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5S & Visual Control5S & Visual Control

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5S and Visual Control5S and Visual Control

5 Elements of 5S5 Elements of 5SWhy 5S?Why 5S?WasteWasteWorkplace observationWorkplace observationSSortortSStraightentraightenSShinehineSStandardizetandardizeSSustainustainVisual FactoryVisual Factory

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5 Elements of 5S5 Elements of 5S

SortSortStraightenStraightenShineShineStandardizeStandardizeSustainSustain

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Why 5S?Why 5S?

• To eliminate the wastes that result from “uncontrolled” processes.• To gain control on equipment, material & inventory placement and position.• Apply Control Techniques to Eliminate Erosion of Improvements.• Standardize Improvements for Maintenance of Critical Process Parameters.

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Types of WasteTypes of Waste

OverproductionOverproductionDelays (waiting)Delays (waiting)TransportationTransportationProcessProcessInventoriesInventoriesMotionsMotionsDefective ProductsDefective ProductsUntapped ResourcesUntapped ResourcesMisused ResourcesMisused Resources

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Elimination of WasteElimination of Waste

5 S Element Waste/ Improvement Item Deliverable

Systematic Organization Elimination of finding. Reduction of part selection errors.

Reduced Costs Improved Quality Increased Product Options

Sorting-Visual Placement

Elimination of finding. Elimination of nonconformances. Elimination of motion. Reduction of part selection errors.

Reduced Costs Increased Safety Improved Quality Increased Product Options.

Scrubbing Clean Increased safety. Preventive maintenance. Increased equipment knowledge.

Increased Safety Improved Quality

Standardization Control Increased equipment life. Higher morale. Clean environment. Increased visibility of nonconformances.

Improved Quality Consistent Delivery Improved Safety

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Waste IdentificationWaste Identification

What waste can be identified in the following photos?What waste can be identified in the following photos?

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After 5SAfter 5S

Clear, shiny aislesClear, shiny aislesColorColor--coded areascoded areasSlogans & bannersSlogans & bannersNo work in processNo work in process

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Workplace ObservationWorkplace Observation

Clearly define target areaClearly define target area

Identify purpose and function of target areaIdentify purpose and function of target area

Develop area mapDevelop area map

Show material, people, equipment flowShow material, people, equipment flow

Perform scan diagnosticPerform scan diagnostic

Photograph problem areasPhotograph problem areas

Develop a project display board (area)Develop a project display board (area)

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SortSort

When in doubt, move it outWhen in doubt, move it outPrepare red tagsPrepare red tagsAttach red tags to unneeded itemsAttach red tags to unneeded itemsRemove redRemove red--tagged items to tagged items to ““dinosaur burial grounddinosaur burial ground””Evaluate / disposition of redEvaluate / disposition of red--tagged itemstagged items

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StraightenStraighten

Make it obvious where things belongMake it obvious where things belongLinesLines

Divider linesDivider linesOutlinesOutlinesLimit lines (height, minimum/maximum)Limit lines (height, minimum/maximum)Arrows show directionArrows show direction

LabelsLabelsColor codingColor codingItem locationItem location

SignsSignsEquipment related informationEquipment related informationShow location, type, quantity, etc.Show location, type, quantity, etc.

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ShineShine

Clean everything, inside and outClean everything, inside and outInspect through cleaningInspect through cleaningPrevent dirt, and contamination from reoccurringPrevent dirt, and contamination from reoccurring

Results inResults inFewer breakdownsFewer breakdownsGreater safetyGreater safetyProduct qualityProduct qualityMore satisfying work environmentMore satisfying work environment

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StandardizeStandardize

Establish guidelines for the team 5Establish guidelines for the team 5--S conditionsS conditions

Make the standards and 5Make the standards and 5--S guidelines visualS guidelines visual

Maintain and monitor those conditionsMaintain and monitor those conditions

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SustainSustain

Determine the methods your team will use to Determine the methods your team will use to maintain adherence to the standardsmaintain adherence to the standards

55--S concept trainingS concept training55--S communication boardS communication boardBefore and after photosBefore and after photosOne point lessonOne point lessonVisual standards and proceduresVisual standards and proceduresDaily 5Daily 5--minute 5minute 5--S activitiesS activitiesWeekly 5Weekly 5--S applicationS application

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Visual Factory ImplementationVisual Factory Implementation

Develop a map identifying the “access ways”(aisles, entrances, walkways etc.) and the “action” areas.Perform any necessary realignment of walkways, aisles, entrances.Assign an address to each of the major action areas.Mark off the walkways, aisles & entrances from the action areas Apply flow-direction arrows to aisles & walkwaysPerform any necessary realignment of action areas.Mark-off the inventory locationsMark-off equipment/machine locations Mark-off storage locations (cabinets, shelves, tables) Color-code the floors and respective action areas