029 A Tools - 5S-lean tools

VOICEOFTHECUSTOMERPROFITABILITYEMPLOYMENTSTABILITYStandardWorkTimeLeadershipTotalEmployeeEngagementFlowLinkageVA-NVA-7PrincipleWastesPolicyDeploymentChangeasaWayofLifeContinuousImprovement-CycleTime=TaktTimeBiasForActionCUSTOMERAHOUSEWITHOUTWASTEENTERPRISEEXCELLENCEPull1PieceTaktTimeSMEDTPMSupplierCert.CurtainOperationSWCSMakeItUgly6SIGMADFM/ADOE%LoadChartsProblemSolvingProcessMappingAdjustmentElimination5SRightSizingPhysicalLayoutLineStopCreativityB4$MRSJidokaSWSHanadashiVisualControls5WhysMistakeProofingMulti-SkilledSWIPTimeObser'nQFDAQS3p5S2Whythe5S’s?AMethodofcreatingaself-sustainingculturethatperpetuatesaneat,clean,efficientworkplace.Intuitivegoodness.Helpsestablish,reinforceanddisciplinetheStandardWork.AToyotaProductionSystemfoundationandtester.5S31.Sort(Seiri)2.Straighten(Seiton)3.Shine(Seiso)4.Standardize(Seiketsu)5.Sustain(Shitsuke)5S’s--Defined5S4TheFirstS-SortSort--Clearlydistinguishingbetweenwhatisnecessaryanddisposingoftheunnecessary•Criticallyevaluateallitemsintheworkplaceanddeterminewhichitemsarereallyneeded•Understandwhyitemsareneeded•Keeponlywhatweneed.•Throwoutwhatwedon’tneedOnlyLeaveinPlaceThoseThingsThatAreNecessarytoSupporttheLWW5S5TheFirstS-SortCaution!WhenwedisposeofunnecessaryCompanyProprietaryorPrivateinformationitmustbedoneproperly--shreddedorburned.5SEnsurethatthosethings“thrownaway”aredonewiththeknowledgeoftheowner6FactoryTheFirstS-Sort5SBeforeApplying1stSAfterApplying1stS7OfficeTheFirstS-Sort5SBeforeApplying1stSAfterApplying1stS8TheSecondS-StraightenStraighten--Organizingthenecessaryitemssothattheycanbeusedandreturnedeasily•Sortfirstsothatwedon’twastetimestraighteningthingsthatwedon’tneed•Organizeallneededitems•Locateitemswheretheyareneededmost•Identifywheretoreturnitemswhennotinuse•Identifyitemsandtheirstoragelocations•Maketheorderofthingsclearlyunderstoodataglance•Eliminateallwastedmotionandtime5S9TheSecondS-Straighten5SAfterApplying2ndSBeforeApplying2ndS10TheSecondS-Straighten5SAfterApplying2ndS11Shine-Takingpropercareofyourworkspace.•Conductroutinecleaning--floorsswept,machinesandfurnitureclean,allareasneatandtidy.•Usethecleaningprocesstoinspectforsourcesofdirt,oil,trash,etc.•CleantoInspect•InspecttoDetect•DetecttoCorrectThe3rdS--Shine5S12Standardize-MaintainingandimprovingthestandardsofthefirstthreeS’s•Whilethefirst3S’sareactivities,the4thSisaprocessthatfacilitatesthemaintenanceandimprovementofthefirstthreeS’s.–Eliminatecausesofdirt,leaks,andspills–Createsystemstokeepthingsneatandorganized•The4thSreliesonwrittenagreements,visualcontrolsandstandardroutinesestablishedbythegroup.Toimprove,wemovefromdetectiontoprevention.The4thS--Standardize5S13The5thS--SustainSustain-Achievingthedisciplineorhabitofproperlymaintainingthecorrect5Sprocedure•To“do”the5thSweneedtopracticeuntilweinternalizewhatwearesupposedtodoandfullyunderstandwhy.•Practicereinforcescorrecthabits.Wemustbestrictabouthowthingsaredone--eventhelittlethings.•Followpostedchecklistsandothervisualcontrolsestablishedunderthe4thS.5S14DefinitionsClearlydistinguishingbetweenwhatisnecessaryanddisposingoftheunnecessarySortStraightenShineStandardizeSustain5SOrganizingthenecessaryitemssothattheycanbeusedandreturnedeasilyTakingpropercareofyourworkspaceMaintainingandimprovingthestandardsofthefirstthreeS’sAchievingthedisciplineorhabitofproperlymaintainingthecorrect5Sprocedure15The5S’sandVisualControlsThe5S’sneedaVisualWorkPlace.Avisualworkplaceiswhenanyonecanwalkinandvisuallyunderstandthecurrentsituation.–Thatis,visuallyunderstandthe:»workplaceorganization,»theworkprocess,»whenthereisanabnormality,and»iftheyareahead,behindoronscheduleWecreatethevisualworkplacewithvisualcontrols5S16The5S’sandThe5Why’sThe5Why’senablethe5S’sthroughGuidedDiscovery.Forexample,whenintheworkarea,foreach“thing”ask:•Whydoweneedit?•Whyisitusedthewayitis?•Ifweneedit,Whydoesitnothaveahome?•Whyaretherenovisualcontrolstomanageit?•Whyaretherenopostedstandardsorstandardworktotellhowtouseitandassignresponsibilityforit?A“thing”canbematerialorinformation.5S17The5S’sandStandardWorkBFGA/AerostructuresGroupFlowStandardWork5S’s•Commonsense•Rudimentary•Fundamental5S’s•Essential•Sophisticated•IntegratedChronologicalTimeLeanJourneyHowwespendourtime,effortandenergyInthebeginningoftheLeanJourneythe5S’scanbeviewedasastandalonetoolwithinherentgoodness.TothosethatcontinueontheLeanJourney,the5S’sbecomeintegraltotheimplementationofStandardWork-theOnGoingDriverofContinuousImprovement5S18Benefitsofthe5S’sReduceWasteImproveSafetyEasierMaintenanceHigherQualityImprovedProfitabilityRespectofCustomersandAssociatesPositiveMentalAttitudePrideintheWorkplace5S19The5S’s-EvaluationSheet5SEvaluationFormSortStraightenShineStandardizeSustainLevel5HabitNeededitemscanberetrievedin30secondsorless.Obsoletematerialsareroutinelyremovedfromthearea.Preventativemeasuresareinplacetokeepunnecessaryitems,reportsetc.fromenteringthearea.Anyonecanwalkintotheworkareaandeasilylocateworkbypriority.Correctivemeasuresareinplacetoaddressabnormalconditions.Workareahousekeepingisaroutinewayoflife.Correct