5 s training dennis j o-boyle - johnson controls 02 21 2008
TRANSCRIPT
2/25/2008 | Confidential and Proprietary1
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Johnson Controls – Saft 5S Program
The 5S Program
A JCS Quality SystemTraining Program
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5S Objectives
• Describe each “S” of 5S
• Describe how 5S contributes to Safety
• Learn how 5S will improve work area efficiencyand reduce waste
• Apply the first 3 S’s in your work area– Put it on your schedule for the next two weeks
• Plan a system to sustain the 5S Principles
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The 5S Program
• SORT
• STRAIGHTEN
• SWEEP
• SCHEDULE
• SUSTAIN
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Basic Concepts of JCS Quality Production
• Minimize Mistakes–Only acceptable product
• Zero Tolerance For Scrap And Rework
• Stable Production Environment
• Customer Focus Drives Production
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5S Supports Zero Tolerance for Scrap and Rework
• 5S is a system for identifying and eliminatingseveral different types of waste:–Wasted Motion–Wasted Time–Correction (Rework)
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5S SupportsStable Production Environment
• The cleaner the work area,the sooner problems are identified
• A clean environment is safer
• A clean, organized environmentis more compatible with team functionality
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5S SupportsEasy Visual Identification and Instant Status
• Workplace Organization is Simpler-- It’s easier to visually recognize items
• Improved Organization and StandardizationAllow Quicker Response (Flexibility)
• Inventory Levels are Easily Controlled
• Communication of Production Status is More Efficient
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5SVisual Management Efficiency
5S SupportsEasy Visual Identification and Instant Status
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This 5S Process Is A Means ToImproving Organization & Cleanliness
Is this important in your work area?
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An Unclean EnvironmentContains Hidden Risks for Workers & Equipment
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Best in Class
Name some companiesthat you consider
as the best in their class
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What Companies Do You Think Of As Being Best In Class?
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There Are Basically Three Different TypesOf Companies and Workplaces
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A Third-Class Workplace
Third Class: People Throw Trash Around and No One Cleans It Up
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A Third-Class Workplace
Second Class: People Throw Trash Around & Someone Else Picks It Up
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A Third-Class Workplace
First Class: No One Throws Trash Around & Everyone Works To Keep Things Clean
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A First-Class Company:Advantages of an Organized and Clean Environment
• Safety
• Quality
• Customer Responsiveness
• Visual Control
• Time Management
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What Is 5S?
• The 5S PrinciplesAre a Means of Improving the Work Environment
• Each “S” Designatesa Progression in Implementation
• Today, We Will Examine Each “S”in Detail and Begin Implementation
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5S SupportsA Safe Work Environment
• A Clean Work Area Results in Injury Reductionand Makes Prevention Easier
• Organization and Visual Management Support JobRotation (Force, Frequency, Duration, Posture)
• Work Conditioning is Organized and Effective
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What Is 5S?
1S Sort2S Straighten3S Sweep4S Schedule5S Sustain
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1S• Sort
• Sort – Separate and Scrap
• Separate needed from unneeded
• Initial “Deep Dive” is Usually Required
• Critically Examine Everything in Your Work Area and Get Rid of What Is Not Needed
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1SSort, Separate, Scrap
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1SSort, Separate, Scrap
• Are There Any Unnecessary Items In Your Work Area?
• Stock• Tools• Pallets• Shelves
• Machinery• Fixtures• Desk or Chairs• Documents
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5SRed Tag Event
•Red Tags Identify Items Not Needed
• Either Scrap Items or Move Themto a Specified Storage Location
• Clearly Define Difference Between What Is Vs. What Might Be Needed
• Remove Items Not Neededon a Weekly or Daily Basis
RED TAG
NAME
TODAY'S DATE (check)
LOGGED
NAME OF ITEM (PART #)
REASON TAGGED
UnnecessaryDefective
Not UrgentOther ____
Purchased Component
Machine/Equipment
Finished Product
Work in Process
Raw Material
Other_____Supplies
CLASSIFICATION
SUGGESTED ACTION
ACTION DATE
Throw awayMove to Storage
Other ________
Return to ______
Y N Have you used in the last week?Y N Have you used in the last month?Y N Will you use next week?Y N Will you use next month?
