Levels of Achievement

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					  Lean Manufacturing




5S and the Visual Workplace
                                                         Objectives

   Understand how to implement a Visual Workplace that
    • Makes each person’s job easier
    • Enables you to successfully manage the workplace
    • Improves the overall success of your company


   Understand impact of 5S on
    • Customer value
    • Throughput
    • Efficiency
 Learn tools for identifying waste in your work area
 Learn tools for eliminating waste in your work area
                                Topics Covered

 Workplace organization (5S)
 Visual Display
 Visual Metrics
 Visual Control
                                                    What is 5S?

   5S is the Japanese concept for House Keeping.

   Sort (Seiri)
   Straighten (Seiton)
   Shine (Seiso)
   Standardize (Seiketsu)
   Sustain (Shitsuke)
                                             The Visual Workplace
                                                         What is It?

5S, Visual Workplace, Lean together create…
   An immaculate (clean and tidy) workplace with
    •   Only what is needed
    •   Only in the amounts needed
    •   Only when it is needed
    •   And at the location where it is needed
   A pleasant and stimulating workplace with
    • Standard procedures that are easily understood
    • Standard procedures that are visually clear
                                             The Visual Workplace
                                                         What is the Goal?

   A workplace that
    •   Responds quickly to customer needs
    •   Enables decisions at the lowest possible level
    •   Is completely aligned (united)
    •   Promotes employee growth
   The least waste way to deliver value to the customer


            If you can't walk a plant and understand the
              product flow and operations immediately,
              then the plant can't be run properly.
                                         Noel Goutard, Valeo SA
                                         The Visual Workplace
                                                         Expectations

   The flow of goods is apparent at a glance
   Information or tools are available in 30 seconds or less
   Historical and current performance levels are apparent
   Waste is visible
   Abnormal conditions are immediately recognizable
   The normal condition is
    • zero defects
    • zero abnormalities
    • zero accidents
                                                 The Visual Workplace
                                                                  Maturity Levels

       Level        Characteristic                   Description
                                              Continuous improvement,
5 Optimized          Visual Control
                                                 prevention of defects
                                               Real time data available,
4 Managed            Visual Metrics
                                             decisions made at local level
                                               Value Streams identified,
3    Defined         Visual Display
                                              work force aligned to them
                                               Workplace organization,
2 Repeatable                 5S
                                                    basic discipline
                                                      No visibility,
1      Initial            Ad hoc
                                                   multiple systems
Ad hoc is a Latin phrase which, literally, means "For this". It generally signifies a
solution designed for a specific problem or task, non-generalizable, and which
cannot be adapted to other purposes.
Visual Display
 Location Marker
      Visual Display
Production Status Board
                                                                                                                                                                      Visual Display
                                                                                                                                                                                Standard Work
                                                Fuel Pump Assembly Cell - Standard Work
                                                                                                                                                                     P/N 60-72101-2
         Housing Assy - P/N 60-98966 (P/N 60-989100-2)                                                                                                               Only
          Housing Assy - P/N 60-98914 (P/N 60-98976-2)
         Housing Assy - P/N 60-75512 (P/N 60-755100-2)                                                                  Bearings, Discharge Plates
                                                                                                                                                                                  Rotor - P/N 78-17512 (P/N 60-989)
          Housing Assy - P/N 60-72110 (P/N 60-72101-2)                                                                  Liners and tubes
                                                                                                                                                               Balancer           Rotor - P/N 78-16917 (P/N 60-755)
                                                                                                                                                                                  Rotor - P/N 78-15337 (P/N 60-721)
                                                        1 unit                   1 unit                                   1 unit     3 units


                                                                   Component                   Component                                                                   Component




                                                                                                                                      Oven Cure
                                    Inspect                                                                                                          Inspect




                                                         Stabond




                                                                                 Stabond
                                                                    Material                    Material                                                                    Material




                                                         Outgas




                                                                                 Outgas




                                                                                                                                       Loctite
                                                                                                                           Rotor
                                                                                                                           Cool
                                     Rotor/                                                                                                           Rotor
                                                                                               Assemble                                                                                              Start
                                    Housing                        Assemble                                                                         Assembly
                                     Height                                                     Rotor -                                              Endplay
                                                                   Rotor into                                                                                             Rotor Assembly
                                                                                               Apply Sta
                                                                    Housing
                                                                                                 Bond
                                                                                                                          7 Min
                                 X minutes           5 minutes                     5                                                               X minutes
                                                                      2         minutes           2                                 1 hour                                     9
                                                                   Minutes                     Minutes                             @ 250 Deg                                Minutes
                     Oven Cure




                                 @ 265 Deg
                      Stabond
    3 units




                                  1 hour




                                                                                              2
                                                   4                                                                             5
                                                                                           Minutes
                                                Minutes                                                                       Minutes
                                                                   20 Min




                                                                                                      Inspect Bonding
                                             Final Assembly -                    Assemble Handle                                 Impeller
                                                                    Assembly

