2. HOME Copyright EASE Inc Tutorials© 1986-2002 The “5S” Philosophy An EASEworks® Manufacturing Tutorial START Ver 6

3. HOME Copyright EASE Inc Tutorials© 1986-2002 The “5S” Philosophy S Based on Japanese words that begin with S, the 5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety. If you’re going to do it, do it RIGHT!

4. HOME Copyright EASE Inc Tutorials© 1986-2002 S The first S focuses on eliminating unnecessary items from the workplace. Sort – (Seiri)

5. HOME Copyright EASE Inc Tutorials© 1986-2002 An effective visual method to identify these unneeded items is called red tagging. A red tag is placed on all items not required to complete your job. These items are then moved to a central holding area. This process is for evaluation of the red tag items. Occasionally used items are moved to a more organized storage location outside of the work area while unneeded items are discarded. Sort – (Seiri)

6. HOME Copyright EASE Inc Tutorials© 1986-2002 If you don’t use it, move it! Sort – (Seiri)

7. HOME Copyright EASE Inc Tutorials© 1986-2002 Sorting frees up valuable floor space and eliminates such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material. The Sort process also helps prevent the ‘hoarder’ job mentality (“I might need it”). Sort – (Seiri)

8. HOME Copyright EASE Inc Tutorials© 1986-2002 A place for everything & everything in its place A place for everything & everything in its place

9. HOME Copyright EASE Inc Tutorials© 1986-2002 Set in Order – (Seiton) 1.What do I need to do my job? 2.Where should I locate this item? 3.How many do I need? S The second S focuses on efficient and effective storage methods. You must ask yourself these questions:

10. HOME Copyright EASE Inc Tutorials© 1986-2002 Strategies for effective Set In Order are: Set in Order – (Seiton)  Painting floors  Outlining work areas and locations  Shadow boards  Modular shelving and cabinets “A PLACE FOR EVERYTHING AND EVERTHING IN ITS PLACE”

11. HOME Copyright EASE Inc Tutorials© 1986-2002 Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutter- free work area and the Shine step will help create ownership in the equipment and facility. Shine – (Seiso)

12. HOME Copyright EASE Inc Tutorials© 1986-2002 Workers will also begin to notice changes in equipment and facility location such as air, oil and coolant leaks, repeat contamination and vibration, broken, fatigue, breakage, and misalignment. These changes, if left unattended, could lead to equipment failure and loss of production. Both add up to impact your company’s bottom line. Shine – (Seiso)

13. HOME Copyright EASE Inc Tutorials© 1986-2002 Once the first three of the 5S’s have been implemented, you should concentrate on standardizing best practice in your work area. Allow your employees to participate in the development and documentation of such standards. They are a valuable but often overlooked source of information regarding their work. Standardize – (Seiketsu)

14. HOME Copyright EASE Inc Tutorials© 1986-2002 Standardize – (Seiketsu)  Workplace Layout and Design  Materials Handling Analysis  Clear and Concise Work InstructionsWork Instructions  Well Defined Work Methods  Safe (Ergonomic) Working Practices Safe (Ergonomic)  Cycle Time Reduction Cycle Time Reduction  Training Training  Documentation Standardize means establishing “Best Manufacturing Practices, including:

15. HOME Copyright EASE Inc Tutorials© 1986-2002 S This is by far the most difficult S to implement and achieve. Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things. Sustain focuses on defining a new status quo and standard of work place organization. Sustain – (Seiketsu)

16. HOME Copyright EASE Inc Tutorials© 1986-2002 The “5S” Philosophy 5S Once fully implemented, the 5S process can increase moral, create positive impressions on customers, and increase efficiency and organization. Not only will employees feel better about where they work, the effect on continuous improvement can lead to less waste, better quality and shorter lead times. Any of which will make your organization more profitable and competitive in the market place

17. HOME Copyright EASE Inc Tutorials© 1986-2002 Thank you for viewing this tutorial. For further information about EASE Inc, our clients, consulting services, software products and software customization, or to end this tutorial, please select from the buttons at left. Thank you for viewing this tutorial. For further information about EASE Inc, our clients, consulting services, software products and software customization, or to end this tutorial, please select from the buttons at left. EASE Inc. CLIENTS CONSULTING SOFTWARE CONTACT US EXIT

