5 S Training

5S5S TrainingTraining

What is Lean What is Lean Manufacturing?Manufacturing?

Lean ManufacturingLean Manufacturing is the continuing is the continuing process of analyzing, then improving, the process of analyzing, then improving, the flow of information and materialsflow of information and materials in order to in order to eliminate eliminate wastewaste and enhance and enhance valuevalue to the to the customer.customer.

In simpler words:In simpler words:

Cut out the waste of non-value activities.Cut out the waste of non-value activities.

Illustration:Illustration:

Like a Like a leanlean piece of Filet Mignon. piece of Filet Mignon.

WHY Go “Lean”?WHY Go “Lean”? Uses less of everything compared Uses less of everything compared

with mass production.with mass production. Less human effortLess human effort Less spaceLess space Less tool investmentLess tool investment Less inventoryLess inventory Less defectsLess defects Reduces costly internal “Wastes”Reduces costly internal “Wastes”

Being Wasteful Helps the Competition!!

Elements of LeanElements of Lean

Philosophy of Excellence in Philosophy of Excellence in becoming a becoming a World ClassWorld Class CompanyCompany

Elimination of Elimination of WasteWaste Synchronization to Customer Synchronization to Customer

DemandDemand Employee InvolvementEmployee Involvement Continuous Improvement Continuous Improvement

What Is Waste?What Is Waste?

Waste is everything we do Waste is everything we do that that takestakes timetime, , adds costadds cost, , and has and has no valueno value in the in the eyes eyes of the customerof the customer..

7 types of Waste (Muda)7 types of Waste (Muda)

1) Overproducing1) Overproducing

2) Waiting2) Waiting

3) Moving3) Moving

4) Downtime4) Downtime

5) Excess Inventory5) Excess Inventory

6) Motion6) Motion

7) Scrap7) Scrap

CAS Medical System’sRoute to World Class Manufacturing

Value Stream Mapping

StandardWork

Instructions

5sEvaluation

Visual Controls

SuggestionProgram

Setup Reductions

One Piece Flow

Layout Changes

FlexibleWork Force

Waste Elimination

(Muda)

Small LotProduction

Takt Time

Short CycleManufacturing

TQM

Kaizen

HighestQuality

QuickDelivery

Best ProcessReliability

Rapid Response to Change

Minimum Investment

PullSystems(Kanban)

Lean Building Tools

6 Sigma

TPM

What is 5s+1What is 5s+1

It’s It’s HousekeepingHousekeeping at at the the highest levelhighest level that’s that’s measurablemeasurable

WHY 5S?To prepare the workplace so the end result is a clear, clean, orderly, and safe environment:

• Eliminates waste from unorganized and/or uncontrolled processes

• Gains control on equipment, material, and supplies

• Allows us to work safely• Helps us to easily & quickly find people,

parts, tools, places, supplies, and information you need in order to do your job

Early Years of 5s

1. Scrounge

2. Steal

3. Stash

4. Scramble

5. Search

S1: S1: SortSort Sort Sort out the clutter. Get rid of items out the clutter. Get rid of items not needed to make your not needed to make your productproduct

S2: S2: ScrubScrub ScrubScrub & Shine your work area. Paint if & Shine your work area. Paint if needed. Don’t needed. Don’t rely on someone else to clean your rely on someone else to clean your messmess

S3: S3: SelectSelect SelectSelect locations for materials, supplies & locations for materials, supplies & equipment. equipment. Anything that takes up real estate Anything that takes up real estate needs to have a needs to have a designated locationdesignated location

S4: S4: SetSet SetSet locations by using borders, ID labels, locations by using borders, ID labels, shadow boardsshadow boards

S5: S5: SafetySafety Prevent Prevent SafetySafety hazards caused by clutter, hazards caused by clutter, garbage, spills, garbage, spills, and disorder. and disorder. Increase safety through visual order.Increase safety through visual order.

+1:+1:Sustain Sustain SustainSustain the 5’s habit. Conduct management the 5’s habit. Conduct management auditsaudits and report cards. and report cards.

