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Lean Training

Lean Training. 5S. Agenda. What is it? What’s it for? How does it work? When do you use it? What’s an example?. What is it?. 5S is a workplace organization technique It is a way to involve associates in the ownership of their workspace

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Lean Training

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  1. Lean Training 5S

  2. Agenda • What is it? • What’s it for? • How does it work? • When do you use it? • What’s an example?

  3. What is it? • 5S is a workplace organization technique • It is a way to involve associates in the ownership of their workspace • It helps create and maintain the efficiency and effectiveness of a work area 5S is a common starting point for Lean activities in a company

  4. What’s it for? • It is a way to create: • Cleaner work areas • More organization • Safer working conditions • Less wasted time • Efficient work processes and practices • More available space

  5. How does it work? • 5S is most effective when applied in a systematic way • The following video illustrates the 5S methodology 5S Video

  6. The Five S’s • Sorting – separating the needed from the not-needed • Simplifying – a place for everything and everything in its place, clean and ready to use • Systematic Cleaningor Sweeping – cleaning for inspection • Standardizing – developing common methods for consistency • Sustaining – holding the gains and improving

  7. The First S - Sorting Separating the Needed from the Not-Needed • Eliminate not-needed items and perform an initial cleaning • Establish criteria/handling of items • Identify not-needed items • Move not-needed items to holding area • Conduct a white-elephant sale • Conduct an initial cleaning

  8. The Second S - Simplifying A place for everything and everything in its place, clean and ready to use • Arrange workplace for safety and efficiency • Identify key equipment and supplies • Determine location for each item • Outline locations and zones • Develop shadow boards, label items • Document layout, equipment, supplies

  9. The Third S – Systematic Cleaning Cleaning for Inspection • Perform daily cleaning and inspection to understand work conditions • Identify points to check for performance • Determine acceptable performance • Determine visual indicators/controls • Mark equipment/controls • Conduct daily cleaning/inspections

  10. The Fourth S - Standardizing Developing Common Methods for Consistency • Make abnormal conditions noticeable and document agreements • Document agreements and checks • Establish/document standard methods across similar work areas • Document new standard methods

  11. The Fifth S - Sustaining Holding the Gains and Improving • Maintain the gains from other 5S activities and improve • Determine 5S Level of Achievement • Perform routine checks • Analyze results of routine checks • Measure progress and plan for continuous improvement

  12. Getting Started • Planning – launches your 5S activity • Evaluating – tells you what you need to do • Preparing – gets you ready for implementation

  13. Planning • Assemble a 5S Lead team • Define the work area 5S boundaries • Assign work group members to their 5S areas • Install a 5S communication board • Determine 5S targets, activities, and schedule • Review/finalize plans with work group and site leadership

  14. 5S Boundaries Area 1 Area 2 Monica & Chandler Joey & Phoebe Area 3 Area 4 Rachel & Ross Jerry & Kramer

  15. Five S Implementation Plan Five S Team Members Five S Implementation Plan Five S Boundaries Photos Photos Five S Routine Checklist Five S Routine Checklist Current Situation After Five S Five S Communication Board Levels of Achievement

  16. Evaluating Your Initial Situation • Prepare to take work area photos • Take work area photos • Evaluate current 5S Level of Achievement

  17. Preparing for Implementation • Obtain existing standards for color-coding and signage • Decide on 5S color-coding and signage standards • Prepare for Sorting • Prepare for Simplifying • Prepare for Systematic Cleaning • Prepare for Standardizing • Prepare for Sustaining

  18. Summary: Implementing Five S’s • Share 5S Overview • Choose work area implementation group • Determine implementation targets, activities, and schedules • Document current situation • Apply 5S’s • Document improvements • Determine new improvement goals and action steps

  19. Issues and Concerns • Communicating across shifts • Disposing of, or moving, personal items • Making time available • Following agreements consistently • Maintaining the gains • Giving rewards and recognition • Integrating 5S with other improvement activities

  20. What’s an example?

  21. What’s an example?

  22. What’s an example? After Before

  23. What’s an example?

  24. What’s an example?

  25. Questions?

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