Beruflich Dokumente
Kultur Dokumente
6S
5S
Information Center
(Plant-wide Reporting)
5S 2
8 WASTES
Defect / Correction Overproduction Waiting Not utilizing employee talents Transportation / material movement Inventory Motion Excessive processing
5S 3
Sort
Straighten
Shine
Standardize Sustain
5S 4
5S
5S
5S
5S
5S
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10
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1S
2S 3S 4S
Sort
Straighten Shine Standardize Sustain
5S
5S
17
5S
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1S Sort
Segregate What Is Needed, Needed Later, and Not Needed Discard What Is Not Needed Segregate Needed Items By Frequency of Use
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20
Where to Perform
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Classification:
Ent er # in box
1. 2. 3. 4.
5. 6. 7. 8.
Reason:
Ent er # in box
1. 2. 3.
4. 5.
Unknown Other______________
Action:
Ent er # in box
Completed:
C E N GL EX X X (-)
Tag Attached:
Action Taken:
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24
Sort
5S
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5S
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5S
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2S
Straighten
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Stage 1
Stage 2
Stage 3
Stage 4
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Before
After
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Before
After
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Before
After
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Before
After
5S 40
5S
41
3S
Shine
5S
42
Why Shine?
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Shine Targets
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47
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48
5S Assessment
5S
To-Do Items
Remove unneeded equipment, tools, furniture, etc. Provide information on department PPB Review excess inventory, supplies, parts, or materials Identify existence of safety hazards (water, oil, chemical, machines, extension cords, etc.)
Observed Condition
Improvement Action
Score Sheet
Remove unnecessary items. All items not required for performing operations are removed from the work area. Only tools and products are present at workstation
Sort
Correct location for items are identified Items are placed in their correct locations Aisle ways, workstations, equipment locations are indicated Items are put away immediately after use Inventory or WIP height and quantity limits are obvious
Floors, walls, stairs, and surfaces are free of dirt, oil and grease Equipment is kept clean and free of dirt, oil, and grease Cleaning materials are easily accessible Lines, labels, signs, etc. are clean and not damaged No other cleaning problems (of any kind) are present
Storage of cleaning equipment: All cleaning equipment stored in a neat manner; handy and readily available when needed Items on floor: Work-in-process, tools and any other material are not left to sit directly on the floor. Large items such as tote boxes are positioned on the floor in clearly marked area, identified by painted or taped lines. Storage and arrangement:: Boxes, containers, and materials are always stored neat and at correct work angles convenient to the operators where appropriate. When items are stacked evenly or in a manner that would not cause them to toppling over. Storage areas are provided for all necessary items at POUS (Point-Of-Use Storage). No items are placed on top of machines, cabinets, and equipment. Unidentified items can not lean against walls or columns. Operating equipment/machinery: Each piece of equipment/machinery has guards and deflectors that prevent debris from falling uncontained to the floor. Document storage: Only documents necessary to the operation are stored at the workstations and are stored in a neat and orderly manner. Tool and gauges arrangement: Tools, gages and fixtures are arranged neatly and stored, kept clean and free of any risk of damage. Aisle ways maintenance: Aisles are always free of materials and obstructions; nothing is placed on the lines and objects are always placed at right angles to the aisles where appropriate. Equipment painting: All machines and equipment are neatly painted; equipment cleaning schedule developed and posted for each major piece of equipment. Workbench and desk control: Kept free of objects including records and documents (unless in use). Tools and fixtures are clean and placed in their proper location. Information boards: PPB, COBs, and PABs are arranged in a neat and orderly manner. No outdated, torn, or soiled documents are displayed Emergency access: Fire hoses and emergency equipment are unobstructed and stored in a prominent easyto-locate area with proper identification. E-Stop switches and breakers are marked or color-coded for immediate visibility. Aisle ways marking: Aisles and walkways are clearly marked and can be identified at a glance; lines are straight and at right angles where appropriate with no chipped, worn floor marking. Equipment maintenance: Controls of machines are properly labeled. Critical points for daily maintenance checks are clearly marked. Equipment check sheets are clean, neatly displayed and completed daily. Tool and gauges convenience: Tools, gages and fixtures are arranged so they can be easily accessed when needed. Shelves and benches arrangement: Arranged, divided and clearly labeled it is obvious where things are stored; status and condition is recorded Document control: All documents are labeled clearly as to content and responsibility for control and revision. Obsolete Equipment cleanliness: All machines and equipment are kept clean by routine daily care. Floor cleaning: All floors are clean and free of debris, oil and dirt. Cleaning of floors is done routinely -- daily at a minimumposted schedule. 5S control and maintenance: There is a disciplined system of control and it is maintained at the highest possible level. It is the responsibility of every one to maintain this system and environment. Documentation exist indicating cleaning responsibility for each team member in the work area.