Do you know your 5S’s +1?Do you know your 5S’s +1?

SORT - The 1st & Most Important“S”SORT - The 1st & Most Important“S”

Purpose of Sort - Purpose of Sort - get rid of the get rid of the junkjunk Sort through items in the areaSort through items in the area Keep what is neededKeep what is needed Eliminate what is not neededEliminate what is not needed Reduce the number of items to the Reduce the number of items to the

quantity required at any given timequantity required at any given time

** Don’t be a Pack-Rat** Don’t be a Pack-Rat

““Red Tag”Red Tag” Unnecessary Unnecessary ItemsItems

Red tagging is a visible way to identify items that are Red tagging is a visible way to identify items that are not needed or in the wrong place:not needed or in the wrong place: Identify unneeded, misplaced itemsIdentify unneeded, misplaced items Attach red tagsAttach red tags Move the items to the holding areaMove the items to the holding area Dispose of unneeded itemsDispose of unneeded items

Ask yourself:

Does it have a function in this area?

Is it needed? How often? By whom?

If we remove it, will it really matter?

Is it in the way? Does it take too much space? Should it be smaller?

Scrub - The 2nd “S”Scrub - The 2nd “S” Definition of Scrub - Definition of Scrub - Clean everything inside Clean everything inside

and out.and out.

Why cleaning is inspection – Why cleaning is inspection – It helps us notice It helps us notice pre-failure conditions, and makes a good pre-failure conditions, and makes a good impression to our customers & visitors.impression to our customers & visitors.

Clean floors are the first thingClean floors are the first thing customers & customers & visitors will notice.visitors will notice.

Establish daily housekeeping list.Establish daily housekeeping list.

Allow time at end of shift for cleaning & Allow time at end of shift for cleaning & organizing.organizing. 5 minutes is maximum time 5 minutes is maximum time needed if everyone chips in.needed if everyone chips in.

Daily Housekeeping Check List

(To be completed before you leave for the day)Associate √

Floors are clean & free of debris. (check underneath your work bench)

Clean all bench tops & equipment from dust, oils & debris

Turn off all equipment, computers, lights

Return all tools, parts, and supplies to designated locations.

All kanban cards are handed in and properly placed with the item

Chemicals & cleaning supplies are stored in proper locations

Dispose all cardboard

Work stations are clutter free and well organized

Nothing is in the aisle ways

Select Locations - 3rd “S”Select Locations - 3rd “S” Definition of Selecting location - Definition of Selecting location - a place for a place for

everything & everything in its place.everything & everything in its place.

Considerations for deciding locations - Considerations for deciding locations - point of use point of use storage, how often is it used, space constraints.storage, how often is it used, space constraints.

A few guidelines - A few guidelines - Don’t select locations for things Don’t select locations for things you don’t need (S1), Standardize & consolidate, you don’t need (S1), Standardize & consolidate, watch personal items.watch personal items.

Don’t fret mistakes; try making it better – Don’t fret mistakes; try making it better – worst case scenario you can always put it back the worst case scenario you can always put it back the

way it was!way it was! “JUST DO IT”. “JUST DO IT”.

Set Locations - 4th“S”Set Locations - 4th“S”

Definition of Setting locations- Definition of Setting locations- IIdentifying your dentifying your selected location so everyone knows where it selected location so everyone knows where it has to go.has to go.

Location Identifiers - Location Identifiers - signs, labels, colored signs, labels, colored tape, shadow boards, floor borderstape, shadow boards, floor borders

3 actions needed3 actions needed 1)1) Put taped border around moveable items.Put taped border around moveable items.2)2) Put an ID label with each border.Put an ID label with each border.3)3) Put an ID label on each item.Put an ID label on each item.

Safety - 5th“S”Safety - 5th“S” EveryoneEveryone is accountable for having a safe is accountable for having a safe

operation and work environment. operation and work environment. Get Get involved.involved.

Improve safety through visual order.Improve safety through visual order.

