sbs 6s & visual management with examples visual management... · sbs 6s & visual...

…Building Strategic Advantage through Enterprise Wide Improvement…

®Simpler ®Simpler

Tool

TechniquesBeliefs

© 1996-2006 Simpler Business System® 11.0© Simpler Consulting, Inc 1996-2006 ALL RIGHTS RESERVED

For the Express Use of Simpler Members Only

SBS 6S & Visual Management with Examples

2

®Simpler ®Simpler

Tool

TechniquesBeliefs



What is…6-S and Visual Management

learn what 6-S means

learn what a visual work place is

Learn what a visual device is

Learn what visual management is

learn how to establish 6-S (basic level)

Objectives:

… part of the Simpler Business SystemSM

3

®Simpler ®Simpler

Tool

TechniquesBeliefs



5S – 6S Background

5-S… in Japanese factoriesfocus: orderliness6th S added in some US companies… Safetycombines orderliness with safety / ergo

overall intention: CLEAN, SAFE, ORDERLY

4

®Simpler ®Simpler

Tool

TechniquesBeliefs



Establishing Cells

establish cells first, then improve themLOWEST

COST

ONE BY ONE

DEFECT-FREE

ONDEMAND

1-Piece Flow

StandardWork

6-S PullSystems

5

®Simpler ®Simpler

Tool

TechniquesBeliefs



Target State for CellsEstablish Model Cells first Improve Cells After They are Established

1-ITEMFLOW

STD.WORK

Quality PULLSYS.

SETUPREDUC-TION

BASICQUALITY

CHECKSTPM

TAKTTIME

OUT-PUT

LOT-SIZE

1

ZERODEFECTS LEVEL-

ING

LOAD-LOAD

DEFECT-FREE ON-DEMAND

1-BY-1 LOWEST COST

6S & VISUAL MANAGEMENT

1-ITEMFLOW

STD.WORK

Quality PULLSYS.

DEFECT-FREE ON-DEMAND

1-BY-1 LOWEST COST

6S &VISUAL MANAGEMENT

6

®Simpler ®Simpler

Tool

TechniquesBeliefs



think of 6-S as a repeating action sequence:1: SORT OUT - get rid of what’s not needed 2: STRAIGHTEN - organize what belongs3: SCRUB - clean up, see and solve problems4: SAFETY - make the work area safe5: STANDARDIZE - assign tasks, track visually6: SUSTAIN - keep it up (audit and insist)

remember…this applies to all areas (value-adding and administrative)basic "6-S” is part of establishing any cell

Overview

7

®Simpler ®Simpler

Tool

TechniquesBeliefs



1: Sort Out

GET RID OF WHAT’S NOT NEEDEDstart with a red tag campaigntag everything that looks disorderly or unsafebe ruthless (9/10 you'll be OK, you'll get over the 1/10)if in doubt throw it outif still in doubt, send it to a “red tag area” for resolutionyou should be removing truckloads of items… be tough(Sometimes you’ll need to ask for forgiveness later!)

8

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sort

9

®Simpler ®Simpler

Tool

TechniquesBeliefs



2: Straighten

ORGANIZE WHAT BELONGScreate a place for everythingdeal with the open red tags from the "Sort Out" step:

RESOLE UNSAFE CONDITIONSORGANIZE PARTS OR MATERIALSRESOLVE THE THINGS YOU WERE AFRAID TO THROW OUTWRITE OFF OR SELL OFF OBSOLETE MATERIALS

10

®Simpler ®Simpler

Tool

TechniquesBeliefs



6. Visual Management in PracticeBest Practice Examples

The Team’s Work cell – Target State1. Identification of area2. Identification of process, resources,

and products3. Identification of the team4. Footprints on the floor5. Footprints of tools and racks6. Technical area7. Communication and break areas8. Information and instructions9. Tool BoardVisual Documentation10. TWI - Std Work DocumentsVisual Production Control11. Computer terminal12. Production schedule13. Maintenance schedule14. Identification of RM and WIPVisual Quality Control15. Monitoring signals for machines16. Statistical process control (SPC)17. Record of problems/defectsMetrics/Key Measures18. Goals, Objectives and Results-

Product/Process Control BoardsVisual Process19. CI activities20. Project List and mission statement

