Aluminum Die Casting 3.1.2 Visual Workplace (6S)
Dec 30, 2015
Aluminum Die Casting
3.1.2 Visual Workplace (6S)
Accelerating Supply Chain Performance
Company Profile ESTABLISHED IN 1950 3RD GENERATION FAMILY BUSINESS DIE CAST MANUFACTURER WITH AN
EMPHASIS ON ADDED VALUE MIRA LOMA, CA 32 EMPLOYEES WE HAVE BEEN WORKING ON THE SEA
ROADMAP FOR APPROXIMATELY 11 MONTHS PRIMARILY SUPPLY MILITARY AND
AEROSPACE
2
Accelerating Supply Chain Performance
Our Products
SURVIVAL BEACON
M.I.L.E.S TRAINING
Accelerating Supply Chain Performance
6S Visual Workplace 3.1.2 We began with an all hands training power point presentation
by the leadership team. Then we broke down into departments for emphasis on each area’s individual needs.
The 6S status is displayed with the current audit in each department, process flow is defined with floor markings, production status is shown with each bin tag, employee training status is noted on dashboard matrix, and continuous improvement is clearly displayed and visible on the dashboard and photos.
Improvements reviewed and recognized through monthly audits and feedback, as well as daily encouragement by the
leadership team.
Accelerating Supply Chain Performance
Process showspositive trends
Process measured,analyzed, and improved
Process standardized
Process documented
Process identifiedand process ownerassigned
5
4
3
2
1
The Process Maturity Model
Accelerating Supply Chain Performance
Process Flowchart
Training Sort Set in Order Shine Standardize Sustain
Safety AuditScorecard
Report
Reward
Score less than 90
High Score
Accelerating Supply Chain Performance
TRAINING Training power point was developed by
leadership team Program is presented in an all hands meeting
by the leadership team in English and Spanish to be certain it was well understood
Comments and discussion is encouraged and productive
Divide into small group sessions by department
Retrain yearly
Accelerating Supply Chain Performance
SORT Eliminate everything that is not
needed in each work area Red Tag event for each department Make certain that everything that is
needed is close at hand and organized so no time is wasted looking for things
Accelerating Supply Chain Performance
SET IN PLACE Developed shadow boards & tool
carts to standardize equipment placement
Labeled containers & shelves Defined areas for part movement in
and out of departments Defined equipment locations
Accelerating Supply Chain Performance
SORTING AREA
Accelerating Supply Chain Performance
LABELED STORAGE
Accelerating Supply Chain Performance
CNC CART
Accelerating Supply Chain Performance
DIE CAST CART
Accelerating Supply Chain Performance
VISUAL MANAGEMENT LINES & SIGNS
FLOOR MARKING COLOR CODEINCOMING WORK
OUTGOING WORK
FIRE EXTINGUISHER
WALKWAYS
EQUIPMENT
Accelerating Supply Chain Performance
LINES & SIGNS STANDARDIZE LAYOUT
Accelerating Supply Chain Performance
STANDARD LOCATIONS
Accelerating Supply Chain Performance
VISUAL INDICATORS
Accelerating Supply Chain Performance
CNC SET UP AREA
Accelerating Supply Chain Performance
SHINE Cleaning equipment on shadow board
for each department Encourage keeping work areas clean
while working to increase productivity The job is not complete until your area
has been cleaned and things are put away
Accelerating Supply Chain Performance
CLEANING SHADOW BOARD
Accelerating Supply Chain Performance
STANDARDIZE Monthly audit of each department to
review that first 3 S’s are maintained Photos of what each area is to look
like are posted to document standard Visual indicators in place to keep
parts moving through the shop
Accelerating Supply Chain Performance
AUDIT FEEDBACK & STANDARD
Accelerating Supply Chain Performance
OFFICE SUPPLY CLOSET
Accelerating Supply Chain Performance
MAINTENANCE DEPARTMENT
Accelerating Supply Chain Performance
CNC SETUP AREA
Accelerating Supply Chain Performance
ITEMS TUCKED BEHIND MACHINES
Accelerating Supply Chain Performance
SUSTAIN Monthly review of department scores Rewards for scores above 90 Yearly retraining
Accelerating Supply Chain Performance
6S Score CardOutgoing
Incoming
Equipment
Aisle Way
FLO
OR
ST
RIP
ES
DE
FIN
ED
Fire Extinguisher
Accelerating Supply Chain Performance
SAFETY Monthly all hands safety meeting Quarterly safety walkthroughs with outside
consultants Post quarterly safety meeting notes on
dashboard
Accelerating Supply Chain Performance
AUDIT
6S Area: (Name the work area)Date: Scored by: Item Score NoteSort Distinguish between what is needed & not needed
(Organize) Unneeded materials or parts?
Unneeded machines or other equipment?
Unneeded items marked for removal?
Procedure in place for removing unneeeded items?Straighten A place for everything and everything in its place
(Set In Walkways clearly identified
Place) Work areas, locations clearly identified
Item indicators (shadow board, labeled shelves)
Tools arranged to facilitate efficient useShine Cleaning and looking for ways to keep it clean
(Cleanliness) Work area, equipment clean & free of debris
Cleaning materials available & accessible
Aisle markings, location indicators clean, unbroken
Cleanliness is a habitStandardize Maintain & monitor for adherance
(Adherance) Improvements implemented and documented
SOP for reviewing first 3 S's in use
Visual Indicators in place and in use
Standard methods documented and in useSustain Following procedures to sustain improvement
(Self Discipline) Procedures being followed
Ongoing Audit and Feedback system in place
Action Plans are created based on audit results
Good habits are re-enforcedSafety Maintaining a safe work place
(Zero Incidents) Appropriate controls in place to use equipment safely
Weight limits being used
45° rule being followed
Strike Zone storage to reduce back strainScoring 1 = Random, unidentified conditions 4 = Reliable methods and standards in use
2 = Indentification, plan in process 5 = Preventative actions are common
3 = Visual indicators in place 120 possible points 90 points triggers retraining
6S Audit Form
Three person audit team walks through each department monthly and scores each “S”
Communication is made at that time & via printed report of the audit
Action items are created and followed up for continuous improvement
Photos are updated for the “New Normal”
Feedback for improvement of the process is solicited
Accelerating Supply Chain Performance
THANK YOU