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5S – The Foundation for Improvements

Safety the “6th” S

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Lean Six Sigma Improvement Process

DefineDefine

MeasureMeasure

AnalyzeAnalyze

ImproveImprove

ControlControl

Define the opportunity from both business and customer perspectives

Search for the key factors (critical X’s) that have the biggest impact on process performance and determine the root causes

Understand the process and its performance

Develop improvement solutions for the critical X’s

Implement the solution and control plan

Critical Enablers• Opportunity Identification &

Project Selection• Project Sponsorship• Tollgate Reviews

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6S Overview:• Safety (Self-Discipline)

– Ensuring compliance and protection of our employees

• Sort

– Clearly distinguish needed items from unneeded items and eliminate the latter.

• Set In Order (Simplify)

– Keep needed items in the correct place to allow for easy and immediate retrieval.

• Shine (Sweep)

– Keep the workshop swept and clean.

• Standardize

– Standardized cleanup. This is the condition we support when we maintain the first three steps.

• Sustain (Self-Discipline)

– Make a habit of maintaining established procedures.

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What is 6S?

• 6S is the foundation for continuous improvement, a safe work area. zero defects, and cost reduction.

• 6S is a process for creating and maintaining an organized, clean, and high performance workplace.

• 6S is a systematic way to improve the workplace, our processes and our products through employee involvement.

• 6S enables anyone to distinguish between normal and abnormal conditions at a glance.

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Step #1: Safety

Implementing Safety

• Identify potential risk (Assessments,Obsevations)

• Develop plan to eliminate defects (risk)

• Make it structured. Convey the message to all

• Give recognition where it is due.

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This is a mess!!

This is so neat!!

Step #2: Sort

Sorting Process1. Separate the necessary from the unnecessary and then clean

everything remaining

– No Tag = necessary item

– Red Tag = unnecessary item

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Step #3: Set in Order

Definition of Set in Order • Set in order means to arrange the items that are needed in the

area and identify them so that anyone can find them or put them away.

• The key word is “anyone.”

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Step #4: Shine

Shine Definition• Shine emphasizes removing the dirt, grime, and dust from the

work area.

• This is a program of keeping the work area swept and clean of debris.

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Step #5: Standardize

Benefits of Standardization

• Easier to train new employees

• Less room for errors and scrap

• Work area is more organized

• Work area is safer

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Step #6: Sustain

Implementing Sustain

• Keep everyone aware of 6S and its benefits.

• Make time each day to perform daily tasks.

• Make it structured.

• Give recognition where it is due.

• Establish checklist for visitors to review.

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Takeaways

• A 6S’d Process is a Much Safer Place to Work

• A 6S’d Process Produces Fewer Defects and Reduces Risk

• A 6S’d Process Meets Deadlines More Frequently

• A 6S’d Process Results in a More Efficient/Cost Effective Process

• 6S can be a useful to implement in any of the Lean Six Sigma Phases

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Can You Identify the Hazards?

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Can You Identify the Hazards?

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Examples of 6S Projects

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Before

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L2 Paper Applicator Project

Hayward, Wisconsin

August 2013

Scott Pahos

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Challenge / Goals / Safety(Business Case)

• Challenge: To Improve reliability in regards to paper application on our L2 forming line. Current state indicates numerous upset conditions both reducing production and increased risk with our employees being exposed to potential hazards while correcting upset conditions.

• Results Achieved (or Expected): Analyze current state and develop alternative options to reduce risk and improve overall safety, production and quality outputs.

• Cost: Minimal

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Team Members / Functions

• Shane Chucka, Converting Supervisor

• Dave Skopek, Plant PCT Green Belt

• John Johnson, Maintenance

• Alex Norquist, Plant PCT

• John Aubart, FSG manager, Green Belt

• Scott Pahos, Project Leader, LSS BB

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Project Scope

In Scope:

• Safety

• Processes and procedures

• Paper Applicator

Out of Scope:

• Production

• Capital expenditures

• Equipment integrity

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Paper Overlay Used in the

process.

Paper Overlay Used in the

process.

Before the conversion of the new paper slitter. Poor guarding/Poor reliability resulting in numerous defects (stops) requiring plant personnel to enter area to clear paper and service cutter resulting in increased exposure to risk.

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After picture on newly installed paper slitter. Note the process is now much improved with safety enhancements such as new guarding and informational data on the equipment

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Pictures of new/additional guarding for employee protection

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Newly designed cutter/motor totally enclosed/guarded

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Motor and Cutter labeling providing critical safety information for the employees.

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Q & A