Visual Workplace - A Prerequisite To Becoming World Class

1. Visual Workplace - A Prerequisite To Becoming World Class 6S As A Tool To Create And Maintain The Visual Work Place

2. What Is 6S? • A process and method for creating and maintaining an organized, clean, high-performance workplace • A conditioning discipline for kaizen

3. What is Lean? • A methodology that focuses on the identification • and elimination of waste. The relentless never ending attack on waste. • Relentless challenge of the status quo with • regard to the elimination of waste. • Customer satisfaction and continual improvement • Also known as the Kaizen process. • A different way of Thinking and Managing A Thought Process!

4. Why Have a 6S Program? • Places high value on safety • Creates proper environment for standard work • Prerequisite to perfect quality • Encourages visual control • Helps identify waste • Promotes employee satisfaction • Promotes customer satisfaction • It is essential for abnormality management

5. The 6S Program • Step 1: Safety • Step 2: Sort – Segregate & Discard (Seiri) • Step 3: Separate – Arrange & Identify (Seiton) • Step 4: Shine – Clean & Inspect Daily (Seiso) • Step 5: Standardize – Revisit Frequently (Seiketsu) • Step 6: Sustain – Motivate To Sustain (Shitsuke) Housekeeping is only a small subset of 6S

6. Step 1: Sort – Segregate & Discard • “When in doubt, move it out, and throw it out.”

7. Step 1: Sort – Segregate & Discard “When in doubt, throw it out.”

8. Step 1: Sort – Segregate & Discard • Survey the work area for unnecessary items, and move them out • Discard as much as possible • Organize the remaining necessary items • Use the Red Tagging process

9. Step 1: Sort – Segregate & Discard Red Tagging: Helpful Hints • Identify a disposition area to put items removed • Train all participants in proper red tag procedure • Be fair—get all areas tagged • Don’tred tag people! • Don’tcompromise: If in doubt, move it out! • Necessary items can be tagged if improvements are known or suggested • Don’tput multiple tags on any one item • Be reasonable about decorative items, family pictures, plants, etc.

10. Red Tag Examples Step 1: Sort – Segregate & Discard Production Areas Office Areas Cabinets / tool boxes Components Documentation Gauges Machines Old Paint Packaging Materials Parts Prints Shelves Supplies Tables Tooling Trash Books Business Forms Cabinets Catalogs Correspondence Equipment Magazines Paper Parts Samples Shelves Supplies Digital files

11. Step 1: Sort – Segregate & Discard Red Tag The Shelf!!!!!

12. Step 2: Separate – Arrange & Identify • Work In Process WIP • Cutting tools, gauges, & lubricants • Tools and jigs • Information

13. Step 2: Separate – Arrange & Identify • Define item placement by frequency of use • Determine address system with part number and address • Label the container with part number and address • Note minimum and maximum quantity (if appropriate) • Make good arrangement a habit (follow steps 1–4) Max Inventory (red) Address Part # A-1 A-2 A-3 A 1 12 1 13 1 14 Min Inventory

14. Step 2: Separate – Arrange & Identify Before For Ease of Use After “A place for everything, and everything in its place”

15. Step 2: Separate – Arrange & Identify For Ease of Use A copy of the scissors is the shadow showing the scissors in use (Home location clearly identified) “A place for everything, and everything in its place”

16. Step 2: Separate – Arrange & Identify Information

17. Identify cleaning activities and routine maintenance required Provide well equipped cleaning supply stations Have painting and marking supplies available Identify individual ownership for all areas Step 3: Shine – Clean & Inspect Daily

18. Step 3: Shine – Clean & Inspect Daily "A clean workplace enhances quality, safety, and pride"

19. Step 3: Shine – Clean & Inspect Daily "If it doesn't get dirty then it doesn't need to be cleaned"

20. Step 4: Standardize – Revisit Frequently • Set-up daily shift hand-off rules • Identify normal state • Conduct weekly 6S audits to uncover 6S abnormalities • Determine root cause(s) of any 6S abnormalities • Implement countermeasures for abnormality prevention

21. Step 4: Standardize – Revisit Frequently

22. Step 5: Sustain – Motivate To Sustain • Implement a 6S performance board • Everyone sets the 6S example: • Daily checklist reviews conducted • All levels participate in audits • All levels ensure countermeasures are implemented • Promote positive results in company communications "If you drop it, pick it up“ “If you spill it, wipe it up”

23. Step 5: Sustain – Motivate To Sustain • Everyone needs to be involved • Integrate 6S principles into daily work requirements • Communicate need for 6S, roles of all participants, how it is implemented • Be consistent in following 6S principles in all areas • Follow through—6S takes effort and persistence • Link 6S activities with all other kaizen initiatives • Remember, 6S is a foundation for world class

24. 6S • Develop a 6S audit schedule • Determine 6S standard work details • Develop a standard clean-up checklist • Develop the implementation plan

25. Thank You.Let’s get started!