                                                SF1 & SF2                          to Assembly                                 Installation
                                                                      Cool




                                                                                                                                                                     Deliver to Test
                                               Component                             Component                                Component
                                                Material                              Material                                 Material
                                                                                                                                                              Inducer - P/N 60-98970 (P/N 60-989100-2)
                                                                                                                                                              Inducer - P/N 60-98916 (P/N 60-98976-2)
                Stator Assy - P/N 78-17515-1 (P/N 60-989)                                                                                                     Inducer - P/N 60-72112 (P/N 60-72101-2)
                        P/N 78-16923 (P/N 60-755)                   1 unit
                       P/N 78-15341-1 (P/N 60-721)
                                                                                                                                                                    Impeller - P/N 60-98917 (P/N 60-989)
 Takt Time = 20 minutes per unit                                                                                       Handle Assy - P/N XX-XXXXX                  Impeller - P/N 60-7440 (P/N 60-755100-2)
                                                                                                                                                                    Impeller - P/N 60-72118 (P/N 60-72101-2)
             Demand of 21 units per day @ 7 Hours per day                                                                                                          Shims - P/N XX-XXXXX
             Takt Time = .33 hours per part                                                         Color Legend
             20 minutes per unit
                                                                                                                             Non-Value
                                                                                                                                                  Non-Value
                                                                                              Value Added                    Added but
 Cycle Time = 181 minutes per unit                                                                                          necessary
                                                                                                                                                   Added

             24 minutes of Value Added Time"                                                                                                                                 Quality Check
             157 minutes of "cure & cool and outgas" time                                           Standard Work In-Process
             24 minutes + 157 minutes = 181 minutes                            10 Units of Standard Work In-Process
                                                                                                                                                                                           9/29/00
                                               Visual Metrics
                                                         Purpose

 Enable a person to self-manage their work.
 Enable management to recognize trends and re-align to targets
  and strategies.




      If you are not going to use the data,
                 don’t collect it!
                                                          Visual Metrics
                                                            Characteristics

   Provide data
     • To people who can act on the data
     • In time to act on the data
     • To people affected by the data
   Visually link results to specific
     • Performance targets
     • Improvement initiatives (plans, projects, ideas)
   Communicate information
     • To workers and management
     • In a format that is easy to understand
                                    Visual Metrics
                                     How to Develop

   What needs to be measured?
   Who is the user?
   How to keep track of details?
   How often to take the data?
   Who will do the tracking?
   How to display it?
   Where to locate the display?
                                  Visual Metrics
            Production monitors at Korry Electronics




               Version 2




Version 1
                                Daily summary
         Visual Metrics
PTP Daily Production Board
                                                                              Visual Metrics
                                                                                Takt Time Sheet
Hydro-Aire - 39-353 Cell                                                        Date

Production Schedule - Orders for March 2001
1. 39-353            4.                  7.                10.                    Crew Size
                                                                                Plan    Actual
2.                   5.                  8.                11.                    1

3.                   6.                  9.                12.                Takt Time 32 mins

         Time             Work        Interval             Cumulative             Comments
     Start    Stop        Min    Plan Pcs Actual   Plan Pcs Actual Variance

     6:45    9:00         2:15      4                4
     9:00    9:15         0:00      0                4                              Break

     9:15 11:25           2:10      4                8
11:25 12:05               0:00      0                8                              Lunch

12:05 13:20               1:15      2                10
13:20 13:35               0:00      0                10                             Break

13:35 15:00               1:25      3                13
15:00 15:15               0:00      0                13                            Clean up


Total                     7:05     13                13
                                               Daily Quantity




                           0
                                     10
                                          20
                                                 30
                                                        40
                                                                50
                                                                     60
                                                                          70
                 Units Rcvd
                   R&O
                               103

                    Units In
                    Admin
                               140


            RMDRs to Shop      158

      Units released to WIP
               R&O
                               140


          Operator teardown    71
                                                                               Total




                     Est. In   101
                                                                               1




                     Est. In
                     Admin
                               118
                                                                               2




              Kits complete
                   R&O
                               0
                                                                               3




              Units repaired   0




Process
                                                                               4




                Units tested   0
                                                                               5




          Inspect/ Summary
                 QA
                               46

              WIP complete
                               82
                                                                               Average




                  R&O


Complete pkgs from shop
        Admin
                               0


      Shipments processed      83
                                                                                         Repair and Overhaul Actual Daily Production - 1st Week of April, 2000




             Pkgs signed off
                  QA
                               76

            Actually shipped
                 Ship
                               47
                                                 Visual Controls
                                                                Purpose

 Enable the work force to get control of the workplace and
  everything that occurs within it.
 Enable a process to create error free product.
 Integrate the standard with the action so that deviation is
  eliminated.
                                                What Is 5S?

Word Association:
 What do you think of when you hear 5S?

           5S is a series of techniques that provide the
           foundation for a visual management system.
                              Why Do 5S?

   Why?
   Why?
   Why?      To create the
   Why?
           Least Waste Way
   Why?
               to deliver

                Value
                 to the

              Customer
                                      Where Does 5S Apply?

