5S Techniques (Lean Manufacturing)

Lean Manufacturing

System & philosophy focused on eliminating all waste in manufacturing processes.

- Eliminating of waste in every area of production including
customer relations, product design, supplier networks and factory management

- Incorporating less human effort, less inventory, less time to

develop products, and less space

- Becoming highly responsive to customer demand while producing

top quality products in the most efficient and economical manner possible

Central Principle of Lean

Friction
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How do we define Friction in this context?

Friction is any frustrating, chronic annoyance, or a chronic inefficiency. Can we think of any?

Can you imagine a workday without these obstacles?

Additional Principles of Lean:

Zero waiting time

never waiting for an approval, signature, materials, equipment

Zero Inventory

why would we want zero inventory?

Scheduling -- internal customer pull instead of push

next person/step is ready and waiting for the handoff

Batch to Flow -- cut batch sizes Line Balancing

Cut process times

Is speed of delivery the only benefit?

No. Reduction of all different types of waste lowers cost improves quality, and emphasizes adding value to the customer. Waste is so important- 7 types are identified:
Over- Production cant be sold Correction - re-work Waiting operator is idle between operations Inventory excess ties up cash! Motion awkward operator motions undue stress Conveyance unnecessarily moving a part Processing unclear customer requirements can cause unnecessary processes

Just in Time (JIT)

Producing and distributing goods in the amount required at the time requested

Produce to TAKT Time TAKT is

german for pace/rhythm. The pace is determined by calculating the number of parts required by the customer divided by the production time available.

- Pace, Rhythm (Qty. Time)

Kaizen?

Depending on your translation

Kai- change, continuous Zen- improvement, good, for the better

It is Continuous Improvement maybe

taking something apart and putting it back together BETTER than before.

The Five Ss

Japanese "S"

Seiri (Organization) Seiton (Tidiness) Seiso (Purity) Seiketso (Cleanliness) Shitsuke (Discipline)

American "S" Sort Set in Order Shine Standardize

Sustain

The Goal

Maximize Value to Customer Maximize Value to Shareholder

Eliminate Waste

Receive Customer Order

Receive Payment

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The Goal
The unavoidable reality of business:

We will never be given more people and more time, to make less, at greater cost. Business will continue to move in the direction of make more, faster & cheaper, with fewer people.

Eliminating waste (by implementing 5S) is a means towards this end.

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The Pillars of 5S

Pillar 1: Sort Pillar 2: Set in order Pillar 3: Shine Pillar 4: Standardize Pillar 5: Sustain

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Introduction to the Five Pillars of 5S

Customer needs are always changing

New technologies New products

Customer expectations continue to rise

What are your expectations of the most recent car you purchased?

To succeed as a business we must continue to change and improve to meet and surpass our customers expectations.

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Introduction to the Five Pillars of 5S

The five pillars of 5S are a starting point for various improvement activities.

Neatness and Order

Important to our personal lives Critical to our work lives Essential for smooth and efficient activities

5S is Simple but important

A neat and clean factory

Higher productivity Fewer defects Greater morale

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SORT - The first pillar

What is needed

When it is needed
In the amount needed

Remove all items from the workplace that are not needed for current operations. When in doubt, throw it out! A Packrats nightmare

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SET IN ORDER - The second pillar

Organize Arrange needed items so that they are

Easy to use Easy to find Easy to put away

. . . . . . . .By Anyone.

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SHINE - The third pillar

Clean
Sweep floors Wipe machinery and equipment Paint and repair Get it clean

Keep everything in good condition so it is always reliable and ready to be used.

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STANDARDIZE The fourth pillar

Standardized Cleanup Establishing a method to maintain the first three pillars Everyones responsibility Prevents problems

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SUSTAIN The fifth pillar

Discipline

Making order and

Establish a culture of
clean cleanliness a habit

SORT (Organization)

SET IN ORDER (Orderliness)

Clearly distinguish Keep needed items needed items from in the correct unneeded items place to allow for SUSTAIN and eliminate easy & quick (Discipline) the latter retrieval Make a habit of maintaining established This is the Keep the procedures condition we workshop support when swept and we maintain the clean first three pillars

STANDARDIZE (Standardized Cleanup)

SHINE (Cleanliness)

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Resistance to Implementing 5S
Whats so great about sort and set in order? It will take too much time. Why clean when it just gets dirty again? Are sort, set in order, and shine really going to boost productivity?

Why bother?

What are the reasons for resisting 5s implementation?

