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Lecture notes
Session 1.0 Session 2.0 Session 3.0 Element 3.1 Element 3.1.1 Element 3.2
Introduction..... 3 Waste Management .. 14 5S Implementation. 20 Systematic Organization... 31 Red Tag System. 47 Sorting Visual Placement.. 33
Element 3.2.1 Visual Sign System.. 66 Element 3.2.2 Visual Color System... 76 Element 3.3 Element 3.4 Element 3.5 Scrubbing Clean. 40 Standardizing Control... 45 Self Discipline Control... 48
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What is 5S ?
s
Standardization/Perseverance Shitsuke
s s
Standardizing Control
Scrubbing clean
Standardizing ControlMaintain and continually improve the previous improvements. Sorting Visual PlacementItems should be easily retrievable, easy to get, and visual-easy to see.
Scrubbing Clean-Keep the area free from debris, dirt, oil, items not needed.
Expand Process Improvement Program to Utilize Kaizen Tool Kit Expand Process Improvement Program to Utilize Kaizen Tool Kit
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6 Sigma Disciplined Methodology Technical Approach (Quantitative) Data Driven - Statistical Customer Focus Reduce Variation Focus on Large Impact Larger/Longer Projects
Kaizen Philosophical Approach Common Sense Approach (Qualitative) Data Driven - Observation Operational Focus Waste Elimination 5S Incremental Change Smaller/Shorter Projects
Complimentary Tools Driving Continuous Improvement Complimentary Tools Driving Continuous Improvement
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Comparative Analysis
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Measure - Data Collection - Determine Process Potential / Goals Evaluate - Root Cause / Vital Few - Statistical Analysis Improve & Verify - Implement Improvement - Validate Improvement Standardize - Standardize / Leverage - SPC - Update Procedures Focus - Reduce Process Variation - Identify Critical Cause and Focus Resources for Maximum Impact Summary - Technical Approach based on Statistical Analysis - Requires Significant Data Collection - Best applied to Manufacturing Processes - Typical Projects 1-3 Months
Improvement Methodologies Similar in Structure Improvements measured against established process Team oriented Similar improvement tools Measure effectiveness of improvements Maintain new performance level Standardize & Proceduralize Results More Efficient Processes Comparison Both are Effective Improvement Mechanisms CPI/6s best applied to large complex problems Kaizen/Lean best applied to achieve incremental changes and eliminate wastes.
Kaizen/Lean
Evaluate - Baseline Process Performance - Establish Target Decide -Compare solutions - Choose Act -Communicate - Implement improvement - Control Measure - Validate improvement - Standardize - Update Procedures Focus - Eliminate Waste 5S - Seek Incremental Process Changes Summary - Common Sense Approach based on Observation - Applicable to all types of processes - Defined improvement strategy - Typical Projects 1 week
Why 5S
Look Familiar
To eliminate the wastes that result from uncontrolled processes. To gain control on equipment, material & inventory place and position. Apply Control Techniques to Eliminate Erosion of Improvements. Standardize Improvements for Maintenance of Critical Process Parameters.
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Wastes
s s s s s s s s s
Overproduction Delays (waiting time) Transportation Process Inventories Motions Defective products Untapped Resources Mis-used Resources
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Think Break
Overproduction ______________________________ 9 Delays (waiting time)__________________________ Wastes Transportation _______________________________ Process_____________________________________ Inventories__________________________________ Motions ____________________________________ Defective products ____________________________ Untapped Resources __________________________ Mis-used Resources ___________________________
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Elimination of Waste
5 S Element Waste/ Improvement Item Deliverable
Reduced Costs Improved Quality Increased Product Options Reduced Costs Increased Safety Improved Quality Increased Product Options.
Elimination of finding. Elimination of nonconformances. Elimination of motion. Reduction of part selection errors.
Increased safety. Preventive maintenance. Increased equipment knowledge. Increased equipment life. Higher morale. Clean environment. Increased visibility of nonconformances.
Increased Safety Improved Quality Improved Quality Consistent Delivery Improved Safety
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5S Implementation Plan
Step 1 Establish 5 S Implementation Team Step 2 Develop Specific Implementation Plan Step 3 Develop Communication Plan
Step 5 Implement 5 S
Systematic Organization
Progressive Enhancements
Standardization
Visual Placement
Cleanliness
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Removing Red Tagged stuff What Stuff would you Red Tag in these pictures ?
Think Break
Think Break
In the following pictures, identify some of the finding wastes ( assume you work in a distribution center and you have to fill an order with product located in the following pictures).
