5s presentation - (dr.govin)
TRANSCRIPT
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5S PRESENTATION
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Learning Objectives
Recognizing Wastes
Learn the 5S (Sort, Stabilise, Shine, Standardise, Sustain)
Understand 5S Assessment Check Sheet
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Recognizing Wastes
MOVE IT OVER
THERE UNTIL WE
NEED IT
WAITING
OVER
PROCESSINGINVENTORY
MOTION
CONVEYANCE
OVER
PRODUCTION
CORRECTION
UNDER-UTILIZED
RESOURCESTHE EIGHTTHE EIGHTTHE EIGHTTHE EIGHTTHE EIGHTTHE EIGHTTHE EIGHTTHE EIGHT
MAJORMAJORMAJORMAJORMAJORMAJORMAJORMAJOR
WASTESWASTESWASTESWASTESWASTESWASTESWASTESWASTES
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Equipment failures
Waiting for support
Unbalanced work
Sharing of tooling and equipments
Standing watching while automatic machines cycle
Waiting for arrival of material or removal of finished goods
Poor reliability and high machine down times
Machinery or process starved by prior process
Machinery or process blocked by subsequent process
8 Wastes - WAITING
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Making more, sooner and faster than required by the nextprocess
Overproduction is the worst waste commonly found in factories,it creates additional waste in the system and contributes to theother wastes.
Additional handling, space, interest paid,
Additional investment in extra equipment
Overproductioncan be caused by:
Unbalanced manufacturing system, long c/o, poor uptimeand excess capacity
Batch and queue processing
8 Wastes OVERPRODUCTION
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Inspection, Rework and Scrap due to:
Lack of Error Proofing
Insufficient operator Training Acceptance of Inspection and Repair is viewed as acceptable
Standardised Work not in place
Failure to adhere to standardised work
Missing components
Incomplete processes
Line Damage
Lack of Process Capability and low FTT rate
8 Wastes CORRECTION
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8 Wastes MOTION
Unnecessary movement of Operators or Equipment due to:
Poor workstation layout and design
Poor Parts presentation
Multiple pick
Lack of workplace organization
Insufficient training
Poor ergonomics
Double Handling and transfer of parts
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8 Wastes OVERPROCESSING
Performing Unnecessary or incorrect processing due to:
Poor Product design
Poor Process design
Lack of process capability
Unclear standards and customer specifications
NVA testing, retesting and inspection as part of the process
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8 Wastes INVENTORY
Excessive Inventories can be caused by:Excessive Inventories can be caused by:Excessive Inventories can be caused by:Excessive Inventories can be caused by:
Unstable and uncontrolled manufacturing systems
Unpredictable productivity due to machine downtime and OEE Unpredictable schedules and inefficient delivery / shipping of materials
In efficient and long change over times
Bad information flow through out the value stream
Large batch sizes
Poor material control processes
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Unnecessary movement of WIP, Finished Goods and Raw materials:
Movement from process to warehouse to next process
Double handling due to excess inventories
Insufficient material storage
Poor plant and marketplace layouts
Material not placed in the workstation
Poor scheduling
Unplanned changeover
Lack of process flow
Batch and queue production
8 Wastes CONVEYANCE
MOVE IT OVER THERE UNTIL WE
NEED IT
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Not using the SKILLSSKILLS and KNOWLEDGEKNOWLEDGE of the work force.
8 Wastes UNDER-UTILIZED RESOURCES
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QUALITY
PRODUCTIVITY
SAFETY
EQUIPMENTRELIABILITY
Prevent errors
Eliminate wastes
Prevent accidents
Eliminate maintenancebreakdowns
Importance of 5S
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5S is a workplace organization tool/process thatmaximizes the cleanliness, organization, and safety of
all elements in a working environment.
Self Discipline and Sustain5. Shitsuke
Standardise4. Seiketsu
Sweep and Shine3. Seiso
Stabilise and Set In Order2. Seiton
Sort1. Seiri
5S Definition
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WHYdo we need this amount?
WHEREis this used / required?
WHATis the frequency of use?
HOWis this controlled?WHYis this stored here?
Sort unneeded and unwanteditems from those required
5S SORT
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1. Capture the current condition of an area
2. Ask the questions around the current
condition
3. Red Tag those items identified as unneeded,
unwanted or unused
4. Move the tagged items to the quarantine area.
5. Enter the items on a red tag log
6. Review the items within an agreed time period
7. Make business decision whether to keep the
item or not
8. Dispose items identified as unwanted or
unneeded in a TIMELY MANNER
9. Move those items identified as needed to a
central holding area
WHYdo we need this amount?
