5s Basic Training Ppt

(1)

5S

BASIC

TRAINING

What is 5S and why do we want to do it? What is 5S and why do we want to do it?

(2)

What is 5S and why do we want to do it? What is 5S and why do we want to do it?

5S is short for: Sort, Set in Order, Shine, Standardize 5S is short for: Sort, Set in Order, Shine, Standardize

and Sustain and Sustain

5S

5S _{represents 5 disciplines for maintaining a visual}_{represents 5 disciplines for maintaining a visual}

workplace (visual controls and information systems). workplace (visual controls and information systems). These are foundational to Kaizen (continuous

These are foundational to Kaizen (continuous

improvement) and a manufacturing strategy based "Lean improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts.

Manufacturing" (waste removing) concepts.

5S is one of the activities that will help ensure our 5S is one of the activities that will help ensure our company’s survival.

(3)

5S

1. Sort

1. Sort _{- All unneeded tools, parts and supplies are}_{- All unneeded tools, parts and supplies are}

removed from the area removed from the area

2. Set in Order

2. Set in Order _{- A place for everything and everything is}_{- A place for everything and everything is}

in its place in its place

3. Shine

3. Shine _{- The area is cleaned as the work is performed}_{- The area is cleaned as the work is performed} 4. Standardize

4. Standardize _{- Cleaning and identification methods are}_{- Cleaning and identification methods are}

consistently applied consistently applied

5. Sustain

5. Sustain _{- 5S is a habit and is continually improved}_{- 5S is a habit and is continually improved}

Also

Also _{- Work areas are safe and free of hazardous or}_{- Work areas are safe and free of hazardous or}

dangerous conditions dangerous conditions

(4)

Some New Words

Red Tag-Process for tagging, removing and disposing of Red Tag-Process for tagging, removing and disposing of

items not needed in the work area. items not needed in the work area.

Lean Manufacturing-concepts that seek continuous Lean Manufacturing-concepts that seek continuous

improvement by removing waste in processes improvement by removing waste in processes Some Japanese words you need to know:

Some Japanese words you need to know:

Kaizen-(pronounced “ki zen”) - improvement Kaizen-(pronounced “ki zen”) - improvement

Kaizen Event and 5S Event-Planned improvements to a Kaizen Event and 5S Event-Planned improvements to a

specific area or process (usually take 3 to

specific area or process (usually take 3 to 5 days).5 days). 5S Events focus on making 5

5S Events focus on making 5S improvements.S improvements. Muda-(pronounced “moo da”) - waste

Muda-(pronounced “moo da”) - waste

Gemba-(pronounced “gim ba”) - workplace Gemba-(pronounced “gim ba”) - workplace

(5)

New Words - Continued

Kanban-(pronounced “kon bon”) - Pull type inventory Kanban-(pronounced “kon bon”) - Pull type inventory control system.

control system. Items are Items are only produced to only produced to meet cmeet customer ustomer needs.

needs. The request The request to produce more to produce more is signaled is signaled from anfrom an upstream operation and/or customer orders.

upstream operation and/or customer orders.

Value Stream Map - A diagram of all processes needed to Value Stream Map - A diagram of all processes needed to make and deliver the product to the customer.

make and deliver the product to the customer.

OTHER PROBLEM SOLVING TOOLS OTHER PROBLEM SOLVING TOOLS TOC-Short

TOC-Short for Theory for Theory of Constraints. of Constraints. Problem Problem solvingsolving and constraint

and constraint management management methods. methods. Use the Use the 5 Step 5 Step formform of TOC to solve problems that you will encounter in your of TOC to solve problems that you will encounter in your continuous improvement efforts.

(6)

Some 5S Examples

Before 5S Before 5S After 5S - Cleaned, After 5S - Cleaned, organized and drawers organized and drawers labeled (less time and labeled (less time and frustration hunting) frustration hunting)

(7)

5S Examples - Sort, Set in Order

See the difference? See the difference?