We already implemented sort and set in order.

Were too busy for 5s.

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We did 5s years ago.

Benefits of Implementing 5S
Workers have an opportunity to provide creative ideas about how the workplace should be organized. Higher job satisfaction. Clear expectations. Reduced changeover time = higher productivity.

Growth.

What are some benefits of implementing 5s?

Reduced defects and higher quality.

Safer environment. Win customer confidence and trust.

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Elimination of cost causing waste. Reduced delays mean timely delivery of product.

Maintained machinery and equipment means reduced downtime.

Implement SORT with a red tag campaign

Red-tagging is a method for identifying potentially unneeded items, evaluating their usefulness, and dealing with them appropriately. Place red tags on items that need evaluation

Ask

Is this item needed? If so, is it needed in this quantity? If it is needed, does it need to be located here?

Evaluate and deal with the item appropriately

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Steps for Implementing the second pillar SET IN ORDER

Decide the location of items that eliminates waste eliminate waste

Principles of motion economy 5S map

Label locations
Area, specific placement, and amount

Tools
Signboards Paint paths and areas Color-coding Outlining
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Label Locations

Once the best locations have been decided, you must identify locations so ANYONE will know:
What goes where How many of each item go in each location How? Outlining Strategy
Signboard Strategy Painting Strategy After 5S Map Color-coding Strategy
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Set In Order Outlining Strategy

Organize items so they are

easy to use easy to find easy to put away

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Signboards
Signboards have: Location indicators

Item indicators Amount indicators

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Painting strategy
Painting identifies locations on floors and walkways. Place markers for work tables Place markers for operators Cart storage locations Pallet storage locations
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Implement SHINE with careful planning

1. Determine targets
Warehouse items Equipment Space

5. Shine 6. Inspect 7. Report Findings 8. Correct Problems Via Approved Methods

2. Determine assignments and schedule

5S Assignment Map 5S Schedule

3. Determine methods
Tools and rules

4. Prepare cleaning tools

Standardize storage Checklists
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Implementing Standardize
Establishing a method to maintain the first three pillars
Decide

who is responsible for which activities for maintaining 3S conditions

3S maintenance into regular work duties to see how well 3S conditions are being maintained

Integrate

Check

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Implementing Standardize

Set up a schedule

Use tools such as:

5S

Maps 5S Schedules 5S Job Cycle Charts

Audit Inspect what you expect

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Implementing Sustain

Make cleanliness a habit

Create conditions which will sustain your efforts

Schedule time to maintain order and cleanliness Committed support and recognition from management
5S Slogans 5S Posters 5S Maps 5S Newsletters 5S Tours 5S Audits 5S Storyboards
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Success with 5S!

What are the results of 5S

implementation?

Lets see some before and after.

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Before 5S

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After 5S

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Before 5S

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After 5S

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Before 5S

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After 5S

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What are other proven results?

Internal Audits:

Commitment from an audit: Renovate the room with stainless steel sinks, cabinets, drains, hooks, and racks

Statements modified to retain confidentiality.

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What are other proven results?

Follow up audit results:

The room has new stainless steel cabinets for storage of utensils, supplies, pumps. The floor sink looks much better and there is a stainless steel covering on wall above sink. It has hooks for neatly hanging mops and items for drying. The water hose is now wound on a retractable hose wheel.

The successful deployment of the 5S program was readily apparent.

Statements modified to retain confidentiality.

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Its up to you.
Implementing

5S is half
SORT (Organization) SET IN ORDER (Orderliness)

the battle.
The Put

other half is sustaining it.

the tools to work for your workplace and team.

Clearly distinguish Keep needed items needed items from SUSTAIN in the correct unneeded items place to allow for (Discipline and eliminate easy & quick ) retrieval the latter Make a habit of This is the maintaining Keep the condition we established workshop support when procedures swept and we maintain the clean first three pillars

STANDARDIZE (Standardized Cleanup)

SHINE (Cleanliness)

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References

Original version of 5S Wyeth presentation developed by Lynn Stot, Wyeth Pharmaceuticals. Blanchard, Ken; John Carlos; and Alan Randolph. 1996. Empowerment Takes More Than a Minute. San Francisco. Berrett-Kohler Publishers. Hirano, Hiroyuki and Melanie Rubin. 1996. 5S for Operators. Portland. Productivity Press.

Hirano, Hiroyuki and Dr. J.T. Black. 1988. JIT Factory Revolution. Cambridge. Productivity Press.
www.productivityeurope.com www.lean.org

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