WHEREis this used / required?
WHATis the frequency of use?
HOWis this controlled?
WHYis this stored here?
SORT Steps to Implement
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Items which are identified for removal and/or notlonger needed
Red Tags should contain: Date when tag attached
Date of decision
Quantity of material
Reason for tagging
What you intend to do with itdispose, store close by, store in area, send to main stores,hold for analysis, etc
Use Red Tag log to track activity
SORT Red Tag
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BEFORE AFTER
SORT Before & After
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5S STABILISE
A place for everything and
everything in its place
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5S STABILISE
Stabilise ensures that there is a place for everything and everything is in its
place and labelled. Sort and Stabilise are best implemented together.
The process allows us to increase our efficiency through properorganisation, the elimination of not needed items and visual controls, it makes
items
Easy to see
Easy to locate Easy to return
It encourages sharing of supplies and tooling, identifies excess inventory
and allows us to maintain and improve performance by highlightingabnormalities
Stabilise ensures that there is a place for everything and everything is in its
place and labelled. Sort and Stabilise are best implemented together.
The process allows us to increase our efficiency through properorganisation, the elimination of not needed items and visual controls, it makes
items
Easy to see
Easy to locate Easy to return
It encourages sharing of supplies and tooling, identifies excess inventory
and allows us to maintain and improve performance by highlighting
abnormalities
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STABILISE Steps to Implement
IllustrationfromTheVisual FactoryGreif1991
1. Create clear visual factory standards for
Safety Production
Materials
Tooling Labelling and Signage
2. Determine the best location for all necessary items.
Locate items according to frequency of use
Store items together according to function orproduct if they are used together
Suspend tools from retractable cords whereappropriate
Ensure storage locations/areas are appropriately
sized to allow placement and removal of items
3. Determine how many of each item will be stored in acertain location and set limits (min max ) etc.
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Our aim is to improve efficiency by making it easy to:
Find, use & return tools and/or equipments
Recognise abnormalities
Provide clear visual standards that everyone recognises and understands
Make it easy to see what does and doesnt belong
Simple visual systems are best
Direction of Flow
AppropriateFluidLevel
STABILISE Steps to Implement
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STABILISE Visual Factory
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STABILISE Visual Factory
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Differentcolorfor:Differentcolorfor:Differentcolorfor:Differentcolorfor:
4ProjectsProjectsProjectsProjects4AreasorDepartmentsAreasorDepartmentsAreasorDepartmentsAreasorDepartments
4EquipmentEquipmentEquipmentEquipment4PrioritiesPrioritiesPrioritiesPriorities4SettingsSettingsSettingsSettings4PersonsPersonsPersonsPersons
4CustomerorSuppliersCustomerorSuppliersCustomerorSuppliersCustomerorSuppliers4SuppliesSuppliesSuppliesSupplies4etc.
ColorCodeSystem
STABILISE Visual Factory
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STABILISE Frequency of Use [Guide]
FREQ.
OF USE
LOW USE
AVERAGE
USE
HIGH USE
Things not used inthe past year
Dispose properly
Things used only
Once in the past
6 12 months
Store at distance
Things used onlyOnce in the past 2 6
months
Things used morethan once a month
Store in acentral place
Things used once aweek
Things usedevery day
Things usedevery hour
Store near work
site or carried byperson
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Cleaning and finding ways to keep the
workplace clean
Emphasizes the elimination of all forms of contamination.
The cleaning process allows us to create pride in the workplace.
It develops a "cleaning is inspection" mindset so problems and safety
hazards will become more visible.
Shine emphasizes clean areas and equipment, makes cleaning a part
of everyday work, and identifies ways to keep the workplace clean.
Shine also promotes keeping everything in top condition so that when
someone needs to use something it is ready to be used.
5S SHINE
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Deep Clean to return equipment and machinery to its original condition
Eliminate sources of contamination and hard to reach places.
Create Simple Visual Cleaning Standards
Who
What
When
How
Review regularly
Make it part of day to day business
SHINE Steps to Implement
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Our aim is to :
Keeping our work areas and equipment clean makes it easier to
identify abnormalities and sources of contamination.