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5SRed Tag Procedure
• Team Places Tags In Area
• Give All Users 48 Hours To Review
• Management Response/ActionIn One Week or Less
• Challenge Yourself.Look at All Items Very Critically.
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5SRed Tag Event
Red Tag Evaluation & Action
• Designation
• Defective Items• Excess Stock• Obsolete Stock• Useful to another group, but not
needed by our group
• Action
• Eliminate• Store • Dispose• Give Away
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5SRed Tag Procedure
Red Tag CampaignSeparate – Scrap - Straighten
Distinction Between Things Needed & Not Needed
Separate/ScrapRed Tag Campaign
Red Tag Storage Area
Dispose
Straighten & Organize
WhereWhatHow Many
Visible
Needed
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2SStraighten
• Organize• Arrange items so they are easy to findand readily retrieved
• A Place for Everythingand
Everything In Its Place
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2SStraighten
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How Will You Know If Good Organization Is In Place?
Can Anybody Immediately:• See Where, What & How Many?• Take Item out?• Return Item After Use?
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5SKeys to Organizing
• Visual ManagementWhere, What and How Many
• Ready Retrieval
• Ready Return
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5SKeys to Organizing
Which Bench Would You Prefer?
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3SSweep – Sweep & Shine – Clean – Repair
• Sweep, Clean, and Repair the Work Area
• Initial “Deep Cleaning” May Be Necessary
• The Challenge Is to Implement Regular HousekeepingSo That Any Dirt, Debris, or Grease Is Immediately Obvious
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3SWhy Sweep?
• Rid Workplace of Undesired Debris, Dirt, Dust, etc.
• Healthier, Safer Environment for Both Humansand Machines
• Improves Visual Inspection Portionof Preventive Maintenance
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3SSweep
Inspect While Cleaning
• Faulty Parts• Hidden, Broken, Uncalibrated Gauges• Loose Nuts and Bolts• Damaged Equipment
• Cleaning is Inspection,Inspection is Detection,Detection is Correction
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3SSweep
Sweep Targets
• Storage Areas: Shelves, Cabinets, Closets,Tool Storage
• Equipment: Machinery, Material Handling, Lift, Packaging Materials, and more
• Surroundings: Aisles, Windows,Conference Rooms, Tops of Cabinets, etc.
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3SSweep
Sweep Management
• Must Be Done On A Regular Basis
• Determine What to Sweep and Clean,Then Assign Tasks to Specific Individuals
• Necessary Cleaning Tools and SuppliesAvailable At Usage Point
• Designate Specific Cleaning Time;e.g., Last Five Minutes of Shift
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3SSweep
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4SSchedule
• Implement A Routine ScheduleIn All Workplace Areas
• Implement Best PracticesThroughout The Workplace
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4SSchedule
• 4S Means Scheduled Routines Throughout The Shop
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4SSchedule
Audit the Workplace for Progress On:
• Sort: Separate and EliminateUnnecessary Items
• Straighten: Needed Itemsin Designated Places
• Sweep: Everything Is Clean & Repaired;Dirt & Damage Are Noticed Immediately
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5SSustain
Sustain
• Personal Commitment to High Housekeeping Standards.
• Are All Workers Intolerant Of A Dirty, Damaged Workplace?
• Would You Stop To Pick Up A Piece Of PaperOn The Floor?
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5SSustain
Make a visual record of your progress
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5SNext Steps
Next Steps
• Choose a “model” area of the BTC
• Conduct the first three of the 5S steps•Do a 5S Red Tag event
• Do the 4th & 5th “S” – Schedule A Routine! – Sustain!
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5S TrainingQuestions and Answers
Thank you