Safety committee is established for CAS. Safety committee is established for CAS. Help to implement committee findings.Help to implement committee findings.

S1 – is your biggest contributor toward a S1 – is your biggest contributor toward a safe environment. safe environment. (Statcorp Pallet story)(Statcorp Pallet story)

Cardinal Rule for 5s Cardinal Rule for 5s ImplementationImplementation

Follow the 5s MethodologyFollow the 5s Methodology

****Do not do S3 or S4 before Do not do S3 or S4 before doing S1 doing S1 (Trident story)(Trident story)

+1 Sustain - The 6th “S”+1 Sustain - The 6th “S” Purpose of +1:Purpose of +1: Is to recognize, reward, and strengthen Is to recognize, reward, and strengthen

adherence to the first 5S’s. It provides feedback for adherence to the first 5S’s. It provides feedback for Continuous Improvement.Continuous Improvement.

Make 5S’ part of the cultureMake 5S’ part of the culture - - Empower workers to Empower workers to manage and control their area.manage and control their area.

55 Techniques for sustaining the 5s Program Techniques for sustaining the 5s Program1)1) 5s Audit Report Card 5s Audit Report Card 2)2) Review of report card with employees Review of report card with employees 3)3) Develop daily housekeeping activities Develop daily housekeeping activities 4)4) Employee Ownership Employee Ownership 5)5) Include in annual performance review. Include in annual performance review.

Reasons for inadequate implementation:Reasons for inadequate implementation: 1. Lack of understanding & training1. Lack of understanding & training 2. Not supported by management2. Not supported by management

3. Little or no employee involvement3. Little or no employee involvement

Review of 5’s +1 Review of 5’s +1 Audit Report Audit Report CardCard

Keys To SuccessKeys To Success

• Management Driven

• Management Involvement

•Gather baseline information

• Get everyone involved

•Audit your results

•Take action – “Just do it”

• Keep it simple!

Total Employee Total Employee InvolvementInvolvement

PEOPLE ARE THE PEOPLE ARE THE KEY!KEY!

5’s 5’s

Dept. PhotosDept. Photos

&&

Hall of Fame Best Hall of Fame Best PracticesPractices

5s Quiz5s Quiz 11) Can you name the ) Can you name the 5s+15s+1 order of methodology? order of methodology?

SortSortScrubScrubSelectSelectSet Set Safety Safety SustainSustain

2) Of the five 5S’s which is the most important?2) Of the five 5S’s which is the most important?SortSort

3) What are the 5 techniques we will use to 3) What are the 5 techniques we will use to SSustain (+1) ustain (+1) the 5s programthe 5s program? ?

Audit Report CardAudit Report CardEmployee Review of Report Card Employee Review of Report Card Daily Housekeeping List of Duties Daily Housekeeping List of Duties Employee OwnershipEmployee OwnershipPerformance ReviewsPerformance Reviews

5s Quiz Continued5s Quiz Continued 4) What do we use for setting locations (S4)?4) What do we use for setting locations (S4)?

SignsSigns LabelsLabels

Tape BordersTape Borders Shadow BoardsShadow Boards

5) Why is S2 – 5) Why is S2 – SScrub so important to do?crub so important to do? It helps to notice pre-failure conditions. It helps to notice pre-failure conditions.

It makes a strong impression to our customers It makes a strong impression to our customers & visitors.& visitors.

6) What’s the Cardinal rule for 5’s Implementation?6) What’s the Cardinal rule for 5’s Implementation?Follow the MethodologyFollow the MethodologyDon’t do S3 & S4 before doing S1Don’t do S3 & S4 before doing S1

Bonus Quiz QuestionBonus Quiz Question

What are the What are the 77 types of types of MudaMuda?? 1) Overproducing1) Overproducing 2) Waiting2) Waiting 3) Moving3) Moving 4) Downtime4) Downtime 5) Excess Inventory5) Excess Inventory 6) Motion6) Motion 7) Scrap7) Scrap