LT6 5S + 1   CONTINUOUS IMPROVEMENT OFFICE

Session Agenda Introduction Background and History Components and Implementation

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.

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.

Elements of 5S + 1 and Visual Workplace 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 Establish policies and procedures to ensure 5S Training, daily activities, audits

Types of Waste Defects Over-Production Waiting Non-Utilized Talent Transportation Inventory Motion Extra Processing Other Wastes: Inappropriate Systems Wasted Utility Resources Wasted Materials

The Good, Bad and the Ugly First the Bad and the Ugly - Life Without 5S

The Good – After 5S + 1

After 5S + 1 Clear, shiny aisles Color-coded areas Posted processes, metrics and other current information Always “customer tour ready”

5S + 1 Examples After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting) Before 5S

Sort Identify clutter and disposition When in doubt, move it out Red tag exercise (more later)

Scrub/Shine Clean everything, inside and out Prevent dirt and contamination from reoccurring Remove outdated material (like old posted charts, news, and metrics!)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

Shine Check Sheet Ceilings Aisles Workstations Corners, under equipment Loading docks Walls Doors Pillars, posts 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.

Safety Does not replace the existing site safety plan During 5S audits also review all areas for safety

Select Locations Make it obvious where things belong Lines Labels 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”

Select Locations Check Sheet Equipment Machines Small tools Dies Jigs Bits Conveyance equipment Cleaning equipment Furniture Cabinets Benches, tables Chairs Carts Shelves Racks Materials Raw material Supplies Parts Work-in-process Finished goods Shipping materials Cleaning supplies Other items Charts, graphs, bulletin boards Pens, pencils Work clothes Helmets Work shoes Trash cans

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

Set Locations & Standards Establish guidelines for the team 5-S conditions Make the standards and 5-S guidelines visual Maintain and monitor those conditions

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

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

© 2007 Superfactory™. All Rights Reserved. 5S Implementation Begin reviewing your areas for 5S Discuss 5S with each of your groups (brief group meeting) Red tag sorting process (one time) Brief, simple daily 5S individual activity (“just look around”) Brief 5S checklist or procedure for each area Monthly 5S audit beginning __________ 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 Identify clutter, unused equipment, etc Fill out and attach red tag Note in red tag log Must disposition Red Tags within (XX) days

Red Tag Example Item Tagged by: ________________________ Name of Item: __________________________ Date: _________________________________ Location of Item: ________________________ Reason for Red tagging (Check One) For Office Use Only: Item No. ___________________________ Disposition:_________________________ __________________________________ Obsolete Defective Scrap Trash Unneeded Used once/day Used once/week Used < once/month Seldom Used Use Unknown

Red Tag Hints Search Floors Aisles Operation areas Workstations Corners, under equipment Small rooms Offices Loading docks Inside cabinets

Look for unneeded equipment Red Tag Hints Look for unneeded equipment Machines, small tools Dies, jigs, bits, Conveyance equipment Plumbing, electrical parts

Red Tag Hints Look for unneeded furniture Cabinets Benches, tables Chairs Carts

Red Tag Hints Search these storage places Shelves Racks Closets Sheds Search the walls Items hung up Old bulletin boards Signs

Red Tag Hints Look for other unneeded items Work clothes Helmets Work shoes Trash cans Other

Red Tag Hints Look for unneeded materials 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

WASTE WALK then Return and discuss