A clean workplace generates pride and ownership
Cleaning Is Inspection! Defects in plant and equipment can be
identified during the cleaning process
Shine applies to all areas of our businessNOT JUST THE FACTORY FLOOR
SHINE Steps to Implement
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SHINE Implementation
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Develop procedures andsystems to monitor the first
three Ss
5S STANDARDISE
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To establish and document clear rules standards
and processes to keep the workplace
clean and organised
It creates a process to maintain and monitor the
first three S.
The purpose of standardise is to establish the
minimum acceptable standard on which we
must improve
It is the foundation for continuous improvement in the
Five S process
To establish and document clear rules standards
and processes to keep the workplace
clean and organised
It creates a process to maintain and monitor the
first three S.
The purpose of standardise is to establish the
minimum acceptable standard on which we
must improve
It is the foundation for continuous improvement in the
Five S process
5S STANDARDISE
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Assign Clear Activities Roles and
Responsibilities
Integrate the first three S into daily work
routines.
Provide a clear link between operators and
cleaning functions and responsibilities
Create a regular review process to ensure
maintenance and continuous improvement of
the first 3 S
Document the process and provide visual
standards to prevent setbacks and maintain the
standard
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
Conformation check
CHECK POINTS
ABSENTEEISM
Is the operator working to QPS sequence?
Is QPS filled out correctly?
VERSATLITY
Is all inf o correct and inclusive of key
points?
W
Is WBB same as the operator job?
VISUAL AIDS
Is the info displayed current and correct?
5S
Is everything tidy, clean and safe?
FTPM
Are tooling, jigs and equipment in a goodcondition?
Audit Card
ENVIRONMENTENVIRONMENT
Cleaning Standard
Clean
Check
Wipe
SweepAll Inside
Oil Hole
Use brush
1
2
3
4
STANDARDISE Steps to Implement
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STANDARDISE Implementation
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5S SUSTAIN
Make Excellence aHabit
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5S SUSTAIN
Making the standard a part of day to day life throughdiscipline at all levels of the organisation.
It makes excellence a habit and changes culture.
Everyone is responsible for sustaining the Five S process.
Management
Leads by example
Coaches
Evaluates the ongoing process of Five S
Encourage Continuous Improvement
Group Leaders and Operators
Apply the Five S process
Maintain the standards
Elevate issues
Drive continuous improvement
Making the standard a part of day to day life through
discipline at all levels of the organisation.
It makes excellence a habit and changes culture.
Everyone is responsible for sustaining the Five S process.
Management
Leads by example
Coaches Evaluates the ongoing process of Five S
Encourage Continuous Improvement
Group Leaders and Operators
Apply the Five S process Maintain the standards
Elevate issues
Drive continuous improvement
SUSTAIN S I l
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Create plant wide awareness of the Five S process
Establish a support structure with clear roles and
responsibilities. Make time for required Five S Activities including
regular Management Reviews
Provide recognition during evaluations and plant
tours
Encourage continuous improvement and continually
raise the standards
Everyone is responsible for setting and maintaining a high standardMake excellence a Habit
Everyone is responsible for setting and maintaining a high standardMake excellence a Habit
SUSTAIN Steps to Implement
SUSTAIN I l t ti
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EffectiveCommunication
SUSTAIN Implementation
SUSTAIN I l t ti
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RecognizeAccomplishments
SUSTAIN Implementation
SUSTAIN Implementation
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SUSTAIN Implementation
Illustration from The Visual Factory - Grief
WHAT IS NEXT?WHAT IS NEXT?WHAT IS NEXT?WHAT IS NEXT?
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WHATISNEXT?WHATISNEXT?WHATISNEXT?WHATISNEXT?WHATISNEXT?WHATISNEXT?WHATISNEXT?WHATISNEXT?
Everyonetoparticipate
Setup5SAdministrativeStructure
5SAssessmentCriteria Dothefirst3Sbeforemovingtotheothers.
5S5S5S5S5S5S5S5S K I i P iK I i P iK I i P iK I i P iK I ti P i tK I ti P i tK I ti P i tK I ti P i t
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5S5S5S5S5S5S5S5S-------- KeyInspectionPointsKeyInspectionPointsKeyInspectionPointsKeyInspectionPointsKeyInspectionPointsKeyInspectionPointsKeyInspectionPointsKeyInspectionPoints