7

1918

13

14

15

1617

20

10

11

12

9

8

6

4

5

3

2 1

4

2

10

11

®Simpler ®Simpler

Tool

TechniquesBeliefs



Straighten

12

®Simpler ®Simpler

Tool

TechniquesBeliefs



3: Scrub

CLEAN UP, SEE AND SOLVE PROBLEMSmake the work area absolutely cleanclean everything (equipment, floors, walls…)paint everything (equipment, floors, walls…)look for problems…

LEAKS?LOOSE OR MISSING ITEMSUNSAFE CONDITIONSCAUSES OF MESSES OR PROBLEMS…QUALITY ISSUES

solve problems (root cause), take corrective action (prevent)

13

®Simpler ®Simpler

Tool

TechniquesBeliefs



Scrub

Break Room - organized and clean

14

®Simpler ®Simpler

Tool

TechniquesBeliefs



Cabinet under sink in Training Room

Scrub

15

®Simpler ®Simpler

Tool

TechniquesBeliefs



4: Safety

MAKE THE WORKPLACE SAFERlook for unsafe conditionslook for potential for unsafe actslook for difficult tasks (are they ergonomic?) try the jobs yourself… where could you get hurt?list the opportunitiesresolve them

put creativity before capital and put safety first!!!

16

®Simpler ®Simpler

Tool

TechniquesBeliefs



Safety

17

®Simpler ®Simpler

Tool

TechniquesBeliefs



Safety

18

®Simpler ®Simpler

Tool

TechniquesBeliefs



Lock Out / Tag Out program includes a storage area at the entrance to the plant floor for all locks and tags (locks are color coded for operators, mechanics, and contractors). Also, there is a place at each machine to store locks and tags when not in use.

Safety

19

®Simpler ®Simpler

Tool

TechniquesBeliefs



5: Standardize

ASSIGN TASKS AND MANAGE VISUALLYWho will do what to keep the area clean, safe and orderly?agree on daily and weekly tasksestablish a visual management system for these tasks

can you tell at a glance if the tasks have been done?

20

®Simpler ®Simpler

Tool

TechniquesBeliefs



Standardize

21

®Simpler ®Simpler

Tool

TechniquesBeliefs



6: Sustain

KEEP IT UP (AUDIT AND INSIST)develop audit checklists for office and for shop floorassign the audit role to someone outside the area track the audit results (a bit of friendly competition?)hold yourselves accountable for sustaining

22

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sustain

23

®Simpler ®Simpler

Tool

TechniquesBeliefs



Cell Tracking Center – Production Control Board

24

®Simpler ®Simpler

Tool

TechniquesBeliefs



Insights

areas with great 6-S usually also have great numbersbasic 6-S is the first step in building a new cultureif you expect 6-S, lead by example (your office!)be persistent (it's OK to nag)

25

®Simpler ®Simpler

Tool

TechniquesBeliefs



Definition of a Visual Workplace

A Clear and precise outcome

A Visual Workplace is:A work environment that is self-ordering, self-explaining, self regulating, and self-improvingWhere what is supposed to happen does happen, on time, every time, day or night…Visual Management is managing a visual workplace

26

®Simpler ®Simpler

Tool

TechniquesBeliefs



Definition of a Visual Device

A Visual Devise is a mechanism or thing:intentionally designedTo influence, direct, or limit behaviorBy making vital information available without speaking a word (Think of a supermarket; Where do you find the breakfast cereal?)Should transmit a non-verbal message in 5 SecondsShould tell us what we need to do (action)Should be at the point-of-useTranslates data into information, information into meaning, and meaning into behavior

27

®Simpler ®Simpler

Tool

TechniquesBeliefs



Visual Systems, Cells, or Communications Centers

A Visual System is a cluster or group of visual devices, aimed at a single performance outcomeBecause these systems are self-explaining, we can be self-regulatingExample: A standard car has on the average of 144 visual devices on or inside the car. Intentionally designed to help us drive, maintain, and repair the carA Visual Cell is a cluster of visual devices within a confined spaceA Communication Center is a cluster of visual information located near people collection areas or meeting locations

28

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sustain: TPOC – Enterprise Level Tracking Center

29

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sustain: TPOC – Enterprise Wide Tracking Center Example

