Visual Factory5S Workshop

1
Visual Factory/5S Workshop
2
Benefits of Visual Factory/5S

• The workplace is more orderly.
• The workplace is safer and healthier.
• There are fewer frustrations.
• Easier to figure out what to do.
• Easier to figure out whats going on.
• Easier to see whether you have what you need to
  do the job.

3
The 5S Approach

• Sort - Remove everything you dont need.
• Straighten - Find a home for everything that you
  need.
• Shine - Sweep, polish, paint, degrease, wipe off,
  inspect.
• Standardize - Develop procedures
• Sustain - Keep it going.

4
The First Pillar Sort

• Remove anything that isnt needed for current
  work.
• Leave only the bare essentials.
• Organization reduces work flow problems,
  increases product quality and productivity and
  improves communication.

5
The Sorting Strategy

• Pick an area to do the 5S blitz
• Pick a red tag area
• Select criteria for Throw Away, Keep, Red Tag
• Ask three questions about every item
• Which pile does it go into?
• If it is Keep, how much?
• Where should it be kept?

6
The Second PillarStraighten

• Arrange everything so that it is easy to find,
  use, and put away.
• Implement at the same time as Sort for best
  results.

7
Principles of Deciding Locations

• Where does it go? Whats the best place for it?
• Is it easy to find? Easy to put away?
• Can I tell easily if its present or missing?

8
Orderliness and Standardization

• Orderliness means that only what is needed is
  present. Dont just tidy up.
• Standardization means that everything you keep
  has a standard place.
• Standard Place means its labeled and its always
  the same.

9
Visual Controls

• Labels, devices, signs, signals, symbols, etc.
  that show, at a glance how things should be done
  or where things should go.

10
Strategies for Identifying Locations

• Signboard Strategy
• Painting Strategy
• Color-coding Strategy
• Outlining
• After 5S Map

11
The Third PillarShine

• Everything swept, cleaned, wiped down, drained,
  picked up, painted, cleared, polished, dusted,
  well-maintained.SHINED!!!
• Keep tools and equipment in top condition, always
  ready to be used.

12
Shine Means Inspection

• Wipe down, clean, really LOOK at all equipment.
• When you Sweep and Shine an area, inspect
  machinery, equipment, and working conditions.

13
Shine Means Cleaning

• Mops, brooms, rags, cleaner, gloves, etc will be
  needed.
• Power washer? Steam cleaner?
• Fix any problems you find right away!

14
The Fourth PillarStandardize

• Properly maintain the first three Pillars.
• Without Standardized Cleanup, improvements made
  with the first three pillars do not last, and
  conditions go back to the way they were.

15
Tools and Techniques

• Action Item Checklist
• Visual 5S
• Five-Minute 5S Walk Through
• 5S Checklist/Procedures

16
Action Item Checklist
Action Item
Who
When
17
5S Procedures

• Each shift
• Each week (or so)
• Each month (or so)
• Each year (or so)

18
The Fifth PillarSustain

• Role of Leadership
• Educating, creating teams, providing time and
  resources, providing motivation and recognition.
• Role of Operators
• Participating in implementation, contributing
  ideas, talking about strengths and areas for
  improvement, helping promote the Five Pillars.

19
Tools and Techniques for Sustain

• Team meets every two weeks to follow up action
  items.
• Schedule additional 5S blitzes.