BUILD WITH US. ™ 5S – The Foundation for Improvements Safety the “6 th ” S

BUILD WITH US. ™ 2 Lean Six Sigma Improvement Process Define Measure Analyze Improve Control Define the opportunity from both business and customer perspectives Search for the key factors (critical X’s) that have the biggest impact on process performance and determine the root causes Understand the process and its performance Develop improvement solutions for the critical X’s Implement the solution and control plan Critical Enablers Opportunity Identification & Project Selection Project Sponsorship Tollgate Reviews

BUILD WITH US. ™ 3 6S Overview: Safety (Self-Discipline) –Ensuring compliance and protection of our employees Sort –Clearly distinguish needed items from unneeded items and eliminate the latter. Set In Order (Simplify) –Keep needed items in the correct place to allow for easy and immediate retrieval. Shine (Sweep) –Keep the workshop swept and clean. Standardize –Standardized cleanup. This is the condition we support when we maintain the first three steps. Sustain (Self-Discipline) –Make a habit of maintaining established procedures.

BUILD WITH US. ™ 4 What is 6S? 6S is the foundation for continuous improvement, a safe work area. zero defects, and cost reduction. 6S is a process for creating and maintaining an organized, clean, and high performance workplace. 6S is a systematic way to improve the workplace, our processes and our products through employee involvement. 6S enables anyone to distinguish between normal and abnormal conditions at a glance.

BUILD WITH US. ™ 5 Step #1: Safety Implementing Safety Identify potential risk (Assessments,Obsevations) Develop plan to eliminate defects (risk) Make it structured. Convey the message to all Give recognition where it is due.

BUILD WITH US. ™ 6 This is a mess!! This is so neat!! Step #2: Sort Sorting Process 1.Separate the necessary from the unnecessary and then clean everything remaining –No Tag= necessary item –Red Tag= unnecessary item

BUILD WITH US. ™ 7 Step #3: Set in Order Definition of Set in Order Set in order means to arrange the items that are needed in the area and identify them so that anyone can find them or put them away. The key word is “anyone.”

BUILD WITH US. ™ 8 Step #4: Shine Shine Definition Shine emphasizes removing the dirt, grime, and dust from the work area. This is a program of keeping the work area swept and clean of debris.

BUILD WITH US. ™ 9 Step #5: Standardize Benefits of Standardization Easier to train new employees Less room for errors and scrap Work area is more organized Work area is safer

BUILD WITH US. ™ 10 Step #6: Sustain Implementing Sustain Keep everyone aware of 6S and its benefits. Make time each day to perform daily tasks. Make it structured. Give recognition where it is due. Establish checklist for visitors to review.

BUILD WITH US. ™ 11 Takeaways A 6S’d Process is a Much Safer Place to Work A 6S’d Process Produces Fewer Defects and Reduces Risk A 6S’d Process Meets Deadlines More Frequently A 6S’d Process Results in a More Efficient/Cost Effective Process 6S can be a useful to implement in any of the Lean Six Sigma Phases

BUILD WITH US. ™ Can You Identify the Hazards?

BUILD WITH US. ™ Can You Identify the Hazards?

BUILD WITH US. ™ 14 Examples of 6S Projects

BUILD WITH US. ™ Maintenance shop overhear storage area Before

BUILD WITH US. ™ Maintenance shop overhear storage area AFTER

BUILD WITH US. ™ L2 Paper Applicator Project Hayward, Wisconsin August 2013 Scott Pahos

BUILD WITH US. ™ 18 Challenge / Goals / Safety (Business Case) Challenge: To Improve reliability in regards to paper application on our L2 forming line. Current state indicates numerous upset conditions both reducing production and increased risk with our employees being exposed to potential hazards while correcting upset conditions. Results Achieved (or Expected): Analyze current state and develop alternative options to reduce risk and improve overall safety, production and quality outputs. Cost: Minimal

BUILD WITH US. ™ 19 Team Members / Functions Shane Chucka, Converting Supervisor Dave Skopek, Plant PCT Green Belt John Johnson, Maintenance Alex Norquist, Plant PCT John Aubart, FSG manager, Green Belt Scott Pahos, Project Leader, LSS BB

BUILD WITH US. ™ 20 Project Scope In Scope: Safety Processes and procedures Paper Applicator Out of Scope: Production Capital expenditures Equipment integrity

BUILD WITH US. ™ 21 Paper Overlay Used in the process. Before the conversion of the new paper slitter. Poor guarding/Poor reliability resulting in numerous defects (stops) requiring plant personnel to enter area to clear paper and service cutter resulting in increased exposure to risk.

BUILD WITH US. ™ 22 After picture on newly installed paper slitter. Note the process is now much improved with safety enhancements such as new guarding and informational data on the equipment

BUILD WITH US. ™ 23

BUILD WITH US. ™ 24 Pictures of new/additional guarding for employee protection

BUILD WITH US. ™ 25 Newly designed cutter/motor totally enclosed/guarded

BUILD WITH US. ™ 26 Motor and Cutter labeling providing critical safety information for the employees.

BUILD WITH US. ™ 27 Q & A