30

®Simpler ®Simpler

Tool

TechniquesBeliefs



Admin Cell Tracking Center

31

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sustain: Mission – Site Level Tracking Center

32

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sustain: Value Stream/Site Level Tracking Center (Mission)

33

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sustain: Value Stream – Mission Level Tracking Center/Board

34

®Simpler ®Simpler

Tool

TechniquesBeliefs



Kaizen/Continuous Improvement Board – CI Events Tracking Center

35

®Simpler ®Simpler

Tool

TechniquesBeliefs



Kaizen/Continuous Improvement Board – 6S Tracking Center

36

®Simpler ®Simpler

Tool

TechniquesBeliefs



Sustain: Cell Tracking Centers - Kiosks

37

®Simpler ®Simpler

Tool

TechniquesBeliefs



6S & Visual Management ExamplesUpdated Hour-by-hour boards

38

®Simpler ®Simpler

Tool

TechniquesBeliefs



Admin. (Design Center) Flow Cells with Cell Control Boards

39

®Simpler ®Simpler

Tool

TechniquesBeliefs



Cell Tracking Centers – Production Control Board Examples

40

®Simpler ®Simpler

Tool

TechniquesBeliefs



Key Points Sheet Example

41

®Simpler ®Simpler

Tool

TechniquesBeliefs



Each machine has a posted start-up and shut-down procedure.

42

®Simpler ®Simpler

Tool

TechniquesBeliefs



Cells – Small parts feeding systemsPoint of use Tools Boards

43

®Simpler ®Simpler

Tool

TechniquesBeliefs



Low Volume, High Mix – Mix Model Cell

44

®Simpler ®Simpler

Tool

TechniquesBeliefs



Single operator assembly cell example

Clear plastic parts hoppers

Point of use tools& controls

Posted standard work doc’s

45

®Simpler ®Simpler

Tool

TechniquesBeliefs



Work Cell Example

Single Kit AssemblyBoards

Work Instructions

Tool Boards at point of use

Stand up cells

Small parts at POU

46

®Simpler ®Simpler

Tool

TechniquesBeliefs



One Piece Flow Cell Example

Posted Standard Work Job Instructions - JR

47

®Simpler ®Simpler

Tool

TechniquesBeliefs



Team A3 Development Cell

48

®Simpler ®Simpler

Tool

TechniquesBeliefs



Visual Controls – TPM Standard Work Example

49

®Simpler ®Simpler

Tool

TechniquesBeliefs



Point of Use Tools – Work Cell

50

®Simpler ®Simpler

Tool

TechniquesBeliefs



Tool Board Example(Tools at point of use)

Tool Board

51

®Simpler ®Simpler

Tool

TechniquesBeliefs



Assembly Cell Example

52

®Simpler ®Simpler

Tool

TechniquesBeliefs



Assembly Cell Example with Automation

53

®Simpler ®Simpler

Tool

TechniquesBeliefs



Cell Example

54

®Simpler ®Simpler

Tool

TechniquesBeliefs



Color Coded Press with visual signals

55

®Simpler ®Simpler

Tool

TechniquesBeliefs



Stamping Press - start of Set-up Reduction Event

56

®Simpler ®Simpler

Tool

TechniquesBeliefs



Stamping Press - Information Board from TPM Event

57

®Simpler ®Simpler

Tool

TechniquesBeliefs



Press - Decoiler, requires coil change with each die change

58

®Simpler ®Simpler

Tool

TechniquesBeliefs



Press - Coil Feeder, front:

Press - Coil Feeder, back

(Feed adjustment required each change)

59

®Simpler ®Simpler

Tool

TechniquesBeliefs



Stamping Press - Rear of press used to collect off-fall

60

®Simpler ®Simpler

Tool

TechniquesBeliefs



Administrative Cell Administrative Cell ––One Piece Flow Example Design EngineeringOne Piece Flow Example Design Engineering

Work FlowWork Flow

Process Control Boards

61

®Simpler ®Simpler

Tool

TechniquesBeliefs



Business Process Cell ExampleBusiness Process Cell Example

62

®Simpler ®Simpler

Tool

TechniquesBeliefs



Administrative Flow Cell ExampleAdministrative Flow Cell Example

Flow