Beruflich Dokumente
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Learning Objectives
Recognizing Wastes Learn the 5S (Sort, Stabilise, Shine, Standardise, Sustain) Understand 5S Assessment Check Sheet
Recognizing Wastes
MOVE IT OVER THERE UNTIL WE NEED IT
MOTION
CONVEYANCE
UNDER-UTILIZED RESOURCES
WASTES
WAITING CORRECTION
OVER PROCESSING
INVENTORY
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8 Wastes - WAITING
Equipment failures Waiting for support Unbalanced work Sharing of tooling and equipments Standing watching while automatic machines cycle Waiting for arrival of material or removal of finished goods Poor reliability and high machine down times Machinery or process starved by prior process Machinery or process blocked by subsequent process
8 Wastes OVERPRODUCTION
Making more, sooner and faster than required by the next process Overproduction is the worst waste commonly found in factories, it creates additional waste in the system and contributes to the other wastes. Additional handling, space, interest paid, Additional investment in extra equipment Overproduction can be caused by: Unbalanced manufacturing system, long c/o, poor uptime and excess capacity Batch and queue processing
8 Wastes MOTION
Unnecessary movement of Operators or Equipment due to: Poor workstation layout and design Poor Parts presentation Multiple pick Lack of workplace organization Insufficient training Poor ergonomics Double Handling and transfer of parts
8 Wastes OVERPROCESSING
Performing Unnecessary or incorrect processing due to: Poor Product design Poor Process design Lack of process capability Unclear standards and customer specifications NVA testing, retesting and inspection as part of the process
8 Wastes INVENTORY
Excessive Inventories can be caused by: Unstable and uncontrolled manufacturing systems Unpredictable productivity due to machine downtime and OEE Unpredictable schedules and inefficient delivery / shipping of materials In efficient and long change over times Bad information flow through out the value stream Large batch sizes Poor material control processes
8 Wastes CONVEYANCE
Unnecessary movement of WIP, Finished Goods and Raw materials: Movement from process to warehouse to next process Double handling due to excess inventories Insufficient material storage Poor plant and marketplace layouts Material not placed in the workstation Poor scheduling Unplanned changeover Lack of process flow Batch and queue production
MOVE IT OVER THERE UNTIL WE NEED IT
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Importance of 5S
QUALITY
PRODUCTIVITY SAFETY EQUIPMENT RELIABILITY
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5S Definition
5S is a workplace organization tool/process that maximizes the cleanliness, organization, and safety of all elements in a working environment.
1. Seiri 2. Seiton 3. Seiso 4. Seiketsu 5. Shitsuke Sort Stabilise and Set In Order Sweep and Shine Standardise Self Discipline and Sustain
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5S SORT
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1. 2. 3. 4. 5. 6. 7. 8. 9.
Capture the current condition of an area Ask the questions around the current condition Red Tag those items identified as unneeded, unwanted or unused Move the tagged items to the quarantine area. Enter the items on a red tag log Review the items within an agreed time period Make business decision whether to keep the item or not Dispose items identified as unwanted or unneeded in a TIMELY MANNER Move those items identified as needed to a central holding area
WHY do we need this amount? WHERE is this used / required? WHAT is the frequency of use? HOW is this controlled? WHY is this stored here?
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Items which are identified for removal and/or not longer needed Red Tags should contain: Date when tag attached Date of decision Quantity of material Reason for tagging What you intend to do with it
dispose, store close by, store in area, send to main stores, hold for analysis, etc
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BEFORE
AFTER
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5S STABILISE
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5S STABILISE
Stabilise ensures that there is a place for everything and everything is in its Stabilise ensures that there is a place for everything and everything is in its place and labelled. Sort and Stabilise are best implemented together. place and labelled. Sort and Stabilise are best implemented together. The process allows us to increase our efficiency through proper The process allows us to increase our efficiency through proper organisation, the elimination of not needed items and visual controls, it makes organisation, the elimination of not needed items and visual controls, it makes items items Easy to see Easy to see Easy to locate Easy to locate Easy to return Easy to return It encourages sharing of supplies and tooling, identifies excess inventory It encourages sharing of supplies and tooling, identifies excess inventory and allows us to maintain and improve performance by highlighting and allows us to maintain and improve performance by highlighting abnormalities abnormalities
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2.
3.
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Direction of Flow
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LOW USE
Things used only Once in the past 6 12 months Things used only Once in the past 2 6 months Things used more than once a month Things used once a week
Store at distance
FREQ. OF USE
AVERAGE USE
HIGH USE
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5S SHINE
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5S SHINE
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Our aim is to :
Keeping our work areas and equipment clean makes it easier to
identify abnormalities and sources of contamination. A clean workplace generates pride and ownership Cleaning Is Inspection! Defects in plant and equipment can be identified during the cleaning process
Shine applies to all areas of our business NOT JUST THE FACTORY FLOOR
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SHINE Implementation
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5S STANDARDISE
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5S STANDARDISE To establish and document clear rules standards To establish and document clear rules standards and processes to keep the workplace and processes to keep the workplace clean and organised clean and organised
It creates a process to maintain and monitor the It creates a process to maintain and monitor the first three S. first three S. The purpose of standardise is to establish the The purpose of standardise is to establish the minimum acceptable standard on which we minimum acceptable standard on which we must improve must improve It is the foundation for continuous improvement in the It is the foundation for continuous improvement in the Five S process Five S process
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Conformation check
Conformation check
ENV IRO NM E NT
Audit Card
Conformation check Conformation check
VERSATLITY
Is all inf o correct and inclusive of key Conformation check points?
Conformation check
W
Is WBB same as the operator job?
VISUAL AIDS 5S
Conformation check
Conformation check
Conformation check
FTPM
Are tooling, jigs and equipment in a good condition?
Conformation check Conformation check
Conformation check
Cleaning Standard
Conformation check
1
Conformation check Conformation check
2 3
Conformation check Conformation check
Clean Check Wipe Sweep All Inside Oil Hole Use brush
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STANDARDISE Implementation
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5S SUSTAIN
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5S SUSTAIN Making the standard a part of day to day life through Making the standard a part of day to day life through discipline at all levels of the organisation.. discipline at all levels of the organisation
It makes excellence a habit and changes culture. It makes excellence a habit and changes culture. Everyone is responsible for sustaining the Five S process. Everyone is responsible for sustaining the Five S process.
Management Management Leads by example Leads by example Coaches Coaches Evaluates the ongoing process of Five S Evaluates the ongoing process of Five S Encourage Continuous Improvement Encourage Continuous Improvement Group Leaders and Operators Group Leaders and Operators Apply the Five S process Apply the Five S process Maintain the standards Maintain the standards Elevate issues Elevate issues Drive continuous improvement Drive continuous improvement
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Create plant wide awareness of the Five S process Establish a support structure with clear roles and responsibilities. Make time for required Five S Activities including regular Management Reviews Provide recognition during evaluations and plant tours Encourage continuous improvement and continually raise the standards
Everyone is responsible for setting and maintaining a high standard Everyone is responsible for setting and maintaining a high standard Make excellence a Habit Make excellence a Habit
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SUSTAIN Implementation
Effective Communication
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SUSTAIN Implementation
Recognize Accomplishments
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SUSTAIN Implementation
Illustration from The Visual Factory - Grief
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WHAT IS NEXT?
Everyone to participate Setup 5S Administrative Structure 5S Assessment Criteria Do the first 3S before moving to the others.
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