Lean Training5S Agenda n n n n n What is it? What’s it for? How does it work? When do you use it? What’s an example? What is it? n n n 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 What’s it for? n It is a way to create: n n n n n n Cleaner work areas More organization Safer working conditions Less wasted time Efficient work processes and practices More available space How does it work? n n 5S is most effective when applied in a systematic way The following video illustrates the 5S methodology 5S Video The Five S’s n n n n n 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 The First S - Sorting Separating the Needed from the NotNeeded n Eliminate not-needed items and perform an initial cleaning n n n n n 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 The Second S - Simplifying A place for everything and everything in its place, clean and ready to use n Arrange workplace for safety and efficiency n n n n n Identify key equipment and supplies Determine location for each item Outline locations and zones Develop shadow boards, label items Document layout, equipment, supplies The Third S – Systematic Cleaning n Cleaning for Inspection Perform daily cleaning and inspection to understand work conditions n n n n n Identify points to check for performance Determine acceptable performance Determine visual indicators/controls Mark equipment/controls Conduct daily cleaning/inspections The Fourth S - Standardizing n Developing Common Methods for Consistency Make abnormal conditions noticeable and document agreements Document agreements and checks n Establish/document standard methods across similar work areas n Document new standard methods n The Fifth S - Sustaining Holding the Gains and Improving n Maintain the gains from other 5S activities and improve Determine 5S Level of Achievement n Perform routine checks n Analyze results of routine checks n Measure progress and plan for continuous improvement n Getting Started n n n Planning – launches your 5S activity Evaluating – tells you what you need to do Preparing – gets you ready for implementation Planning n n n n n n 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 5S Boundaries Area 1 Monica & Chandler Area 2 Joey & Phoebe Area 3 Rachel & Ross Area 4 Jerry & Kramer Five S Communication Board Five S Team Members Five S Boundaries Five S Routine Checklist Five S Implementation Plan Levels of Achievement Photos Current Situation Photos Five S Implementation Plan Five S Routine Checklist After Five S Evaluating Your Initial Situation n n n Prepare to take work area photos Take work area photos Evaluate current 5S Level of Achievement 5S Workplace Organization Levels of Achievement Level 5: Continuously Improve Level 4: Focus on Reliability Level 3: Make it Visual Level 2: Focus on Basics Level 1: Just Beginning N eeded items are routinely reworked / rep laced as needed t o improve w ork area performance N eeded items c an b e retrieved w ithin 3 0 s econds and req uire a minimum number o f s tep s P roblem s ources are documented w ith s olutions defined and implemented M ethods f or hous ekeeping , labeling , ins pections , and work p lace d es ig n are continually improved and s hared externally as applicable N eeded items are routinely N eeded items have b een D aily ins pection o ccurs t o A g reements f or labeling , as s es s ed ag ains t b us ines s minimiz ed in number/ s iz e and as s es s area readines s , hous ekeeping , ins pections , needs t o as s ure f unctionality are p roperly arrang ed f or potential p roblems are and w ork p lace d es ig n are and f it retrieval and us e identified and f ixed cons is tently f ollowed and demons trate area performance improvement A lis t o f needed items f or t he N eeded items have d ed icated V is ual c ontrols f or W ork area ag reements f or work area has b een locations and are p roperly eq uipment, f iles and s upplies needed item labeling and documented labeled w ith req uired have b een es tablis hed f or t he vis ual c ontrols are p os ted quantities work area and f ollowed b y w ork t eam R oot c aus es have b een eliminated and improvement actions f ocus o n d eveloping preventive methods S ources and f req uency o f problems are d ocumented as part o f routine w ork, root caus es are identified , and corrective action p lans are developed W ork t eam is routinely checking area t o maintain 5S ag reements and p os ting res ults N eeded and not needed items have b een s orted and not needed have b een removed f rom w ork area N eeded items have b een s afely s tored and o rg aniz ed according t o f req uency o f us e K ey w ork area items t o b e checked are indentified and documented W ork area ag reements are 5S level has b een d etermined identified and d ocumented and p os ted o n t he for needed item o rg aniz ation communication b oard and w ork area c ontrols N eeded and not needed items are mixed t hroug hout the w ork area Items are p laced randomly throug hout t he w ork p lace K ey w ork area items t o b e checked d uring a s weep are not identified N o w ork area ag reements exis t Sorting Simplifying Sweeping Standardizing T here is no meas urement o f 5S p erformance Sustaining rev. 0 4 -‐0 6 -‐0 1 Preparing for Implementation n n n n n n n 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 Summary: Implementing Five S’s n n n n n n n 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 Issues and Concerns n n n n n n n 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 What’s an example? What’s an example? What’s an example? Before After What’s an example? What’s an example? Questions?