   Any process involved in delivering value to the customer
    • Factory
    • Office
    • everywhere
                                                 Who Does 5S?

 Any one involved in delivering value to the customer
 TOP-DOWN Leadership
    • Lead by example
    • Active in the culture change
   BOTTOM UP Implementation
    • Everyone has to be involved
    • It’s not a program - it’s a way of life.


           It starts in YOUR
               workplace!
                                                                       5S

   Sort           -   Identify and eliminate what is not needed
   Set in order   -   A place for everything and everything in its place
   Shine          -   An effective, organized, professional environment
   Standardize    -   Develop standards and stick to them
   Sustain        -   5S is a way of life




          Corporate goal is to have all companies
              at a level 3 by the end of 2003.
                                                        Sort

           Remove the clutter (disorder) so
              you can see what is
                  happening.




 Separate the necessary from the unnecessary
 Unnecessary tools, equipment, and procedures need to be
  removed from the workplace
                                                              Sort
                                            Levels of Achievement

Level        Sort      Identify & eliminate what is not needed
 1      Necessary and unnecessary items are mixed together in
        the work area.
 2      Necessary and unnecessary items are separated (excess
        inventory, Obsolete tools & Equip)
 3      All unnecessary items have been removed from the work
        area.
 4      Documented method to maintain work area free of
        unnecessary items.
 5      Waste is immediately visible and triggers a planned
        response with root cause analysis and corrective action.
                                            Set In Order

               A place for everything,
             and everything in its place.




 Able to find things in 30 seconds
 Clean and ready for use
 Most important is the transparency
                                                 Set In Order
                                         Levels of Achievement
     Set in Order          A place for everything
Level                    and everything in its place
  1 Tools, supplies and materials are randomly located.

 2   Designated location established for all items as needed.

 3   Designated locations are marked to make organization
     more visible (color, outlines, labels, numbers, etc).
 4   Documented method of visual sweep to identify items out
     of place or exceeding quantity limits.
 5   Defined process to evaluate and improve movement and
     motion.
                                                            Shine

         An effective, organized environment.




   Identify customers, suppliers, value
   Make the normal visible – regular cleaning, visual data
   Visual controls on delivery of value – signal and response
   Data driven, continuous monitoring
                                                             Shine
                                            Levels of Achievement

Level       Shine         An effective, organized environment
 1      No visuals are in place. Work/break areas and machinery
        are dirty and disorganized.
 2      Visual display of data. Work/break areas and machinery
        are cleaned on a regularly scheduled basis.
 3      Visual controls are in place. Machines are cleaned daily.
        Customers/suppliers are identified and value defined.
 4      Real time metrics and visual management are in place.
        Preventative maintenance is implemented.
 5      Abnormal is immediately visible and triggers a planned
        response with root cause analysis and corrective action.
                                                                                                                                                                                                                                                                                                              Standardize

                                        Develop standards and stick to them.

                                                                                                                                       Fuel Pump Assembly Cell - Standard Work
                                                                                                                                                                                                                                                             P/N 60-72101-2
                                                                                                Housing Assy - P/N 60-98966 (P/N 60-989100-2)                                                                                                                Only
                                                                                                 Housing Assy - P/N 60-98914 (P/N 60-98976-2)
                                                                                                Housing Assy - P/N 60-75512 (P/N 60-755100-2)                                                                 Bearings, Discharge Plates
                                                                                                                                                                                                                                                                          Rotor - P/N 78-17512 (P/N 60-989)
                                                                                                 Housing Assy - P/N 60-72110 (P/N 60-72101-2)                                                                 Liners and tubes
                                                                                                                                                                                                                                                       Balancer           Rotor - P/N 78-16917 (P/N 60-755)
                                                                                                                                                                                                                                                                          Rotor - P/N 78-15337 (P/N 60-721)
                                                                                                                                               1 unit                   1 unit                                  1 unit      3 units


                                                                                                                                                          Component                   Component                                                                    Component




                                                                                                                                                                                                                              Oven Cure
                                                                                                                           Inspect                                                                                                           Inspect




                                                                                                                                                Stabond




                                                                                                                                                                        Stabond
                                                                                                                                                           Material                    Material                                                                     Material




                                                                                                                                                Outgas




                                                                                                                                                                        Outgas




                                                                                                                                                                                                                               Loctite
                                                                                                                                                                                                                 Rotor
                                                                                                                                                                                                                 Cool
                                                                                                                            Rotor/                                                                                                            Rotor
                                                                                                                                                                                      Assemble                                                                                               Start
                                                                                                                           Housing                        Assemble                                                                          Assembly
                                                                                                                            Height                                                     Rotor -                                               Endplay
                                                                                                                                                          Rotor into                                                                                              Rotor Assembly
                                                                                                                                                                                      Apply Sta
                                                                                                                                                           Housing
                                                                                                                                                                                        Bond
                                                                                                                                                                                                                7 Min
                                                                                                                        X minutes           5 minutes                     5                                                                X minutes
                                                                                                                                                             2         minutes           2                                 1 hour                                      9
                                                                                                                                                          Minutes                     Minutes                             @ 250 Deg                                 Minutes




