XYZ Company 1. XYZ Company 2 Lean Building Blocks Quick Changeover Standardized Work Batch Reduction Teams/Employee Involvement Quality at Source 5S System.
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XYZ Company
1
XYZ Company
2
Lean Building BlocksLean Building Blocks
Quick Changeover
Standardized Work
Batch Reduction
Teams/Employee Involvement
Quality at Source
5S SystemVisual
Systems
Plant Layout
POUS
Cellular/FlowPull/Kanban
TPM
ValueStreamMapping
Continuous Improvement
Source: The MEP Lean Network
XYZ Company
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Visual FactoryVisual Factory
“Ability to understandunderstand the status of a production area in 5 minutes or less by simple observationsimple observation without use
of computers or speaking to anyone.”
XYZ Company
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5S5S
Method for
creating and maintainingcreating and maintaining
an organized and cleanorganized and clean
workplace.
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1S - Sort - Seri1S - Sort - Seri
Separate and DiscardSeparate and Discard
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Identify all necessary and unnecessary items. Move unnecessary items from workplace to a
designated area or “throw it out”. Remove all excess items from working areas –
work pieces, personal items etc. Organize all remaining necessary items. Designate a team to “hunt down unnecessary
items”.
1S - Sort - 1S - Sort - SeriSeri
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2S - Stabilize - 2S - Stabilize - SeitonSeiton
Set – in – Order Set – in – Order
StraightenStraighten
Arrange and identify for ease of useArrange and identify for ease of use
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2S - Stabilize - 2S - Stabilize - SeitonSeiton
Locate materials and tools at POINT- OF- USE (POUS).
Store items needed by most people in a common storage area.
Make items easily identifiable and easy to obtain. Label all containers, totes, supplies etc. Storage areas, work areas, containers should have
floor marking and identifying labels. Place Maintenance/Operator instructions close to
the point of use. Use special device (carts/shelves/racks) to organize
tools and fixtures. Performance boards – daily/weekly production,
scrap/rework rate chart….
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2S – Visual Controls2S – Visual Controls
Label – Containers, Cabinets, Supplies, Inventory, Machines, Tools, Scrap, Rework,……..
Color – Parts container, floor markings, safety, work areas, trash cans,.. Green – Shipping, Yellow – Work in process, Blue –
Storage/Trash. Checkered – Aisles.
Footprints – Anything that is movable. Tool Boards – Shadow board, Peg board. Performance Boards – Hour by hour, 5S Measurement,… Standard Work visible. Re-order points, Inventory levels. Material Flow indicators within, into, out of your cell. Equipment related information. Documents on safety, quality,…
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3S - Shine - 3S - Shine - SeisoSeiso
Clean – upClean – up
ScrubScrub
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3S - Shine - 3S - Shine - SeisoSeiso
Use dust collecting devices to prevent possible dirt. Ensure that electrical and other cords are not a
hindrance to all personnel. Operators should clean their work area and
equipment and perform preventive maintenance. Keep everything clean for constant state of
readiness.
A Clean Workplace enhances A Clean Workplace enhances QUALITY, SAFETY, and PRIDE.QUALITY, SAFETY, and PRIDE.
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4S - Standardize - 4S - Standardize - SeiketsuSeiketsu
Keep CleanKeep Clean
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4S - Standardize - 4S - Standardize - SeiketsuSeiketsu
Implement a plan to keep the workplace clean all the time
No – unnecessary items, mess, dirt
Who? When? How?
DODO
ACTACT
PLANPLAN
CHECKCHECK
DEMING DEMING CYCLECYCLE
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5S Schedule5S Schedule
No 5S Job
So
rt
Se
t
Sh
ine
Sta
nd
ard
ise
Su
sta
in
CO
NT
INU
OU
SL
Y
DA
ILY
(AM
)
DA
ILY
(PM
)
WE
EK
LY
MO
NT
HL
Y
1 Red-Tag (company wide)2 Red-tag (cells / lines)3 Inventory check4 Tool check5 Wipe area6 Vacuum area7 Machine Clean Inspection (Ops)8 Degrease work area9 etc
5S Job Cycle Chart Name:
Date:
Dept:
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5S - Sustain - 5S - Sustain - ShitsukeShitsuke
Motivate
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5S - Sustain - 5S - Sustain - ShitsukeShitsuke
Commitment Adherence Cell meets 5S principles at the end of each shift 5S Daily Checklist
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5 Minute 5S5 Minute 5S
Five Minute 5S
Area: Contact:
Sort Remove unwanted tooling
(red tag to holding area)
Set Mark out product variants
(floor tape from Joe)
Shine Degrease banjo press
(gloves, solvent from Joe)
Standardise Why is banjo press greasy,
Why are variants mixed
Sustain Who is/are responsible for press
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