Lean Manufacturing Visual Systems XYZ Company

Source: The MEP Lean Network Lean Building Blocks Continuous Improvement Pull/Kanban Cellular/Flow Quick Changeover Quality at Source Plant Layout Batch Reduction TPM 5S System Standardized Work Visual Systems POUS Value Stream Mapping Teams/Employee Involvement XYZ Company Source: The MEP Lean Network

Visual Factory “Ability to understand the status of a production area in 5 minutes or less by simple observation without use of computers or speaking to anyone.” XYZ Company

creating and maintaining 5S Method for creating and maintaining an organized and clean workplace. XYZ Company

XYZ Company

1S - Sort - Seri Separate and Discard XYZ Company

1S - Sort - Seri Identify all necessary and unnecessary items. Move unnecessary items from workplace to a designated area or “throw it out”. Remove all excess items from working areas – work pieces, personal items etc. Organize all remaining necessary items. Designate a team to “hunt down unnecessary items”. XYZ Company

Arrange and identify for ease of use 2S - Stabilize - Seiton Set – in – Order Straighten Arrange and identify for ease of use XYZ Company

2S - Stabilize - Seiton Locate materials and tools at POINT- OF- USE (POUS). Store items needed by most people in a common storage area. Make items easily identifiable and easy to obtain. Label all containers, totes, supplies etc. Storage areas, work areas, containers should have floor marking and identifying labels. Place Maintenance/Operator instructions close to the point of use. Use special device (carts/shelves/racks) to organize tools and fixtures. Performance boards – daily/weekly production, scrap/rework rate chart…. XYZ Company

2S – Visual Controls Label – Containers, Cabinets, Supplies, Inventory, Machines, Tools, Scrap, Rework,…….. Color – Parts container, floor markings, safety, work areas, trash cans,.. Green – Shipping, Yellow – Work in process, Blue – Storage/Trash. Checkered – Aisles. Footprints – Anything that is movable. Tool Boards – Shadow board, Peg board. Performance Boards – Hour by hour, 5S Measurement,… Standard Work visible. Re-order points, Inventory levels. Material Flow indicators within, into, out of your cell. Equipment related information. Documents on safety, quality,… XYZ Company

3S - Shine - Seiso Clean – up Scrub XYZ Company

A Clean Workplace enhances QUALITY, SAFETY, and PRIDE. 3S - Shine - Seiso Use dust collecting devices to prevent possible dirt. Ensure that electrical and other cords are not a hindrance to all personnel. Operators should clean their work area and equipment and perform preventive maintenance. Keep everything clean for constant state of readiness. A Clean Workplace enhances QUALITY, SAFETY, and PRIDE. XYZ Company

4S - Standardize - Seiketsu Keep Clean XYZ Company

4S - Standardize - Seiketsu Implement a plan to keep the workplace clean all the time No – unnecessary items, mess, dirt Who? When? How? XYZ Company

5S Schedule XYZ Company

5S - Sustain - Shitsuke Motivate XYZ Company

5S - Sustain - Shitsuke Commitment Adherence Cell meets 5S principles at the end of each shift 5S Daily Checklist XYZ Company

5 Minute 5S Five Minute 5S Area: Contact: Sort Remove unwanted tooling (red tag to holding area) Set Mark out product variants (floor tape from Joe) Shine Degrease banjo press (gloves, solvent from Joe) Standardise Why is banjo press greasy, Why are variants mixed Sustain Who is/are responsible for press XYZ Company