5S Workplace Organization Operating Principles Job-Aid

Transcription

1 5S is foundation of a Lean, efficient and effective work environment. 5S is applicable to all work areas including manufacturing, warehousing, engineering, sales, marketing and other functional areas. The name 5S refers to five Japanese words that begin with the letter s, each describing actions needed to create and maintain an organized and safe workplace. English S Japanese S Symbol Description Sort Seiri S1 Eliminate what s not needed Set in Order Seiton S2 Arrange in best order and label Shine Seiso S3 Clean the work area and keep the equipment productive Standardize Seiketsu S4 Establish and maintain standards Sustain Shitsuke S5 Sustain a highly productive workplace When implemented in sequence, 5S creates a standardized, waste-free way to work. Only the things needed in a work area are there, freeing workspace and eliminating clutter. Items are easy to find, so work flows smoothly and materials, tools and information are easily shared. When an occasional problem appears and interrupts the smooth workflow in a 5S environment, it is noticeable and quick action can be taken. With fewer disruptions, variation is reduced and quality and throughput improve. When items are easy to find and problems are quickly corrected, time that would otherwise be wasted by searching, walking or correcting can now be used for value-added activities. Benefits to individuals, teams and the organization from 5S include: an efficient and productive workplace improved morale and safety reduced wasted time quick response to problems improved productivity, quality and profits greater customer satisfaction Management has important responsibilities in 5S. Beyond expressing commitment to the principle, management must train all Associates. They must also demonstrate through their actions their ongoing commitment to developing and maintaining a well-organized workplace. To help management accomplish this, 5S includes the development of standards for organizing each workplace and frequent verifications to maintain compliance. Descriptions of each of the 5S elements are found on the following pages. Page 1 of 7

2 S1 = Sort (Seiri): Sort (Seiri): Eliminate everything that is not needed in the workplace. Eliminating what is not needed makes the workplace more efficient and productive. Floor space and workspace are increased because the area is cleared of clutter, which might otherwise block or interrupt the smooth flow of work. Determine what s necessary and what s not necessary in the area. Define rules for disposal of items no longer used or needed. For example, decisions might include: move to another location where it s needed, move to a central or shared location, dispose of the item. Special approvals might be needed for disposal of assets or highvalue items. Often red tags are used as visual identifiers for items to be moved or eliminated, with instruction for disposition. Set-up a red-tag area where others can freely shop for items you no longer need. Remove or dispose of anything not currently needed. Examples include: tools, gauges, notebooks, files, documents, catalogs, equipment, supplies, etc. Begin cleaning the area as space is freed and surfaces emerge. Examples: Move hand tools used for infrequent repairs to a central tool crib. Remove the unused computer and monitor that is taking up workspace. Delete useless s from your Inbox. Dispose of boxes containing outdated product literature. Home example of Sort: Spring cleaning, when you clear your closet at home of old clothes. You might donate the clothes to charity or give them to a friend. Ideas for Application on the Job: Page 2 of 7

3 S2 = Set in Order (Seiton): 5S Workplace Organization Set in Order (Seiton): Arrange, organize and label items used in the workplace. Arranging items and standardizing their home location will further improve efficiency and productivity. Items remaining after S1 that are needed to do a job are neatly arranged and identified for ease of use. People work most efficiently when there is uniformity. Therefore, planning the workplace layout and assigning set locations for important tools, materials, and information will maximize human productivity. List the items that remain after S1 which are in the area. List items that are needed to do the work, but missing. Determine where needed items should be located, and how many of each are needed right in the work area. Consideration should be given to safety and to security of confidential information. Systematically arrange items needed in the workplace items used frequency should be close by, items less frequently used far away. Make accommodations for bulky and heavy items. Define and obtain effective storage areas, storage containers, shelves, cabinets, organizers, etc. to facilitate storage and retrieval of needed items (e.g., tools, supplies, parts, documents, etc.) Legibly identify, label or tag parts, storage areas, shelves, bins, etc. for easy visual identification. Set standards for label stock, font type and size. Utilize shadow boards to standardize placement of tools. Color code with durable paint or apply tape lines on the floor to mark-off areas designated as the home location for anything that might be moved this will standardize the location regardless of personal preference and provide a quick visual check to verify compliance. These guidelines are most effectively implemented by involving and achieving consensus of the people who work in and manage the area to ensure their commitment to maintaining the agreed-upon arrangement of the area. Examples: Organize parts used in component assembly to minimize operator footsteps and reach. Purchase a Lazy-Susan storage device with small bins for items that previously were scattered. Apply labels with brief document descriptions on the rack which contains the various forms. Organize brooms and barrels in the warehouse. Utilize tool holders or a shadow board to establish home locations for all tools. Page 3 of 7

