Toyota 5S

5PillarsoftheVisualWorkplaceAnintroductionto5SContent1.Thevisualworkplacevision2.Whatis5S?3.Benefitsof5S4.Expectations5.Conclusion1.ThevisualworkplacevisionWasteiseasilydiscoveredZerodefectisnormalStandardproceduresareclearAbnormalitiesareimmediatelydetectedThereisnothingextraorunneeded.ThevisualworkplacevisionCleanworkplaceCleanworkplaceandeasyandeasyrecognizablelimitsrecognizablelimitsEasyaccesstoolingEasyaccesstoolingMachineStatusMachineStatusClearClearworkinstructionsworkinstructionsThevisualworkplacevisionItisatoolto:-improveworkplacesafety-reducewaste-Improveworkflow-ensurequality2.Whatis5S?ItisNOTaboutjusthavingacleanfactory….hitsuke-SustainThedifferentsteps...Seiri-Sorteiton-Setinordereiso-Shineeiketsu-StandardiseSSSSPillar1:SortOut-Organisation-Eliminatewhatisunneeded“Whenindoubt,throwitout”Pillar1:SortOutTechnique:Red-TaggingIdentifyingallunneededitemsandremovethemPillar1:SortOutPillar2:SetinorderDeterminealocationforeverything-Setlimits&locations-MakeitobviouswhensomethingisnotinorderImprovelay-outandproductflowTechnique:Signboarding&ColorPainting☺396322658Labels19631AItemID1963ShelfIDPillar2:SetinorderUsingSignsUsingSignsTMME6thEuropeanSuppliersConferenceLimitsMAXMINMAXDisplays☺InJapan,12colorsareusedasastandardUsingColorUsingColorPillar2:SetinorderOKNOKPillar3:ShineCleaningworkspreventivelyCleaningdetectsabnormalconditionsCleaneverythingandkeepitcleanTechnique:Defineperiodicandsystematiccleaningactivities(Eliminatealldirt,dustandscrap)-Acleanandsafeenvironmentwillbestimulatingforeverybody-AdaptcleaningasaninspectionPillar3:ShinePillar4:StandardisePreventfall-backof3S,standardise3Sandmaintain3SCreateguidelinesandmaketheseobviousCreatestandardoperations(definebestwayofworking):MachiningOperationsAssemblyOperationsMaintenanceOperationsChangeoverOperationsCleaningOperations…Pillar4:StandardiseTechnique:UsevisualtechniquesDisplayPillar4:StandardiseStandardoperationSheetJan-02N°LocationMethodCriteriaActionTimeWhoShiftDayWeek2wksMo1LubtankWipenolubFillo2A2HydtankWipenoleakTago2A3McbodyBrushnodirto1A4McbaseBrushnodirto3A5LiquidWipenoleakTago4A6TankWipeoilfreeo1A7Oilpanemptyoilfreeo2A8MotorWipedustfreeo1A9MachineStatusPillar5:Sustain-Self-discipline-MakeahabitofmaintainingestablishedproceduresAssurethateveryonefollowstherulesContinue5STechnique:5SPatrols,5SAuditsXXXSORTEDSETLIMITSSHINESHARECHECK5SCHECKLISTXXTrainingsessions&communicationboardsPillar5:SustainWe’retoobusy!Whycleandailywhenitgetsdirtyagain?Wealreadyhaveanicefactory!Wedid5Syearsago!Wedonotneed5S,we’remakingenoughmoneyalready...ThisisgoodforJapanese...Theoutputwillnotincreasewiththis!So,whatarethebenefits?So,whatarethebenefits?HigherQualityLowercostsReliableDeliveriesImprovedSafetyHigherAvailabilityrateReductionofDefectsReductionofWasteReductionofdelaysReductionofInjuriesReductionofBreakdowns5SThebenefits:4.ExpectationsActivemanagementparticipationAdequatefollow-upInvolvementfromtop-managementNecessaryresources5.ConclusionMoreseveremarketrequirementsTighterdeadlinesFlexiblemanufacturingprocessFoundation=5SFoundation=5Saneasystep-by-stepapproachwithoutbiginvestmentThereisnothingmagicalaboutitJustusecommonsenseThankyou