1. The toyota production system 5S Applied in
Summer internship
The toyota production system 5S
Applied in

2. ABOUT THE COMPANY
World’s largest airline caterer Headqaurtered in Zurich, Switzerland and Reston Virginia
Clients include Delta, United, British Airways and Renfe (Spain Rail Network)
Part of the GATEGROUP network including sister company GATESAFE (security), DeSTER (utensil manufacturer), POUSHIN (food supplier)

3. I was at Gategourmet Honolulu……ALOHA!

4. What are the 5s? Sorting Staighten Shine (Sanitize for Food Industry)
Standardize
Sustain
-> 5S is set to reduce the key 8Waste:Transport; Inventory; Motion; Waiting; Over Production; Rework; Skills; over processing.

5. Sorting BEFORE KAIZEN AFTER KAIZEN
LEFT: Items in boxes, unsorted, undecanted
RIGHT: Items in Ergonomic bins, with PAR levels
KAIZEN: Japanese term for “improve”

6. Sorting BEFORE KAIZEN AFTER KAIZEN LEFT: Undefined work area
RIGHT: Work area defined with clear drop zones and passage way. Drop zone helps the delivery system to become more efficient.

7. International Vs Domestic
SORTING
Aisle vs Work area
International Vs Domestic

8. Straighten

9. Straighten(Have a place for everything)

10. VISUAL MANAGEMENT (STATIC DISPLAY

11. WHY 5S?
Minimizes time by not wasting time looking for items when processing (increase productivity defined as MHPF-Man Hour Per Flight)
The one arm rule policy to reduce walking
(one of the 8 waste).
Ergonomic bins for easy access
PAR Levels to control material cost
Dropzones for efficient delivery System

12. Shine(keep the area clean)

13. Standardize (COMBINATION WORK FLOW)

14. Continued: Standardized
Map of Cell Layout

15. Sustain(maintain the system and continue to improve it)

16. Continued: Sustain
Daily Tracking Tool

17. Conclusion
5S contributes to productivity which is related to labour cost savings. It also aims to control material cost by reducing waste, and increase quality
Statistically, it takes an hour for an operator to set up a station. Assuming there are 100 employees. That would have been a 100 hour opportunity in savings. (Do the math: 50 X $8.5 per hour X 20 days a month X 12 months = $204,000. If this was in overtime dollars, it would be $102K X 1.5 = $306,000 excludes benefits and insurance the company have to pay for employees)
5S such as Visual Management simplifies process that is useful for new hires as it reduces the complexities of training. Also useful for cross training, increasing skills (where under-utilization of skills is one of the 8 Waste)