1. Sort

1. Sort _{- All unneeded tools, parts and supplies are r}_{- All unneeded tools, parts and supplies are r}_emoved_emoved

from the area from the area

2. Set in Order

2. Set in Order _{- A place for everything and everything is}_{- A place for everything and everything is}

in its place in its place

(8)

5S Examples - Shine

3. Shine

3. Shine _{- The area is cleaned as the work is performed}_{- The area is cleaned as the work is performed}

(best) and\or there is a routine to keep the work

(best) and\or there is a routine to keep the work areaarea clean.

(9)

5S Examples - Standardize

4. Standardize

4. Standardize _{- Cleaning and identification methods}_{- Cleaning and identification methods}

are consistently applied are consistently applied

Departments have weekly 5S tours Departments have weekly 5S tours

Every job has duties that use Sort, Set in Order

Every job has duties that use Sort, Set in Order andand Shine

Shine

We all have common duties to do our part to keep all We all have common duties to do our part to keep all areas of the plant in shape - breakr

areas of the plant in shape - breakroom, restrooms,oom, restrooms, locker area, parking lot, etc

(10)

5S Examples - Sustain

5. Sustain

5. Sustain _{- 5S is a habit and is continually}_{- 5S is a habit and is continually}_improved_improved

5S is a simple concept with powerful results. 5S is a simple concept with powerful results.

You will get additional information on 5S so that you You will get additional information on 5S so that you will be well equipped.

will be well equipped.

Our experience is that the more we do 5S the better the Our experience is that the more we do 5S the better the work environment becomes: cleaner, safer, more

work environment becomes: cleaner, safer, more

organized, the work is easier, less confusion and less organized, the work is easier, less confusion and less stress.

stress.

Use the 5S (work\home\play) - The more you use it the Use the 5S (work\home\play) - The more you use it the easier it becomes and life just gets better and better.

(11)

The Good, Bad and the Ugly

First the Bad and the Ugly - Life Without 5S First the Bad and the Ugly - Life Without 5S

(12)

The Good

(13)

What is Waste (Muda)?

Some of the main forms of waste are: Some of the main forms of waste are: Overproduction

Overproduction

Waiting for materials, machines, or instruction Waiting for materials, machines, or instruction Transportation or movement

Transportation or movement Excessive inventory

Excessive inventory

Inefficient machine processing and/or operation Inefficient machine processing and/or operation Producing defects

Producing defects

Part or line changeover or machine setup Part or line changeover or machine setup Inadequate housekeeping

Inadequate housekeeping

Miscommunication or inadequate instruction Miscommunication or inadequate instruction

(14)

Improvement (Kaizen) Principles

Get rid of all old (false) assumptions. Get rid of all old (false) assumptions.

Don't look for excuses, look for ways to make it happen Don't look for excuses, look for ways to make it happen . . Don't worry about being perfect - even if you only get it . . Don't worry about being perfect - even if you only get it

half

half right right “start “start NOW”!NOW”!

It does not cost money to do KAIZEN. It does not cost money to do KAIZEN. If som

If something ething is wrong is wrong “Fix i“Fix it t NOW”.NOW”.

Good ideas flow when the going gets tough. Good ideas flow when the going gets tough. Ask "WHY" five times - get t

Ask "WHY" five times - get to the root cause.o the root cause. Look for wisdom from Ten people rather than one. Look for wisdom from Ten people rather than one. Never stop doing KAIZEN.

(15)

Summary

5-S is for you. 5-S is for you.

Clean-up and organize your work area every day so that Clean-up and organize your work area every day so that each new day is easier and safer than the day befor

each new day is easier and safer than the day beforee Share your input with your leaders so that the tools you Share your input with your leaders so that the tools you need will be available to you, increasing your efficiency. need will be available to you, increasing your efficiency. Volunteer to help with the 5S tours and 5S events.

Volunteer to help with the 5S tours and 5S events.

Take a good look around...Imagine zero waste/zero Take a good look around...Imagine zero waste/zero confusion!