Lean Manufacturing Series 5S and Visual Factory Lean Manufacturing Series

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Contents Introduction Background and History Components and Implementation Knowledge Check

Introduction 5S is a method to improve and sustain workplace organization 5S represents 5 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.

Components and Implementation 5S and Lean Manufacturing Elements of 5S Sort Straighten Shine Standardize Sustain Safety Visual Factory Implementation plan

Elements of 5S Sort Straighten Shine Standardize Sustain Remove all unnecessary materials and equipment Straighten Make it obvious where things belong Shine Clean everything, inside and out Standardize Establish policies and procedures to ensure 5S Sustain Training, daily activities Safety (often called “6S” or “5S + 1”) A safety commitment in all activities

Types of Waste Overproduction Excess inventory Defects Non-value added processing Waiting Excess motion Transportation Other Wastes: Untapped Human Potential Inappropriate Systems Wasted Utility Resources Wasted Materials

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

The Good – After 5S

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

5S 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)

Straighten Make it obvious where things belong Lines Labels Signs 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.

5S Examples – Sort and Straighten See the difference? Sort - All unneeded tools, parts and supplies are removed from the area Straighten - A place for everything and everything is in its place

Straighten 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

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

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.

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

Standardize 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

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

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

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 Red tags must be dispositioned within 30 days

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

Red Tag Inspection Sheet Look for unneeded equipment Machines, small tools Dies, jigs, bits, Conveyance equipment Plumbing, electrical parts Look for unneeded furniture Cabinets Benches, tables Chairs Carts

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

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

Knowledge Check

Name the five “S” components. (Mark all that apply) Sort Straighten Shine Standardize Sustain

Match the 5S component name with it's description by dragging the description to the name. Sort Straighten Shine Standardize Sustain Safety Description Training, daily activities Clean everything, inside and out A safety commitment in all activities Establish policies and procedures to ensure 5S Make it obvious where things belong Remove all unnecessary materials and equipment F E B D A C

What are some ways in Straighten that you can make it obvious where things belong? (Mark all that apply) Lines Labels Signs

Performing Shine results in which of the following Performing Shine results in which of the following? (Mark all that apply) Fewer breakdowns Slower processing Greater safety Product quality More satisfying work environment

What are some ways your team can Sustain 5S? (Mark all that apply) 5-S concept training Before and after photos Checklists, standards and procedures Daily 5-minute 5-S activities

Strategy is sometimes called the sixth "S". A) True B) False

Which of the following are a part of the “red tag” activity Which of the following are a part of the “red tag” activity? (Mark all that apply) One-time activity to remove or disposition clutter Identify clutter, unused equipment, etc Fill out and attach red tag Note in red tag log

What are some ways that you can maintain a Visual Factory What are some ways that you can maintain a Visual Factory? (Mark all that apply) Mark-off the inventory locations Mark-off equipment/machine locations Visually indicate amount of allowed inventory Label all cabinets, shelves, etc with their contents

How can you implement 5S in your organization?

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