0 0
Straighten
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5S Implementation Audit Score =
Necessary information is visible All standards are known and visible Checklists exist for all cleaning and TPM maintenance jobs All quantities and limits are easily recognizable All necessary items can be located in 30 seconds
All team members have had 5S training Daily 5S actions performed Place all personal belongings stored in a neatly maintained location Job aids are current and readily accessible Routine 5S Implementation Audit is performed until sustained
2 to 4.75
>4.75 (GREEN)
0.00
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49
5S
50
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51
It is important that we establish the first 3S before we progress to the next 2S.
5S 52
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53
4S Standardize
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54
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55
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56
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57
5S Sustain
5S
58
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59
January 2007
June 2007
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60
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62
?
5S 63
5S
64
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Remember
1S 2S 3S 4S 5S Sort
5S
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70
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Visual Factory/Office
1st Level: See the Shop/Office Basic 6S 90% never get beyond this point 2nd Level: See the work In 5 Seconds, can you see whats going on?
5S
74
Remember
This applies to all areas (value-adding and
5S
75
over the 10%) If in doubt throw it out If still in doubt, send it to a red tag area for resolution You should be removing truckloads of items be tough (sometimes youll need to ask for forgiveness later!)
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76
Meet with shop/office personnel on what should be where Organize parts and material Resolve things you were afraid to throw out Write off or sell off obsolete materials
Deal with the open red tags from the "Sort Out" step:
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77
Straighten
5S
78
Straighten
5S
79
Straighten
5S
80
Straighten
5S
81
(prevent)
5S
82
Scrub
5S
83
5S
84
Safety
5S
85
orderly? Agree on daily and weekly tasks Establish a visual management system for these tasks
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86
Standardize
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area & all items within the area Use checklist daily or weekly as appropriate Once a year have Examiners perform independent review Fix and clean daily Continue to train & heighten awareness Remember you are World Class! Act like it.
89
5S
Sustain - 6S Scorecard
0 = No evidence that 6S is being considered for implementation 1 = Some evidence of 6S being started 2 = 6S is partially implemented (some gains are evident) 3 = 6S has been implemented but not self-sustaining 4 = 6S has been implemented & is self-sustaining (standard throughout) 5 = 6S is entrenched; efforts have resulted in high achievements 6 = Out-of-the-box; Area is doing extraordinary things, above & beyond the norm
5S
90
Sustain - 6S Scorecard
0 20 = Some organization, needs much improvement 21 40 = Signs of 6S in place, good organization, needs more time to mature 41 60 = 6S implemented, signs of maturing, not selfsustaining 61 80 = 6S implemented, system is self-sustaining 81 100 = 6S is entrenched with high achievements 100+ = Extraordinary, overand-above, outside-thebox
5S
91
5S
92
All cleaning material stored in a neat manner Floors clean of debris, oil and dirt Bulletin boards updated, straight and neat Easy access to emergency equipment, highly visible Items on floors are in clearly marked areas Aisles are clear and kept free of material Storage of boxes is square, neat, orderly Machines, tools, equipment kept clean Nothing on top of machines or cabinets Documents and binders stored in a neat manner Tools, jigs, fixtures, details are labeled, shadowed, identified, easy to reach Shelves, benches, desks kept free of unused objects, including files and documents
5S
93
For Offices
Remove unnecessary items, minimum personal items Cleaning equipment stored in a neat manner Floors clean and free of debris and dirt Bulletin boards are updated, straight and neat Easy access to emergency equipment, stored in a prominent manner Nothing on the floor but furniture, CPU, recycle bin and garbage can
Office layout posted at each entrance, name and task/position outside cubicle/office
Office equipment and furniture is functional and in good repair Paper, cabinets, and bins squared up, centered and at right angles, PC wiring is routed and secured/clamped Desks, surfaces, cabinets, chairs cleaned weekly Nothing on top of overheads or cabinets, nothing leaning against walls or columns, everything labeled Documents and binders stored in a neat and orderly manner
Shelves, cabinets, desks kept free of unused objects, including files and documents
5S 94
Acknowledgements
Lean Thinking by James Womack and Daniel
Jones Toyota Production System by Taiichi Ohno Simpler Business System, www.simpler.com
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95
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96