does your shop look like this? - arkansas trucking association · 2016-07-22 · 1. implement 5s in...

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Does this look efficient?

Does your shop look like this?

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5S Standardization Method

WHAT IS 5S?

• A structured program designed to systematically achieve total

organization, cleanliness, and standardization in the workplace.

• The backbone of the organization’s Continuous Improvement

program.

WHAT DOES 5S

MEAN?

• Developed in Japan to remove waste from manufacturing

operations.

• 5S is based on the 5 Japanese words that describe the 5 steps in the

systematic process.

WHY IS 5S

IMPORTANT?

• Promotes individual commitment and responsibility to a well

organized work environment.

• Enhances morale and safety.

• Improves communication.

• Makes variations in the normal process visible.

• Reduces waste and improves productivity.

SeriSORT

SeitonSET IN ORDER

SeisoSHINE

SeiketsuSTANDARDIZE

ShitsukeSUSTAIN

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5S Standardization Method

WHEN / WHERE IS

5S USED?

• Implementation should be throughout the entire organization

including the shop floor, warehouse, exterior, and office spaces.

• Maintained daily on each shift.

• Verified at the start/end of each shift.

• Scheduled improvement events.

WHO IS

RESPONSIBLE?

• All employees must be responsible for the application of 5S within

their workspaces.

• Must be supported from the top, down.

WHAT IS THE

END VISION?

• A safe, clean, orderly, and efficient work environment where

everything has a place.

• To create a “culture” that breeds continuous improvement.

Makes variations in normal process visible

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STEP 2: SET IN ORDER

STEP 1: SORT

STEP 3: SHINE

STEP 4: STANDARDIZE

STEP 5: SUSTAIN

Visualizing 5S

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STEP 2: SET IN ORDER

STEP 1: SORT

STEP 3: SHINE

STEP 4: STANDARDIZE

STEP 5: SUSTAIN

Visualizing 5SSeparate the

essential from the

non-essential

Arrange and label for

easy access

Clean and inspect

work area

Standardize practices in work area

Perform 5S process on an

on-going basis

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What is the usefulness of the items for performing the work?

What is the frequency for which the item is needed?

What is the quantity of the item needed to perform this work?

Dispose of unneeded items.

When in doubt, throw it out!

STEP 1: SORT

Separate the essential from the non-essential by

identifying unneeded items, evaluating their usefulness,

and dealing with them appropriately.

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Utilize external services to dispose of unneeded items.

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STEP 2: SET IN ORDER

Locate items according to their frequency of use

Label locations where it makes sense

Address overall work flow to improve efficiency

XXXXX

YYYYY

ZZZZZ

A place for everything and everything in its place!

Organize the necessary items by arranging them so they are easy to find, use,

and return. The result is a streamlined workplace and the elimination of time

spent searching for items and information.

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STEP 3: SHINE

Determine what needs to be cleaned

Determine proper cleaning supplies and make available

Painting an area really supports the shine step

Start to shine!

If it doesn’t get dirty,then it doesn’t need to be cleaned!

The act of cleaning the work area, and inspecting tools and equipment.

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STEP 4: STANDARDIZE

Assign responsibilities – everyone must know exactly what they are responsible for maintaining.

Utilize a 5S schedule and a 5S assignment map.

Visual 5S

5 minute shine

Without standards, there can be no Continuous Improvement!

The act of making sure that the results of Sort, Set in Order, and Shine are

maintained. Assures that conditions do not go back to their old, undesirable

levels and makes implementing 5S a habit.

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Foot Printing/Labeling

What is it?

• A standardized method of identification that visually marks work locations, materials, tools, and other important areas within the facility.

What are the benefits?

• Creates an organized work area.• Increases process efficiency.• Makes abnormal conditions obvious.• Eliminates wasted space.• Promotes visual management.• Enhances morale and safety.

How is it used?• Used to designate locations for shared equipment, toolboxes,

parking, parts, and safety equipment. • Used to direct customers to certain areas within the dealership.

Who uses it?

• Used primarily in the parts and service departments.• All employees will benefit from the use of this tool and should be

aware of its purpose.

1 2Axe Example

Foot Printing /Labeling

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Techs all aware of location.

Visible and stored in the middle of the shop.

Clean area free of debris and grease.

Foot Printing /Labeling

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Foot Printing /Labeling

Signs can be used in

lieu of floor markings.

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Shadow Boards all should have contrasting colors standardized throughout the dealership.

Shadow Boards can be used for marking where tools need to be returned when not in use.

Shadow Boards are labeled according to engine models, wheel end sockets, etc.

Tools are outlined in a color that is easily visible.

Size should be adequate for the number of tools.

Shadow Boards / Tool Boxes

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Shadow Boards / Tool Boxes

The shadow boards can be displayed with picture and description format.

A quick, visual identification for missing tools is the result.

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Shadow Boards / Tool Boxes

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STEP 5: SUSTAIN

What is the best method to make sure the results of the other steps are maintained?

How can we assess how well we are doing with 5S?

5S audits - used to evaluate and measure the implementation of 5S.

5S creates a simpler work environment!

Address the need to perform the 5S process on an on-going and

systematic basis to maintain the new standard. 5S should become

second nature, a habit. Success is based on Discipline.

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Before After

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Before After

Safety (all hoses have hooks, spills immediately cleaned, reduce trip hazards).

Reduced waste (limit the walking and searching for equipment).

Improved efficiency (Shared equipment should be placed in the most efficient location within the shop).

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Before After

5S should also be practiced in the office.

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5S - SHOP FLOOR Trash cans in every bay

Clean Floors and Aisle ways

Good Lighting

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5S - PARTS STORAGE

Organized shelves

Clean Floors and Aisle ways

Managed Part Locations

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NEXT STEPS

1. Implement 5S in one area of the Service shop.Key Considerations:

• Assign a 5S Champion to lead implementation of the 5S dealership wide. • Take Before and After pictures to document improvement. • Assure that each step in the 5 step process is completed thoroughly

before moving to the next step. Each of the steps builds upon the prior, so take your time on each step.

• This area should be used to train and visually demonstrate expectations for the remaining areas of the facility.

2. Create a 5S Assignment Map and begin Sorting the remaining areas of the dealership.

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5S ASSIGNMENT AND SHINE MAP

Nate F.Aisles

Front Offices

Parts Front and Back

S. Brown

Ray S.

Bruce M.

Bay #1 Bay #2 Bay #3

Bay #11 and #12

Jeff T.

Bay # 12

Bay #4 Bay #5 Bay #6

Bay # 11

Pat W.

Brian M.

Matt S.

Joe S.

Parts Inventory

Paint/Body Shop

Bay # 7 Bay # 8 Bay # 9 Bay # 10

Service Offices

Fro

nt

Off

ices

Assigned Area Champion

John F.

Service

Area

Parts

Parts

Inv

5S Red Tag Champion

Bay #7 and #8

Paint and Body Shop

John S.

Marty M.

Bay #5 and #6

Paul D.

Bay #9 and #10

Bay #1 and # 2

Bay #3 and #4

John F. Joe S. Matt S.

Matt S.

Ray S. Paul D. Brian M.

John S.

Jeff T.

Nate F.

Bruce M.

Marty M.