                                                                                                            Oven Cure




                                                                                                                        @ 265 Deg
                                                                                                             Stabond
                                                                                           3 units




                                                                                                                         1 hour
 A N I                                                                        Z I
                                                                               2
                                                                                                                                                                                                                                                                                                              N G
                                                                                                                                          4                                                                            5
                                                                                                                                                                                  Minutes
                                                                                                                                       Minutes                                                                      Minutes
                                                                                                                                                          20 Min




                                                                                                                                                                                            Inspect Bonding
                                                                                                                                    Final Assembly -                    Assemble Handle                                  Impeller




                                                                                                                                                           Assembly
 A
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    I N
      O AAP E
          TTL A
            SF1 & SF2 to Assembly E
                                  Installation                 DD
                                                                N                                                                                                                                                                                                                                                    T
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         SNE        D                                           T




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          G
          IN          S              )         G
                                               Deliver to Test  S
                                                                                                                                      Component                             Component                               Component
                                                                                                                                       Material                              Material                                Material
                                                                                                                                                                                                                                                      Inducer - P/N 60-98970 (P/N 60-989100-2)
                                                                                                                                                                                                                                                      Inducer - P/N 60-98916 (P/N 60-98976-2)
                                                                                                       Stator Assy - P/N 78-17515-1 (P/N 60-989)
                                                                                       Inducer - P/N 60-72112 (P/N 60-72101-2)
   R U  M B            P/N 78-16923 (P/N 60-755)  1 unit       L E
   N  O  N -          P/N 78-15341-1 (P/N 60-721)        C                                                                             O                                                                                                                                                                           R
                                                                                             Impeller - P/N 60-98917 (P/N 60-989)
   A
    (
      N D
      1 0 %
            Takt Time =D         20 minutes per unit       Handle Assy - P/N XX-XXXXX
                                                            )
                                                                                             Impeller - P/N 60-7440 (P/N 60-755100-2)
                                                                                             Impeller - P/N 60-72118 (P/N 60-72101-2)
                                                                                                                                      IP
              Demand of 21 units per day @ 7 Hours per day                                  Shims - P/N XX-XXXXX
              Takt Time = .33 hours per part                                                                                                                                               Color Legend
              20 minutes per unit
                                                                                                                                                                                                                   Non-Value
                                                                                                                                                                                                                                          Non-Value
                                                                                                                                                                                     Value Added                   Added but
                                                                                        Cycle Time = 181 minutes per unit                                                                                         necessary
                                                                                                                                                                                                                                           Added

                                        24 minutes of Value Added Time"
                                      C 157 minutes of "cure & cool and outgas" time Standard Work In-Process Quality Check                                                                                                                                                                                  H
                                                                                                    24 minutes + 157 minutes = 181 minutes                            10 Units of Standard Work In-Process
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                          Define and document the current process
                          Make it the standard for everyone
                          Define and work to the future state
                                                   Standardize
                                           Levels of Achievement

Level   Standardize     Develop standards and stick to them
 1      No attempt is being made to document or improve current
        processes.
 2      Current process is known, but not documented.

 3      Current state is documented as Standard Work
        performed the same by all employees.
 4      Future state is documented. Implementation plan is
        actively worked.
 5      Improvements are based on data and tracked for actual
        results.
                                                                                                                                                               Sustain

                     5S is a way of life!
                      Level Sort                                   Identify and eliminate what is not needed                  Level of Excellence   Comments
                        1 Necessary and unnecessary items are mixed together in the office area. (Piles of paper work)        1 2 3        4 5
                            Necessary and unnecessary items are separated, excess files, unused ref Matl, Boxes of files,
                        2
                            Broken items are still present.
                        3 All unnecessary items have been removed from the office area, files and drawers are organized.
                            Documented method has been established to maintain work area free of unnecessary items. Use
                        4
                            of Red Book.
                        5 Employees continually seeking improvement opportunities.

                      Level Set in Order                          A place for everything and everything in its place          Level of Excellence   Comments
                        1 Office area shows no sign of organization. Items are randomly located.                              1 2 3        4 5
                        2 Designated location established for all items as required.
                        3 Designated locations are marked to make organization more visible, in basket, WIP, Task board
                            (color coding, outlining, labeling, numbering, etc).
                            Documented method has been established to recognize with visual sweep if items are out of
                        4
                            place or exceed quantity limits. Use of Red Book.
                            Vehicle developed to provide continual evaluation and process in place to implement
                        5
                            improvements.

                      Level Shine                               An effective, organized, professional environment             Level of Excellence   Comments
                        1 No Visuals in place. Office and computers are dirty and disorganized.                               1 2 3        4 5
                        2 Some Visuals in place. Office and personal work surfaces cleaned on a reg. scheduled basis.
                        3 Visual controls in place as required. Office area cleaned daily.
                            Visual controls practiced continually. Housekeeping tasks are practiced continually. Use of Red
                        4
                            Book.
                        5 Excellent visual controls. Office has professional appearance.

