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The “5S” Philosophy The Art of Good Housekeeping START Ver 6
The “5S” Philosophy 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!
Some New Words Red Tag-Process for tagging, removing and disposing of items not needed in the work area. Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes Some Japanese words you need to know: Kaizen-(pronounced “ki zen”) - improvement Kaizen Event and 5S Event-Planned improvements to a specific area or process (usually take 3 to 5 days). 5S Events focus on making 5S improvements. Muda-(pronounced “moo da”) - waste Gemba-(pronounced “gim ba”) - workplace
New Words - Continued Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders. Value Stream Map - A diagram of all processes needed to make and deliver the product to the customer. OTHER PROBLEM SOLVING TOOLS TOC-Short for Theory of Constraints. Problem solving and constraint management methods. Use the 5 Step form of TOC to solve problems that you will encounter in your continuous improvement efforts.
Some 5S Examples Before 5S After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
The first S focuses on eliminating unnecessary items from the workplace. Sort – (Seiri)
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)
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)
A place for everything & everything in its place
Set in Order – (Seiton) <ul><li>What do I need to do my job? </li></ul><ul><li>Where should I locate this item? </li></ul><ul><li>How many do I need? </li></ul>The second S focuses on efficient and effective storage methods. You must ask yourself these questions:
Strategies for effective Set In Order are: Set in Order – (Seiton) <ul><ul><li>Painting floors </li></ul></ul><ul><ul><li>Outlining work areas and locations </li></ul></ul><ul><ul><li>Shadow boards </li></ul></ul><ul><ul><li>Modular shelving and cabinets </li></ul></ul>“ A PLACE FOR EVERYTHING AND EVERTHING IN ITS PLACE”
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)
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)
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)
Standardize – (Seiketsu) <ul><li>Workplace Layout and Design </li></ul><ul><li>Materials Handling Analysis </li></ul><ul><li>Clear and Concise Work Instructions </li></ul><ul><li>Well Defined Work Methods </li></ul><ul><li>Safe (Ergonomic) Working Practices </li></ul><ul><li>Cycle Time Reduction </li></ul><ul><li>Training </li></ul><ul><li>Documentation </li></ul>Standardize means establishing “Best Manufacturing Practices, including:
The Good, Bad and the Ugly First the Bad and the Ugly - Life Without 5S
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)
What is Waste (Muda)? <ul><li>Some of the main forms of waste are: </li></ul><ul><li>Overproduction </li></ul><ul><li>Waiting for materials, machines, or instruction </li></ul><ul><li>Transportation or movement </li></ul><ul><li>Excessive inventory </li></ul><ul><li>Inefficient machine processing and/or operation </li></ul><ul><li>Producing defects </li></ul><ul><li>Part or line changeover or machine setup </li></ul><ul><li>Inadequate housekeeping </li></ul><ul><li>Miscommunication or inadequate instruction </li></ul>
Improvement (Kaizen) Principles <ul><li>Get rid of all old (false) assumptions. Don't look for excuses, look for ways to make it happen. </li></ul><ul><li>Don't worry about being perfect - even if you only get it half right “start NOW”! (but FINISH it) </li></ul><ul><li>It does not cost money to do KAIZEN. </li></ul><ul><li>If something is wrong “Fix it NOW”. Good ideas flow when the going gets tough. </li></ul><ul><li>Ask "WHY" five times - get to the root cause. </li></ul><ul><li>Look for wisdom from Ten people rather than one. </li></ul><ul><li>Never stop doing KAIZEN. </li></ul>
The “5S” Philosophy 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