4 The arrangement of the keys on a standard English language keyboard is an example of Set in Order. The layout of the keys was defined years ago to optimize typing speed based on frequency of common letter usage. Home example of Set in Order: Using a shadow board and tool racks in the garage or workshop. Before After Ideas for Application on the Job: Page 4 of 7

5 S3 = Shine (Seiso): 5S Workplace Organization Shine (Seiso): Clean the workplace and continue to keep machines and the working environment clean and neat. Cleaning the workplace every day eliminates and prevents build-up of dirt and waste. Maintaining a clean workplace allows for quick detection of things that shouldn t be there things that might get in the way or cause a problem. Daily tidying and cleaning prevents the need to periodically stop for more extensive cleaning; and it sets the tone for pride and ownership in the workplace. Similarly, frequent and on-time preventative maintenance (TPM) decreases unplanned downtime for equipment repair. In addition to further improving productivity, a clean workplace positively affects customer impressions. Initially, plan time and resources to thoroughly clean up the workplace this will vary by area, but some will need a half day or more. Remove debris, spots and stains restore equipment and tools to like new condition. Going forward, keep the area, equipment, work surfaces, and floors clean. Maintain and inspect machines, equipment and tooling to ensure capability and safe operation. Perform a daily 5-minute shining routine, restoring the workplace to the set order before the next shift. Examples: Clean or paint the area to look like new. Sweep the floor of the assembly line every few hours to remove any fasteners or components that may have dropped on the floor. File paperwork from all open project folders at the end of the work day. Use environmentally friendly spray-cleaner to remove spots and stains from the conference table upon conclusion of the lunch meeting. Home example of Shine: Cleaning up the kitchen after dinner every night is an example of Shine. Ideas for Application on the Job: Page 5 of 7

6 S4 = Standardize (Seiketsu): Standardize (Seiketsu): Standardize the system to maintain a productive workplace. Standardizing methods, labels, routines and responsibilities reduces variation and provides an easy way to check for compliance. Standards might be established for items such as: color coding, position of scrap bins, use of shadow boards, and organization of computer file directories. Establishing standards to support 5S helps assure realization of its intent things that are needed are found quickly, regardless of whose workplace it is. Establishing and holding standards maintain the benefits of S1 through S3, resulting in staffing flexibility, less wasted time, and improved customer satisfaction. Establish standards using consensus ensure that people are willing to live with and work with the decisions. Find common methods that work across all departments. Document and communicate the 5S standards. Assign responsibilities so that 5S becomes a part of daily routines. Utilize the standards to keep the 5S system in place and prevent compliance deterioration over time. Examples: Format all labels within a cabinet the same way, so that it s easier to scan the labels and find what s needed. Designate red containers for scrap, yellow containers for suspect parts, and green containers for known conforming parts. Standardize stamping press and die cart heights to facilitate sliding new tooling directly from the cart to the press without need for liftassists or adjustments. Include a 5 minute end-of-shift station clean-up in everyone s job description. Home example of Standardize: Assignment of household chores; set weekday wake-up times to coordinate bathroom time; set regular meal times and duties. Ideas for Application on the Job: Page 6 of 7

7 S5 = Sustain (Shitsuke): Sustain (Shitsuke): Sustain efforts and make 5S activities a habit. Sustaining 5S activities is a management responsibility that is necessary to ensure a productive workplace. Management s role is to ensure that what has been agreed to is followed. Human nature causes us to resist change and find short-cuts that work for us. Sustaining 5S activities prevents the 5S principles from deteriorating and sets the tone for waste elimination and continuous improvement. Provide training and ensure understanding of 5S principles. Develop and utilize checklists to ensure compliance schedule 5S verification checks frequently enough to keep areas clean. Also, keep the verification tasks small enough to be manageable. Utilize all layers of management to perform 5S checks and assure participation among all layers of management. Perform checks routinely and include completion checks for scheduled preventative maintenance tasks. Establish management review of any weakness in the 5S system and define methods for problem resolution. Continue to look for ways to improve so that work can occur without disruption or waste. Examples: Develop 5S checklists and audit areas every few weeks to measure compliance give each area a score and suggestions for improvement. Promote 5S through quick correction of barriers. Provide incentives and consequences to reward 5S compliance. Utilize staff from different areas to visit and make recommendations to further improve an unfamiliar work area. Home example of Sustain: If you asked your teenager to clean his/her room, but didn t check the room afterward or provide feedback, what outcome would you expect the next time? Ideas for Application on the Job: Page 7 of 7