                      Level Standardize                                   Develop standards and stick to them          Level of Excellence          Comments
                        1 No attempt is being made to document or improve current processes.                           1 2 3        4 5
                        2 Methods are being improved but changes haven't been documented.
                        3 Information on process improvements and reliable methods are shared with employees.
                            Changes are being incorporated and documented.(Past 5S sheets, Value Stream Implementation
                        4 Plans, Process Improvement Sheets. OpEx Metrics are being tracked and demonstrate area
                            improvement).     Use of the RED BOOK
                        5 Employees are continually seeking elimination of waste with all changes
                            documented and information shared with all.

                      Level Sustain                                                       5S is a way of life                 Level of Excellence   Comments
                        1 Minimal attention is spent on adhering to the 5 S’s.                                                1 2 3        4 5
                        2 A recognizable effort has been made to adhere to the 5 S’s.
                        3 Adherence to 5 S policy and procedures.
                                                                                               Use of the Red Book
                        4 Documented methods have been put into place to ensure Self-discipline.                  .
                        5 General appearance of a confident understanding of and adherence to the 5S culture.


                          AREA FOCAL'S NAME:___________________________________                       TOTAL 5S LEVEL:         _________




   Set a good personal example
   Regular evaluation of 5S program
   Constantly look for ways to improve the program
   5S becomes part of the culture of the entire organization
                                                          Sustain
                                              Levels of Achievement

Level     Sustain                   5S is a way of life
 1      Minimal attention is spent on 5S.

 2      5S is a scheduled event.

 3      5S practices are evaluated on a regular basis.

 4      Documented methods (Red Book) have been put into
        place to ensure adherence to 5S.
 5      Employees continually seek improvement opportunities.
                              Implementation
                               In Your Company

   5S your workplace
   Select company approach
   Train
   Provide support
   Establish audit program
   Walk the floor
                                             Company Approach
                                                        Alternatives

   Company-wide program
    •   + High visibility
    •   + Quick progress
    •    Can become its own goal
    •    Can get focused on housekeeping
   Value stream by value stream
    • + Integrated into the conversion to lean
    • + Tied to providing value and eliminating waste
    •  Some are doing it, some aren’t
                                                      Support
                                             Role Of Management

   Provide Resources
    • Tools, Materials
    • Training
    • Time
   Promote Ongoing Efforts
    • Encourage Creative Involvement By Everyone
   Acknowledge And Support Efforts
    • Tangible And Intangible Rewards
   Set An Example
                                                        Support
                                             Role of the Individual

   Learn 5S
   Participate In 5S Implementation
   Help To Educate Coworkers
   Show Enthusiasm
   Take The Initiative
   Bring Ideas To Promote Or Implement 5S
   Ask For Support Or Resources
Audit Example 1
Audit Example 2
Audit Example 3
Audit Example 4
Audit Example 5
                                    Implementation
                                    In Your Workplace

 Identify your customers
 Determine the value you deliver
 Eliminate waste
    •   Sort
    •   Set In Order
    •   Shine
    •   Standardize
    •   Sustain
                                                 Implementation
                                         What Should Be the Goal?

   A person should be able to walk into your area and within 5
    minutes (without the need for a presentation) be able to
    determine
    •   The customers and suppliers
    •   The process flow
    •   The deliverables
    •   The resources being used
    •   The value being measured
    •   The current status
                                        How Do I Deal With…?

   The person who doesn’t mind working in a cluttered
    environment or in a disorganized layout. “I can find anything
    instantly!”
    • Can they really find anything?
    • Is there really never any wasted time?
    • Do they understand that the information is a company resource
      and needs to be available to everyone?
   The person who is not motivated
    • Do they understand how this makes their job easier?
    • Do they understand they have multiple customers and one of them
      (the stockholders) expect the least waste way
                                                            Summary
                                                            Why Do 5S?

   Increased Customer Satisfaction
       A clean, organised environment gives customers confidence
   Improved On Time Performance
   Reduced Cost
   Improved Morale
   Improved Safety
   Improved Quality
                                                             Sort
                                                 Red Tag Program

   Red tag all unnecessary items
   Create a temporary red tag holding area
   Move red tagged items to the holding area for one week
   Dispose of remaining red tagged items
   Continue red tagging regularly.
                                        Sort
                                      Criteria

 Three Main Factors
 Usefulness
    • Required
    • Helpful
    • In the way
   Frequency of Use
    •   Daily
    •   Weekly
    •   Monthly
    •   Rarely
   Cost
    • Resources Required to Replace
    • Resources Required to Store
                                                             Sort
                                               Making Decisions

