6.1-14 prezentacija 5s ohrid 2009

IMPROVEMENT OF A SHIPYARD WITH INTRODUCING THE 5S METHOD

Prof. Dr. Ivica Veža, Prof. Dr. Boženko BilićUniversity of Split, CroatiaProf. Dr. Franci Čuš, University of Maribor, Slovenia

September 28th, 2009, Ohrid

Agenda

1. Toyota Production System2. 5S3. Case study4. Conclusion

The Toyota Production System

TOYOTA

The five main principles of Toyoda

Development of Toyota Production System

Sakichi Toyoda’s Contribution - Jidoka

House of Lean

The seven wastes

Heijunka

Single Minute Exchange of Die (SMED)

Simultaneous work between worker and machines

Wall slogans

3 S Speed, simple, slim

5 S

Quality CostDelivery Safety

- urediti

- pravo mjesto

- čistoća- organizacija- disciplinirati

New models

Agenda


What are the five ‘S’ ?

1. SEIRI (Sorting out)- Identification of best physical organisation of workplace.

2. SEITON (Systemic Arrangements)- Implementation of optimum organisation identified in Seiri .

3. SEISO (Cleanliness)- Cleaning-up the workplace completely.

4. SEIKETSU (Maintain a Serene Atmosphere)- Audit, review & actions by which we maintain the first three S’s.

5. SHITSUKE (Stick to Self-discipline)- Train people to follow good housekeeping autonomously.

Progress indicators of 5-S implementation

Start: Cigarette butts, scraps of paper, cotton waste, hand tools, materials, and parts are scattered around factory / office floor

Floor cleaning-up is completed, sorting out and throwing away unwanted things started. Still clutter is found by the walls, the pass ways are not clear.

Cleaning-up of machinery and equipment completed. The walk-ways are clear and the factory is clean. But tools, parts and machineaccessories are disorganized in the cabinets, shelves or storage area.

The machinery and equipment are kept clean. Storage areas are clearly designated and identified by numbers or codes. Storage area shows many parallel lines, and right angles.

There is constant and continuous cleaning from wall to wall. The walk area is immaculate. Tools, materials and parts are laid-out squarely. The causes of dirt are removed. Employees are disciplined to keep the place clean.

Benefits of 5S

n Reduce waste hidden in the plantn Improve quality and safetyn Reduce lead time and costn Increase profit

1. Seiri – sort

n Ensuring each item in a workplace is in its proper place or identified as unnecessary and removed.

n Sort items by frequency of usen Get rid of unnecessary stuff

q Bare essentials for the jobq Red Tag systemq Can tasks be simplified?q Do we label items, and dispose of waste frequently?

before after

2. Seiton – set in order

n Time spent looking for things, putting awayn Arrange materials and equipment so that they are easy

to find and useq Prepare and label storage areasq Use paint, outlines, color-codedq Consider ergonomics of reaching itemsq Frequent, infrequent users

Before After

3. Seiso – shine

n Repair, clean & shine work area (“Everyone is a janitor”)n Important for safetyn Maintenance problems such as oil leaks can identified

before they cause problems.n Schedule for cleaning, sweeping, wiping offn Cleaning inspection checklistsn Workspace always ready to workn See workspace through customers’ eyes

4. Seiketsu – standardize

n Formalize procedures and practices to create consistency and ensure all steps are performed correctly.

n Prevention steps for cluttern Otherwise improvements from first 3 lost n Everyone knows what they are responsible for doing, when

and hown Visual 5S – see status at a glancen Safe apparel, no wasted resources

5. Shitsuke – sustain

n Keep the processes going through training, communication, and organization structures

n Allocate time for maintainingn Create awareness of improvementsn Management support for maintainingn Training, rewards

Visual Management

n Indicators for tools, parts, and production activitiesn Placed in plain sight of all workers so everyone can

understand status of system at a glancen If a machine goes down, or a part is defective or delayed,

immediate action can be taken

Agenda


Shows the state in which the workplaces were before and after sorting

Setting in order by the use of visual method

Before After

The machinery processing unit before and after sorting and setting in order

Way to 6 S

Agenda


The results of implementing the 5S method (1)

n Increase of finances (extra income): accumulation of financial resources provided by selling the technically out of date, uneconomical, and no longer in use means of work

n The increase of usable workplace: surface of 250m2 freed by removing unnecessary means of work and materials.

n The reduction of firm expenses: the reduction of costs of safetyat work and fire protection (the costs of evaluation and attestation)

n Apart from these economy results, during the realization of the pilot programme other positive moves were made. But it should be pointed out that during the realization of the above steps some obstacles appeared which slowed down considerably the implementation.

The results of implementing the 5S method (2)

n Insufficient awareness of the importance of quality managing of the resources

n Passive participation of preparation, service and administrativeservices in the processes of change

n Absence of clearly defined processes and interrupted directory chains

n The absence of knowledge about modern management (project and innovating management)

n These obstacles are not insuperably, but they require long-term education about the importance of managing the resources of which the organization disposes. More important results can be expected in long-terms.

Conclusion

n The implementing of the 5S method resulted in sum-total financial savings and the increase of free work spaces. But the results are related to short-term effects of the first three stages of the method while for the next two stages and long-term effects some there are some obstacles.

n Mainly they are obvious from cultural differences between Japanese and Croatian way of living, so greater education and animation of the employees is required while implementing the method.

Application of 5S in the best shipyards in the world

Thank you for your attention!

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6.1-14 prezentacija 5s ohrid 2009

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