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WelcomeWelcomeWorkplace Organization & Housekeeping 101
Kurt Fink
Corporate Manager Marketing & Public Rel.
15 years of Lean & Six Sigma experience
Workplace Organization & Housekeeping 101
Kurt Fink
Corporate Manager Marketing & Public Rel.
15 years of Lean & Six Sigma experience
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ObjectivesObjectives
Present the 5S history & methodology
What is in it for the MFG Teammates
Define what the Teammates role will be
Learn to SEE
Begin the process!
Present the 5S history & methodology
What is in it for the MFG Teammates
Define what the Teammates role will be
Learn to SEE
Begin the process!
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The Challenges
In order to become a Profitable company,
MFG needs to do three things well, all at
the same time!Reduce
CostImproveQuality
CompetitiveFaster
ReduceLead Time
Better
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These Challenges can only be
met, through a continuous war onWaste
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Waste
Waste is an activity which, from the
customer point of view,
is Not needed!
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7 Types of WASTE
Transportation
Defects
Unnecessary
Inventory
Over-Production
Processing
Motion
Wait time
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Over-production - Waste
Definition: Producing more than
needed by the customer orfaster than the customercan take it.
Process 1 Process 2
Extra
ProcessingDefects Inventory
Waiting
Time
Motion
Correc
tion
WHO IS YOUR CUSTOMER???
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Waiting Time - Waste
Definition:
Cycle Time That Is Too Long
Due To Insufficient Organization
Operator Wait Time Ex: Waiting on a machine to be fixed
Machine Wait Time Ex: Waiting on materials from the
previous process
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Transportation - Waste
Definition
Any Material Movement That
Does Not Directly Support a
Lean Manufacturing System
Parts temporarily on racks
Multiple handling
Excessive travel
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Processing - Waste
Definition:
The use of the wrong set of
tools or wrong procedures,which will take longer than
required!
Parts
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Unnecessary
Inventory -
Waste
Definition:
Any Supply in
Excess of Process
Requirements
Parts
Parts
Parts
Parts
Parts
Parts
Parts
Parts
Parts
Parts
Parts
The Evils of Inventory
Takes up Space
Hides Problems Could damage products or wind up
being obsolete
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Motion - Waste
Definition:
Any Movement of
Teammates Which Does
Not Contribute Added
Value To The Product, such
as: too much walking,
stretching, bending,reaching.
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Defects - Waste
Definition:
Repair of a Product
in order to deliver
the right quality Rework
Repair Re-inspect
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War On Waste starts withimproving the Workplace
organization & Housekeeping
or
Implementing
War On Waste starts withimproving the Workplace
organization & Housekeeping
or
Implementing
In order for MFG to become aWorld Class Company, we must
initiate a War on Waste
In order for MFG to become aWorld Class Company, we must
initiate a War on Waste
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History of 5SHistory of 5S
Started by Toyota Motor Company in the 1950s
Total Productive Maintenance Program
Eliminate unnecessary equipment downtime (Line Pulls)
Increase life of capital equipment investments
Improve Safety for associates
Improve Quality of parts produced
A place for everything and everything in its place.
Started by Toyota Motor Company in the 1950s
Total Productive Maintenance Program
Eliminate unnecessary equipment downtime (Line Pulls)
Increase life of capital equipment investments
Improve Safety for associates
Improve Quality of parts produced
A place for everything and everything in its place.
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Where did Toyota get the idea???Where did Toyota get the idea???
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Good house keeping
A barometerof how well the business is being run
A method to reduce Waste
A method to improve Safety
The foundation to become a World Class Company
A way of life Culture within the organization
Good house keeping
A barometerof how well the business is being run
A method to reduce Waste
A method to improve Safety
The foundation to become a World Class Company
A way of life Culture within the organization
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MFG Entity
RED TAG EVENT
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Sort - Separate, red tag, remove from the workplace anyitem that is not immediately needed
Set In Order Orderliness: arrange items so that they
are identified and easy to reach
Shine Cleanliness: sweep the floors, wipe off
equipment, paint walls and equipment
Standardize - Formalize activities, frequencies, and
responsibilities
Sustain - Discipline, practice, audit, and repeat these
procedures so they become a way of life
Sort - Separate, red tag, remove from the workplace any
item that is not immediately needed
Set In Order Orderliness: arrange items so that they
are identified and easy to reach
Shine Cleanliness: sweep the floors, wipe offequipment, paint walls and equipment
Standardize - Formalize activities, frequencies, and
responsibilities
Sustain - Discipline, practice, audit, and repeat these
procedures so they become a way of life
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If in doubt, move it out!
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Red Tag Procedure:
Identify unneeded items in an area
Ask, what is this? Do we need it? Keep it? If yes, How Many?
Store it?
Dispose it?
Red tag staging area - for final review
One time event only!
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Red Tag Labeling: When in doubt, put a red tag on it!!!
Common places to find clutter:
Shelves and lockers
Aisles and corners
Tool and gauge cribs
Odd corners, under tables, behind
machines,...
