XYZ Company 1. XYZ Company 2 Lean Building Blocks Quick Changeover Standardized Work Batch Reduction Teams/Employee Involvement Quality at Source 5S System.

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

3

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

4

5S5S

Method for

creating and maintainingcreating and maintaining

an organized and cleanorganized and clean

workplace.

XYZ Company

5

XYZ Company

6

1S - Sort - Seri1S - Sort - Seri

Separate and DiscardSeparate and Discard

XYZ Company

7

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

XYZ Company

8

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

XYZ Company

9

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….

XYZ Company

10

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,…

XYZ Company

11

3S - Shine - 3S - Shine - SeisoSeiso

Clean – upClean – up

ScrubScrub

XYZ Company

12

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.

XYZ Company

13

4S - Standardize - 4S - Standardize - SeiketsuSeiketsu

Keep CleanKeep Clean

XYZ Company

14

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

XYZ Company

15

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:

XYZ Company

16

5S - Sustain - 5S - Sustain - ShitsukeShitsuke

Motivate

XYZ Company

17

5S - Sustain - 5S - Sustain - ShitsukeShitsuke

Commitment Adherence Cell meets 5S principles at the end of each shift 5S Daily Checklist

XYZ Company

18

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