 Each person determines what is necessary for his/her own work
  area.
 The group decides what is necessary for group areas.
  Necessary                           Unnecessary
    Used for daily work                Unsafe
    Used periodically                  Defective
    Used by someone in group           Obsolete (outdated)
    Required by law or regulation      Unused
                                       Extra (duplicate)
                                                             Sort
                                 Opportunities in the Office Area


   Books                                Paper
   Business Forms                       Prints
   Cabinets                             Processes
   Catalogs – Correspondence            Programs
   Documentation – References           Samples
   Equipment                            Shelves – Tables
   Magazines                            Supplies
                                         Trash
                                             Sort
                       Opportunities in the Factory

   Raw Material
   In Process Items
   Completed Items
   Tools
   Machines
   Space
                                                           Set In Order
                                                                Simplify

   Put everything in its place
    • Frequency of use
    • Economy of Motion
   Use visual aids
    •   Shadow boards
    •   Standard work
    •   Labels (return addresses)
    •   Clearly marked places for items that are movable
    •   Colors, shapes
   Keep it that way
                    Set In Order
                    Value of Space

         The value of space drops in
           direct proportion to the
        distance from the work place.



Work   Distance
Area



             Only store what you
              immediately need
            within the work place.
                                       Set In Order
                                 Economy of Motion




                                                   111 ft
                                                  Detour

Define   Measure   Analyze   Improve    Control
              Set In Order
           Economy of Motion

Tools


Material
Supply
               Set In Order
 Put Everything in Its Place


             Labeled as to what is
             in the cabinet




Return Address Labeled




Locations Marked
              Set In Order
Put Everything in Its Place




No Private Tool Boxes
                Set In Order
                Shadow Boards



A place for
 everything
     and
 everything
in its place.
                 Set In Order
Common Area Reference Materials




                        List of
                        Contents
                                                                                                                                                                                                                                                               Set In Order
                                                                                                                                                                                                                                                                Standard Work
  Chempump 56 Frame Stator Assembly Cell
                                                                                                                                                                                                                                                           Incom ing Material w ith Orders
                                                                                                                  20-January-2000


                                                                                                                                                                                                                              Com ponent




                                                             Arbor Press -
                                                             Install Liner




                                                                                                                                                                                      Load Weld
                                                                                                                                                                                                                            Material - Gravity




                                                                                                                                                                                                    Varnish
                                                                                                                                                                                       Fixture
                                                                                           Clean
                                                                                                                                                                                                                                 Feed




                                                                                           Liner




                                                                                                                  Liner




                                                                                                                                                                                                     Cure
                                                                                                                  Prep




                                                                                                                                                    Cool
                                                                                                                                                              Weld Endbells                                                                                               Start
                                                                                                                                                                                                                              Prep backup
                                                                                                                                                                                                                              sleeves and
                                                                                                                                                                                                                               install TCO
                                                                                            5                      4
                    Trim                                                                                                                                            3                      2
                    Liner                                          6
                                                                                                                                                                                                                                           1


                                            7



                                                                                                                  9             Gas Check
  Liner & Shrouds
    Fusion Weld




                                                                                                                  11             Roller Burnish
                                                                                   Stator
                                                                                   Stand
                                                                                                                  12            Gas Check                                                         Final Assembly Cell
                            8


                                                                                                                                                                                                    17          18             19              20
                                                                                                                                                               16
                                                                 10               13                 14                        15
                                                                                                                                     Inspection &
                                                                                                   Cure Potting
                                                                                                   and Varnish




                                                                                                                                                                                                    Assem ble


                                                                                                                                                                                                                Gas Check
                                                Hydro Form




                                                                             Potting and




                                                                                                                                                                                                                                               Spot Weld
                                Gas Check




                                                                              Varnish




                                                                                                                                                                                                                                Oil Fill
                                                                                                                                                                              Lam p
                                                                                                                                         Test




                                                                                                                                                                              Heat
                                                                                                                                                                                                                                                                     Deliver to Final
                                                                                                                                                           Paint Booth
                                                                                                                                                                                                                                                                          Paint
                                                                                                                          Inspection
                                                                                                                            Outside




                                                                                                                                                                                                   Assem bly Com ponents -
                                                                                                                                                                                                     Gravity Feed Racks




Safety Caution                                                                     Standard Work In-Process                                                                           Quality Check


TAKT TIME: 106 Minutes                                                                                                                                                  CYCLE TIME: 793 Minutes
Set In Order
Marked Spaces
     Set In Order
    Colors & Shapes




       
                                                      Set in Order
                                                  Keep It That Way


                        Identify potential problems with a
                       regular physical and visual sweep.