18. HOME Copyright EASE Inc Tutorials© 1986-2002 EASE Incorporated EASE Incorporated is an international corporation, founded in 1986. EASE EASE is headquartered in Southern California with satellite offices in Europe and the United States. EASE Incorporated EASEworks® EASE Incorporated provides productivity improvement services through the application of the EASEworks® Software, training, consulting services and implementation support. Who is EASE Inc? HOME

19. Copyright EASE Inc Tutorials© 1986-2002 EASE Customers HOME

20. Copyright EASE Inc Tutorials© 1986-2002 The Service Our major focus is to offer sustainable productivity improvements and cost reductions for our clients. We can provide you with consulting assistance for.. HOME  Equipment Evaluation  Facility Layout  Establishing “Best Practices”  Competitive Benchmarking  Design Engineering  Process Engineering  Production Engineering  Implementing Ergonomic Improvements  Training and Training Support & Certification  Improving Labor Efficiency  Productivity Analysis  Implementing Lean Manufacturing  Manufacturing Engineering  ISO 9000 Implementation  Developing Work Standards  Process Mapping YOUR with confidence EASE will provide engineers with extensive experience in YOUR industry. Your engineers will have the ability to take over, with confidence, where we leave off.

21. HOME Copyright EASE Inc Tutorials© 1986-2002 SoftwareSoftware EASEworks® Software modules cover: HOME Work Standards Product Cost Estimating Line Balancing Work Instructions Ergonomics Design For Assembly EASE Inc. provides full training, start up assistance and consulting services for all modules. Software customization services are also available.

22. HOME Copyright EASE Inc Tutorials© 1986-2002 Phone:Fax:E-Mail:Web: sales@easeinc.com HOME (949) 348-7511 (973) 201-1600 www.easeinc.com HOME Contact Information EASE Inc EASE Inc. 27405 Puerta Real, #380 Mission Viejo, CA 92691 EASE Inc EASE Inc. 27405 Puerta Real, #380 Mission Viejo, CA 92691 Ver 6

23. HOME Copyright EASE Inc Tutorials© 1986-2002 HOME SAMPLE ONLINE WORK INSTRUCTION

24. HOME Copyright EASE Inc Tutorials© 1986-2002 Full motion video can be displayed as part of a work instruction HOME

25. Copyright EASE Inc Tutorials© 1986-2002 Work tasks can be analyzed in great detail to evaluate alternative methods. HOME

26. Copyright EASE Inc Tutorials© 1986-2002 HOME PROCESS STEPS NECESSARY TO PRODUCE OUTPUT CONTRIBUTES TO CUSTOMER DEMANDS? CONTRIBUTES TO BUSINESSR DEMANDS? VALUE ADDED ESSENTIAL NON-VALUE ADDED NON-VALUE ADDED ASSEMBLY METALWORK PACKAGING FINANCIALS SCHEDULING MINIMAL MATERIAL HANDLING MOVEMENT REWORK STORAGE Determining Value/Non-Value Added Activities Value Added: Activities that must be performed to meet customer requirements Non-Value Added: Activities that do not contribute to meeting customer requirements. These activities can possibly be eliminated. YES NO YES

27. HOME Copyright EASE Inc Tutorials© 1986-2002 This chart illustrates Value Added/Non-Value Added, Walking and Internal Time. HOME

28. Copyright EASE Inc Tutorials© 1986-2002 This shows methods comparison and cost benefits. HOME

29. Copyright EASE Inc Tutorials© 1986-2002 Here is a comparison of the value added. HOME

30. Copyright EASE Inc Tutorials© 1986-2002 Not only can existing working practices be evaluated, but alternatives can be considered and cost justified. HOME

31. Copyright EASE Inc Tutorials© 1986-2002 A leading beef processing plant uses EASE to compare the same task for training and work content across all of their plants. HOME