Using 5S to Start Your Lean Journey Presented by: Brian D Krichbaum Process Coaching Incorporated

Process Coaching Incorporated Page 2 of 73 © 2008 Process Coaching Incorporated What is 5S? Sort Set-In-Order Shine Sustain Standardize If your factory hasn’t adopted 5-S, it is likely dirty with oil, dirt, and chips. Parts can’t be found and boxes are lying around in non- designated areas. New equipment is purchased, but not well maintained. Jigs and fixtures can’t be found when needed, and the morale in the plant is poor. In short, you are struggling and things aren’t getting better.

Process Coaching Incorporated Page 3 of 73 © 2008 Process Coaching Incorporated Why use 5S?  Well lit facilities are more productive  Tidy facilities produce fewer defects 1.5S Helps Sales  Neat and clean facilities impress customers  Organized facilities win more contracts

Process Coaching Incorporated Page 4 of 73 © 2008 Process Coaching Incorporated 3. 5S Enhances Safety  Facilities are spacious, bright, visibly appealing  Work areas and traffic areas are clearly marked  Hoses and electrical cords are not on the floor Why use 5S? 2. 5S Saves Money  Supplies aren’t lost so don’t have to prematurely replaced  Parts and assemblies are less likely to be damaged

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Process Coaching Incorporated Page 6 of 73 © 2008 Process Coaching Incorporated The Meaning of 5S Separate what is needed and what is not needed. Keep only those things that are needed in the workplace. Discard unnecessary items. Sort Keep only everyday items. We do not necessarily use all of the “everyday” items everyday. But if they are lost or damaged a replacement would be necessary.

Process Coaching Incorporated Page 7 of 73 © 2008 Process Coaching Incorporated The Key to Sorting Sort does not mean that you throw out only items that you are sure you will never need. Nor does it mean that you arrange things into neat, straight patterns. When you sort, you leave only the bare essentials. When in doubt, throw it out! Sort Meaning

Process Coaching Incorporated Page 8 of 73 © 2008 Process Coaching Incorporated Step 1 - Make a clear standard for deciding what is necessary  Things used daily; Place in work cell  Things used once a week; Place close to the work cell  Things used once in 2 months; Place close to the plant  Things we don’t know if we’ll use; Place in a temporary storage  Things not used; Throw away Sort Process

Coaching Incorporated Page 9 of 73 © 2008 Process Coaching Incorporated Sort Process Step 2 – Choose a work area where success is sure  Schedule a red tag event  Straighten up according to your standard  Decide on the spot, implement on the spot

Process Coaching Incorporated Page 10 of 73 © 2008 Process Coaching Incorporated The Red Tag Strategy is simple method for identifying unneeded items in the work cell, evaluating their usefulness, and dealing with them appropriately. Red Tag Targets InventoryEquipmentPhysical Areas Raw Materials Procured Parts In-Process Inventory Finished Parts Machines Jigs / Tools Bits / Gauges Tables, Computers Floors Shelves Walkways Operation Areas Sort Red Tag