Look for:
• Unrealistic conditions or expectations.
                                                    ?
• Program errors, broken or malfunctioning
  equipment or fixtures.
• Missing information and out of location
  files, references, material, supplies etc.
                                                                  Shine
                                                     Physical Process

   Determine shine targets and assignments
    • Product, equipment, space (work area)
   Prepare for the shining process
    • Specify supplies and equipment
    • Store cleaning tools where they are:
        • Easy to find
        • Easy to return
   Establish a cleanliness standard
    • The cleanliness acceptance criteria must be understood
    • 5 minutes of shine time should be adequate for most areas
                                                       Shine
                                                Visual Process

   Identify customer and suppliers
   Identify value as defined by the customer
   Define primary measurements of value
   Determine trigger points
   Define Response
    • Who
    • What
                                                Standardize
                                 Define the Work Environment

 Define the current process
 Define the “better way” for each task to be performed
 Make it visual
                                                      Standardize
                                                        Communicate

   Every territory should have a communication board
    •   5S Vision
    •   5S Targets                            5 S Information Board

    •   Area Layout
    •   Team
    •   Before & after photos
    •   Current status
    •   Red Tag status
    •   Improvement Ideas
    •   Results
Standardize
Communicate
                                                     5S Audit Form - Office
Level         Sort                               Identify & eliminate what is not needed                       Level of Excellence   Comments
  1     Necessary and unnecessary items are mixed together in the work area (mixed piles of paper work)        1   2    3   4    5
  2     Necessary and unnecessary items are separated (boxes of files, unused reference material)
  3     All unnecessary items have been removed from the work area (no broken items)
  4     Documented method to maintain work area free of unnecessary items.
  5     Waste is immediately visible and triggers a planned response with root cause analysis and corrective
        action.

        Set in Order                                   A place for everything
Level                                               and everything in its place                                Level of Excellence   Comments
  1 Office area shows no sign of organization. Items are randomly located.                                     1   2    3   4    5
  2 Designated location established for all items as needed.
  3 Designated locations are marked to make organization more visible (In Basket, Task Board, color,
      outlines, labels, numbers, etc).
  4 Documented method of visual sweep to identify items out of place or exceeding quantity limits.
  5 Defined process to evaluate and improve movement and motion.

Level      Shine                               An effective, organized environment                             Level of Excellence   Comments
  1 No visuals are in place. Office and computers are dirty and disorganized.                                  1   2    3   4    5
  2 Visual display of data. Office and personal work surfaces are cleaned on a regularly scheduled basis.
  3 Visual controls are in place. Work surfaces are cleaned daily. Customers/suppliers are identified and
      value defined.
  4 Real time metrics and visual management are in place.
  5 Abnormal is immediately visible and triggers a planned response with root cause analysis and corrective
      action.

Level     Standardize                           Develop standards and stick to them                            Level of Excellence   Comments
  1     No attempt is being made to document or improve current processes.                                     1   2    3   4    5
  2     Current process is known, but not documented.
  3     Current state is documented as Standard Work performed the same by all employees.
  4     Future state is documented. Implementation plan is actively worked. Area metrics are linked to OpEx
        metrics.
 5      Improvements are based on data and tracked for actual results.
Level       Sustain                                      5S is a way of life                                   Level of Excellence   Comments
  1     Minimal attention is spent on 5S.                                                                      1   2    3   4    5
  2     5S is a scheduled event.
  3     5S practices are evaluated on a regular basis.
  4     Documented methods (Red Book) have been put into place to ensure adherence to 5S.
  5     Employees continually seek improvement opportunities.


                         AREA FOCAL'S NAME:___________________________________                                 _________
                                                                                                    TOTAL 5S LEVEL:
                                                                       5S – Group Chart
                                                                                   Overall Rating
                            Set in order               Standardize                   by Team      Overall Team
Team Member Name Sort Level    Level     Shine Level      level      Sustain Level   Member         Rating
                                                5S Audit Form - Sample
Level         Sort                               Identify & eliminate what is not needed                       Level of Excellence   Comments
  1     Necessary and unnecessary items are mixed together in the work area (mixed piles of paper work)        1   2    3   4    5
  2     Necessary and unnecessary items are separated (boxes of files, unused reference material)
  3
  4
        All unnecessary items have been removed from the work area (no broken items)
        Documented method to maintain work area free of unnecessary items.
                                                                                                                       X
  5     Waste is immediately visible and triggers a planned response with root cause analysis and corrective
        action.

        Set in Order                                   A place for everything
Level                                               and everything in its place                                Level of Excellence   Comments
  1 Office area shows no sign of organization. Items are randomly located.                                     1   2    3   4    5
  2 Designated location established for all items as needed.
  3 Designated locations are marked to make organization more visible (In Basket, Task Board, color,
      outlines, labels, numbers, etc).
                                                                                                                           X
  4 Documented method of visual sweep to identify items out of place or exceeding quantity limits.
  5 Defined process to evaluate and improve movement and motion.

Level      Shine                               An effective, organized environment                             Level of Excellence   Comments
  1 No visuals are in place. Office and computers are dirty and disorganized.                                  1   2    3   4    5
  2 Visual display of data. Office and personal work surfaces are cleaned on a regularly scheduled basis.
  3 Visual controls are in place. Work surfaces are cleaned daily. Customers/suppliers are identified and
      value defined.
                                                                                                                   X
  4 Real time metrics and visual management are in place.
  5 Abnormal is immediately visible and triggers a planned response with root cause analysis and corrective
      action.

