)