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Location CriteriaPRIORITY FREQUENCY OF USE HOW TO STORE
Low Less than once a yearA few times a year Distant storage
Medium Once every 2-6 months In the plant
Once a month Near the use point
Once a week Within eyesight
High Few times a week At point of use
One or more times a day
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A Place For Everything
and
Everything In Its Place
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Observe how Teammates get things inand out
Study variables:
Distance to parts Distance to tools
Frequency of use
Time required to take out and
put away objectsNote: Time values for each variable might be
small but think of the cumulative effect, andimpact on productivity
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Designate Storage Locations
Containers, boxes, cabinets,
shelves, and racks must be
identified
Materials and tools should be
waist to shoulder high
Frequently used tools should
be kept at point of use Use shadow boards where
practical Good Visual Management Tool!
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Clean and paint, walls, floors, and equipment
Divide area in small manageable sectors
Define Who is the owner/responsible for cleaning
Define what are the cleaning rules Set time frequencies for cleaning
Be aware of:
Clean equipment is much more easier to read
Quality issues or cause of problems become more evident
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Implement working procedures forcleaningUse pictures! A picture is Worth a Thousand
Words
Specify responsibilities
Indicate frequencies, and specific times forcleaning
Borders on the floor for: pallets, WIP, endproduct
Visualize good and out of rangeparameters
Red Light warnings for equipment failures
Preventive Maintenance indicators
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Do not let the daily problems take your focus away from 5S!
Post 5S bulletin boards in each area
Post before and after pictures on bulletin board to show the
improvements
Keep 5S rankings and progress reports visible
Active management involvement AT ALL LEVELS
Perform frequent (monthly) formal 5S audits
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Frequent audits indicate the level ofproficiency
What are we looking for?
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Sort
Unneeded items have been completely disposed of
All unneeded items are stored away from work place(awaiting disposition)
It is easy to distinguish between needed and unneeded items
Unneeded items do not reappear in the area
5S Audit System
What are we looking for?
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Set In Order
All tools and gauges are identified and placed in their properlocation. Supplies and raw materials are clearly marked and intheir proper location.
Color-coding, outlining or other methods are used to facilitateplacement of tools, gauges, supplies and materials.
Location and item indicators are clearly used for tools, gauges,supplies and raw materials. Aisles are clearly marked.
5S Audit System
What are we looking for?
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Shine
Cleaning tasks include dirt preventing methods for Floors, Walls,Tools, Fixtures, and Gauges.
Cleaning tasks have been established, documented, and postedon a checklist.
The work area is cleaned according to the checklist.
The work area is cleaned on the proper frequency.
5S Audit System
What are we looking for?
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Sustain
A disciplined system of control and maintenance is in place toassure the 4 previous steps of 5S are maintained at the highestpossible level.
All Teammates have been educated on the principles of 5S and Waste.
5S practices and audits are in place throughout the facility.Improvements are identified and implemented.
5S Audit System
What are we looking for?
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Before After
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After
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Before After
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BeforeAfter
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E i 30 i t
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Exercise: 30 minutes
Take a look at your current area
Identify and write down things you
would improve
Discuss findings with the group
Pictures from the areas
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AfterBefore
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What did you see?
Overproduction ______________________________
Delays (waiting time)__________________________
Transportation _______________________________
Process_____________________________________
Inventories__________________________________
Motions ____________________________________
Defective products ____________________________ Untapped Resources __________________________
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What is in for YOU!
5S Aims on
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5S Aims on
Teammate Participation
100% Teammate5S education
Teammates will be involved in Sorting, Set In Order,Shining, and Sustaining
Teammates will be the main source for improvement ideas
Teammates will help determine individual responsibilities for
each area
5S will be included in the job descriptions
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5S Means Teamwork
5S can only work if all Teammates act as a Team
Each shift will have to maintain the 5Ss
Each Teammate will have clear responsibilities
Roles and Responsibilities
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You the Leader/Trainer:
Learn as much as you can about 5S
Educate co-workers
Be enthusiastic and promote 5S
Take initiative by implementing 5S in your area
Ask manager for support and resources
Participate in implementing and promoting 5S
Bring your 5S ideas to your manager
Lead by example
Roles and Responsibilities
5S Benefits for the
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5S Benefits for the
Teammates Better and safer workplace
Eliminates the search time for tools and
materials, these will always be at the work cell
Teammates will have more fun and less stress
Preserve our investment in MFG, and improve
long term employment, contribute to profit sharing
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5S will be as important as Qualityand
Productivityand Attendance
5S will be included in the Teammate
evaluations
Will be an important part of the
MFG work routine!
Clean-up and organize your work area every day so thateach new day is easier and safer than the day before
Share your input with your leaders so that the tools you
need will be available to you, increasing your efficiency.
I l ti 5S
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Lets get started!
Meet Tomorrow @ 7:00 am
Be prepared to think outside the
norm!
Implementing 5S
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Determine the area which will be part of the scope
Define the boundary limits
Take before pictures of the area
Establish a red tag holding area (COMPLETED)
Come to an agreement who will be responsible for each area
Steps for the 5S Team
Next Steps for the 5S Team
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Make an initial audit through this area and look for
everything that needs improvement
Write down the required improvements (always think
how can we create a better work environment!)
Be very specific.
Indicate what, where, who, and when.
p
(continuation)
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Summarizing!
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MFG Entity
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Points to Remember
1. Take responsibility for your work
environment
2. A place for everything, and everything
in its place If in doubt, move it out!
3. Develop habits you wont forget
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