Level     Standardize                           Develop standards and stick to them                            Level of Excellence   Comments
  1     No attempt is being made to document or improve current processes.                                     1   2    3   4    5
  2     Current process is known, but not documented.
  3
  4
        Current state is documented as Standard Work performed the same by all employees.
        Future state is documented. Implementation plan is actively worked. Area metrics are linked to OpEx
                                                                                                                   X
        metrics.
 5      Improvements are based on data and tracked for actual results.
Level       Sustain                                      5S is a way of life                                   Level of Excellence   Comments
  1     Minimal attention is spent on 5S.                                                                      1   2    3   4    5
  2     5S is a scheduled event.
  3
  4
        5S practices are evaluated on a regular basis.
        Documented methods (Red Book) have been put into place to ensure adherence to 5S.
                                                                                                               X
  5     Employees continually seek improvement opportunities.


                         AREA FOCAL'S NAME:___________________________________                                 _________
                                                                                                    TOTAL 5S LEVEL:
                                                                                              5S
                                                                     Level 3 Office Guidelines
                             5S Office Guidelines
The following are recommendations toward achieving a Level 3 office.
Furniture & Equipment
 Sort out and remove unnecessary items from work surfaces. Minimize the number of
   items.
 Clean surfaces (top and general): Keyboard, desk, file cabinet, bookshelf, etc
 Cables & Wiring: Tie-wrap / stow neatly
 All files, paperwork, etc. should be properly stowed at the end of each day, leaving all
   surfaces clear, clean and neat

Desk (Drawers & Contents)
 Sort out and remove unnecessary items. Retain what is needed.
 Label each drawer with general description (supplies, open PO’s, forms, personal, etc.)
 At least one (1) drawer should identify supplies (pens, paper, post-its)
 Public access drawers (those not labeled personal or private) should be generally clean
   and organized

Files (Filing cabinets, standing files, desk drawers where applicable)
 Sort out and remove unnecessary items. Retain what is needed.
 Label outside drawer(s). Drawers with personal contents should be identified.
 Locked files / keys: Area manager should be provided spare key / access in the event
    of an emergency
 Desktop file racks: Label. Should provide easy visual review of contents.

Cleaning Supplies
 Each person should have a general cleaner and wipes, easy to access and use daily
   as needed

Walls / Doors
 Sort out and remove unnecessary items. Retain what is needed.
 Utilize business appropriate items (personal items included)

Bookshelves
 Sort out and remove unnecessary items. Retain what is needed.
 Label binders / materials with subject or title
 Attach owner’s business card or name as a “return address” on critical items
 Use magazine file holder or device to consolidate floppy / random materials
 Group items by logical categories (supplier catalogs, training, general reference, etc.)
 Position most frequently used items closest to your “strike zone”
 Label shelf with grouping identification
 Use dots, tape, or other device to provide visual cue if something is missing
 Create and maintain bookshelf directory (listing items by shelf and sequence). Keep
   electronic bookshelf list for easy updates.
                                                                                                        5S
                                                                                            Level 4 Red Book
                                Level 4 5S Red Notebook
Tips for the Red Notebook – Desk Top Procedure
The intent of the Red Notebook is to provide a documented method to adhere to the 5S Culture.
Required to achieve an honest level 4.
Standard for 5S documentation:
    Red Vinyl Binder, size as required
       Located within reach of your work station or central to your factory area
       Be easily seen when entering your office or work area
    Each office should have a 5S Red Notebook, every factory cell or department
This book should be maintained as if you where to train someone for your job or take over a
portion of your responsibilities. This person could use the Red Notebook and find enough
information to do the required tasks. This is not solely about housekeeping and keeping your area
“looking good.” It is about defining what you do and how you do it.
This book provides four benefits:
    A documented way to define your tasks are and how they are performed.
      (This will cause you to think about what you do and the value of those tasks.)
    A quick reference for anyone on how you perform a task.
      In case you are gone and they need to perform the task.)
    A “hand-off” document for cross training or training a new person.
    It’s a path to achieve an honest level 4 in a 5S Culture.
Things that should be included as a minimum but not limited to:
    Table of Contents
    Your company’s 5S Policy
    Actions to adhere to the Spirit of 5S Culture
      (How you or your cell will adhere to the 5S Culture and any agreed upon team items)
    My duties and responsibilities as a (Job Title or Product Line)
      **List of tasks and how to accomplish them.
      Short statements of additional duties or responsibilities
      Time lines for reports / meetings
    Reference lists of books, videos and binders
    Past 5S Audit Sheets
    Process Maps (if needed)
      **Dividers for each section
      Sub-Dividers within each section (if needed)

**     Descriptions of each necessary task should be short and brief. Mention where to locate
materials/information (from people, files, etc.) important phone numbers or contacts, what is to be
done with the materials when finished (who gets what, e-mail who, and so on). List where to find
necessary information that might be in another binder. Again as if you where to train someone to
do that task or job. Even Notes from when you first learned some of your tasks.

				
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