Finding Wastes
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Develop a map identifying the access ways(aisles, entrances, walkways etc.) and the action areas. Perform any necessary realignment of walkways, isles, entrances. Assign an address to each of the major action areas. Mark off the Walkways, Aisles & entrances from the action areas Table 1.0 Apply flow-direction arrows to aisles & walkways Table 1.0 Perform any necessary realignment of action areas. Mark-off the inventory locations Table 1.0. Mark-off equipment/machine locations Table 1.0 Mark-off storage locations( Cabinets,shelves,tables) Table 1.0 Color-code the floors and respective action areas per Table 1.0.
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Cleanliness involves cleaning every aspect of the Organization and the removal of dirt, dust,oil, scraps on the floor, & garbage. Key Deliverables
Increased Safety
Increased Efficiency
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Step 2: Allocation:
Assign resources to the specific tasks required to make 3S a habit.
5S To DoPlan
Date: 5S Team Members Company/Division Name: Page of Person Preparing This Sheet
Item #
Date Started
5S element
5S Task - Action
Person Responsible
Location/ Department
100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75
Percent Complete
25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50
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Remember to focus on the elimination of waste. Strive to maximize yields and obtain cost reductions from existing machinery and equipment before buying solutions Improve current systems and . techniques before automation. Automating a system or practices without first having an understanding of the process will not solve underlying process problems. Perhaps the most important point to remember is that we must understand a process before we make any attempt in changing it. Tamperingis the first rule No of continuous improvement. We can not tamper with a process without understanding it. By using these tools, we will all share a common and systematic approach for questioning, analyzing, proposing solutions, experimenting, and finally, implementing proven changes. Measurement Improvement 5S Template
Identify waste
The problems that exist in the world today cannot be solved by the same level of thinking that created them.
Table of Contents
Section 1
Development of 5S DoPlan: Establishment of the 5S team focused on To the development, training, and implementation of the company 5S program. s Deliverable includes action plan and associated tasks with the 5S implementation. Waste Identification Map: Identification of the 9 wastes associated with production of products and services. A detailed map of each major work area is developed describing the major types of wastes in each area. These wastes are the improvement opportunities that exist prior to 5S ... The overall wastes is calculated for all the work areas and identified on the 9 Waste Radar Chart
Section 2
Section 3
5S Action sheet: Establishing baseline key performance metrics in terms of key deliverables, photographs, and current conditions of the before5S implementation phase. Deliverable includes the 5S action sheet . Red Tag Strategy: The utilization of Red Tagsto visually identify items which are not needed or used infrequently ..
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Section 5
Visual Color Sheets: Utilization of colors to identify specific work actions, inventory locations, access areas within the work environment. Initialization begins with development of Visual Color Sheets .
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Section 6
Visual Sign Sheets: Utilization of signs to identify machine, equipment, tooling, inventory, safety, hazard and work center locations. Sample Sign Sheets . Standard Cleaning Work Sheet: A cleaning matrix identifying the work area responsibilities, supplies, and schedules for cleaning. .. Cleaning Do List A action list identifying specific cleaning tasks for each To : work area identified on the Standard Cleaning Work Sheet .. 5S Status Report: A report identifying implementation effectiveness of each 5S steps applied. A variable metric ranging from 0-5 is established for each step implemented .. Waste Identification Map: Identification of the 9 wastes associated with production of products and services. A detailed map of each major work area is developed describing the major types of wastes in each area. These wastes are the improvement opportunities that exist prior to 5S 9 Wastes Radar Chart: After the completion of 5S, the results of the waste reduction is recorded, charted and compared to the initial 9 Waste Radar Chart.
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23 27
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Section 10
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S e c tio n 2
Waste Identification Map
When To Use
How To Use It
1. Referring to the 5S Do Pla identify each respective area 5S will To n, be implemented. Develop a Waste Identification Map for each area or department and complete sections A, B, C, with the necessary information. Note you may have multiple Maps for the entire 5S implementation program. 2. For each work department, fill in the equipment, access areas, storage areas, inventory locations etc. on the Map. It is best to draw these to scale. 3. Next identify the processes for each area on the Map. 4. Next, list the products and services at each applicable workstation. 5. Next, identify the product/service flow through the respective processes & work stations. 6. Establish time trials for each major activity and when completed document the time for each major activity within the department. 7. Document the type of waste a nd time associated with each waste at each activity, process, equi pment, inventory, storage, and office location. 8. For each type of waste identified, complete the waste matrix section on the bottom of the 9 Waste Radar Chart in the be forecolumn. Note: The y-axis list % of waste, use whatever metric makes sense i.e. time, $, labor hours, productivity etc. Remember that your goal is to reduce these wastes as a result of the 5S Program.
Chart the % waste value for each type of waste on the Radar Chart. Connect each of the values on the radar chart. This is extremely important, this is your baseline metric and will be used to determine the magnitude of your improvements.