5S_basics
Download as PPT, PDF2 likes1,429 views
The document provides an overview of 5S, a workplace organization technique used in Lean activities. 5S involves five steps: (1) sorting to identify needed vs unneeded items, (2) simplifying by having a designated place for everything, (3) systematic cleaning, (4) standardizing processes, and (5) sustaining the organization. It describes each step in detail and how to implement 5S by forming a team, taking initial photos, evaluating the current state, and creating an implementation plan with targets and activities. The goal is to create cleaner, safer and more efficient work areas through organizing and standardizing processes.
5S_basics
- 2. Agenda What is it? What’s it for? How does it work? When do you use it? What’s an example?
- 3. What is it? 5S is a workplace organization technique It is a way to involve associates in the ownership of their workspace It helps create and maintain the efficiency and effectiveness of a work area 5S is a common starting point for Lean activities in a company
- 4. What’s it for? It is a way to create: Cleaner work areas More organization Safer working conditions Less wasted time Efficient work processes and practices More available space
- 5. How does it work? 5S is most effective when applied in a systematic way The following video illustrates the 5S methodology 5S Video
- 6. The Five S’s Sorting – separating the needed from the not-needed Simplifying – a place for everything and everything in its place, clean and ready to use Systematic Cleaning or Sweeping – cleaning for inspection Standardizing – developing common methods for consistency Sustaining – holding the gains and improving
- 7. The First S - Sorting Separating the Needed from the Not- Needed Eliminate not-needed items and perform an initial cleaning Establish criteria/handling of items Identify not-needed items Move not-needed items to holding area Conduct a white-elephant sale Conduct an initial cleaning
- 8. The Second S - Simplifying A place for everything and everything in its place, clean and ready to use Arrange workplace for safety and efficiency Identify key equipment and supplies Determine location for each item Outline locations and zones Develop shadow boards, label items Document layout, equipment, supplies
- 9. The Third S – Systematic Cleaning Cleaning for Inspection Perform daily cleaning and inspection to understand work conditions Identify points to check for performance Determine acceptable performance Determine visual indicators/controls Mark equipment/controls Conduct daily cleaning/inspections
- 10. The Fourth S - Standardizing Developing Common Methods for Consistency Make abnormal conditions noticeable and document agreements Document agreements and checks Establish/document standard methods across similar work areas Document new standard methods
- 11. The Fifth S - Sustaining Holding the Gains and Improving Maintain the gains from other 5S activities and improve Determine 5S Level of Achievement Perform routine checks Analyze results of routine checks Measure progress and plan for continuous improvement
- 12. Getting Started Planning – launches your 5S activity Evaluating – tells you what you need to do Preparing – gets you ready for implementation
- 13. Planning Assemble a 5S Lead team Define the work area 5S boundaries Assign work group members to their 5S areas Install a 5S communication board Determine 5S targets, activities, and schedule Review/finalize plans with work group and site leadership
- 14. 5S Boundaries Area 1 Area 2 Area 3 Area 4 Monica & Chandler Rachel & Ross Joey & Phoebe Jerry & Kramer
- 15. Five S Communication Board Levels of Achievement Five S Team Members Five S Boundaries Five S Routine Checklist Five S Routine Checklist Five S Implementation Plan Five S Implementation PlanPhotos Photos Current Situation After Five S
- 16. Evaluating Your Initial Situation Prepare to take work area photos Take work area photos Evaluate current 5S Level of Achievement
- 17. 5S Workplace Organization Levels of Achievement Level 5: Continuously Improve Needed items are routinely reworked/ replaced as needed to improve work area performance Needed items can be retrieved within 30 seconds and require a minimum number of steps Problem sources are documented with solutions defined and implemented M ethods for housekeeping, labeling, inspections, and work place design are continually improved and shared externally as applicable Root causes have been eliminated and improvement actions focus on developing preventive methods Level 4: Focus on Reliability Needed items are routinely assessed against business needs to assure functionality and fit Needed items have been minimized in number/ size and are properly arranged for retrieval and use Daily inspection occurs to assess area readiness, potential problems are identified and fixed Agreements for labeling, housekeeping, inspections, and work place design are consistently followed and demonstrate area performance improvement Sources and frequency of problems are documented as part of routine work, root causes are identified, and corrective action plans are developed Level 3: Make it Visual A list of needed items for the work area has been documented Needed items have dedicated locations and are properly labeled with required quantities Visual controls for equipment, files and supplies have been established for the work area Work area agreements for needed item labeling and visual controls are posted and followed by work team Work team is routinely checking area to maintain 5S agreements and posting results Level 2: Focus on Basics Needed and not needed items have been sorted and not needed have been removed from work area Needed items have been safely stored and organized according to frequency of use Key work area items to be checked are indentified and documented Work area agreements are identified and documented for needed item organization and work area controls 5S level has been determined and posted on the communication board Level 1: Just Beginning Needed and not needed items are mixed throughout the work area Items are placed randomly throughout the work place Key work area items to be checked during a sweep are not identified No work area agreements exist There is no measurement of 5S performance Sorting Simplifying Sweeping Standardizing Sustaining rev. 04-06-01
- 18. Preparing for Implementation Obtain existing standards for color-coding and signage Decide on 5S color-coding and signage standards Prepare for Sorting Prepare for Simplifying Prepare for Systematic Cleaning Prepare for Standardizing Prepare for Sustaining
- 19. Summary: Implementing Five S’s Share 5S Overview Choose work area implementation group Determine implementation targets, activities, and schedules Document current situation Apply 5S’s Document improvements Determine new improvement goals and action steps
- 20. Issues and Concerns Communicating across shifts Disposing of, or moving, personal items Making time available Following agreements consistently Maintaining the gains Giving rewards and recognition Integrating 5S with other improvement activities
- 23. What’s an example? Before After
- 26. Questions?