Team members: Dhruv, Rijul Daga, Riyanka Daggubati, Hitesh

Department of Manufacturing System &

Engineering Management

Instructor: Professor Hamid Gholami

3rd May, 2012

1S - SORT (Seiri)

Identifying unnecessary tools,

Red tagging, yellow tagging

2S – SET (Seiton)

Synchronize by item labeling,

color coding & markings

3S – SHINE (Seiton)

Cleaning, eliminating small imperfections

4S – STANDARDISE (Seiketsu)

Updating SOP

5S – SUSTAIN (Shitsuke)

Audits, newsletters, review meetings, goals

A place for everything

and everything in its place.

“Behind all workplace successes or

failures are the 5S” – Hirayuki Hirano

5S Event

“The value of performance”

Project Charter Problem statement

machine shop areas are not as organized for efficient work flow waste in space usage and raw materials damaged or unused tooling

MPD (Mechanical Production Directorate) plans to consolidate some machine shops,

and this is a preliminary step towards that consolidation.

Project description Within a kaizen framework, use 5S principles to specific work areas and organize,

clean, standardize and sustain 5S

Project Target/Objectives Apply 5S to specific areas in MPD M3 first floor mechanical fabrication areas only

Scope In : M3 First Floor Mechanical Fabrication Production Areas Out : Office areas on same floor, NO MOVEMENT OF FLIGHT H/W

4

Schedule

5

M3 1st Floor – Areas to 5S

6

Area 1

Milling-1

Area 2

Milling-2

Area 3

Lathe &

Turn

Area 4

Sheet Metal

Fab

Area 5

Precision

Assembly

1 2 3 4

5

Lean Kaizen event

7

5S SUMMARY ASSESSMENT OF WORK AREA

Date scored: 11/18/05

ENTER AN OVERALL REPRESENTATIVE SCORE OF 0 TO 4 FOR YOUR SUBTEAM'S AREA

(Based on observations and results of interviews of area performers)

Score

Team 0 1 2 3 4 Comments

1: Milling-1 XNewer, high vol. Mostly needed org around workflow,

tooling racks, minor cleanup. Move machine Sat; heavy

duty storage already on hand- can accomplish lots Sat

2: Milling-2 X2 major areas of improvement: lead man room not needed,

rack of tooling, consolidation, scrutiny of tools, work area

layout. Red-tagged 29 items

3-Lathe & Turn X Area was very dirty and has some setup issues

4-Sheet Metal Fab X40--50 red tags. Area to be consolidated, moved into 202.

Focus on getting rid of things in prep for consolidation.

Move MRB cage

5-Precision Assembly X

Examined workflow including tower, currently in a location

away from the room. Plan to move mostly into room as

majority is small. Later feedback from Fred Deninger that

this area is slated to move to 202 anyways, so concentrate

more on sorting and organization and cleaning rather than

moving. Also saw some opportunities to ensure incoming

kits are correct before starting to work on them

Mitch - see if we can give some surplus equipment to employees legally

Overall, received constructive comments from area performers, very positive.

Mike McVey:, "Try to keep them engaged. People will want to keep a cleaner area clean."

Standard Kaizen Process

Develop the Plan Kaizen To-Do Lists developed for each sub team

8

# Actionee

Date

Asngd Due Date

Status

(Open or

Closed) Required Action

%

Done

Desired

Outcomes1 Mike, Pat 11/19/05 Saturday, November 19, 2005 Open Move EDM machine (multiple areas - same

functions)

Centralize

EDM

machines and

tooling

2 Elmo 11/19/05 Saturday, November 19, 2005 Open General cleaning of whole area

3 Pat, Luis 11/18/05 Saturday, November 19, 2005 Open Acquire heavy duty industrial shelving (have 1,

need 2 more)

Localized

area for

boxline tooling

and raw

material

4 Luis, Imre, Mike Open Optimize carts and raw material storage area Surplus

excess carts

and

standardize

storage of

carts

5 Allen 11/21/05 Tuesday, December 20, 2005 Open Tool holder storage for CAT-40's Safe place to

store tool

holders

6 Allen 11/21/05 Tuesday, December 20, 2005 Open In-process hybrid storage area Safe storage

of in process

flight

hardware

7 Allen 11/21/05 Tuesday, December 20, 2005 Open Acquire die card for boxline tooling Eliminate

storage for

tooling around

machine

8 Brian 11/19/05 Saturday, November 19, 2005 Open Optimize work benches Clean and

neat work

areas

# Actionee

Date

Asngd Due Date

Status

(Open or

Closed) Required Action1 Subteam plus

some other

people

11/18/05 Friday, November 18, 2005 Open Red tag cabinets by going through them. Get

some night shift people involved in sorting.

Create the red tag log. Determine what

cabinets can be eliminated or consolidated

2 Clements and

area performers

11/18/05 Saturday, November 19, 2005 Open Go through existing cabinets and identify what

to eliminate, redistribute, scrap and/or donate

tools

3 Subteam plus

some other

people

11/19/05 Saturday, November 19, 2005 Open Physically eliminate redundant and inefficiently

used cabinets. Move them

4 Subteam plus

some other

people

11/18/05 Saturday, November 19, 2005 Open Scrap the bookshelf and outdated manuals

5 Subteam 11/19/05 Saturday, November 19, 2005 Open Go through Storage rack to eliminate tools,

clean, reorganize rest of tools. Move items

Saturday

6 Otera 11/18/05 Friday, December 02, 2005 Open Eliminate blanketed area formerly known as

the lead man office area

7 Clements 11/18/05 Saturday, November 19, 2005 Open Get right people together including subteam 1

to re-layout area mentioned above as well as

adjacent areas to be more efficient per

markup.

8 Otera 11/18/05 Friday, December 23, 2005 Open Do new CAD layout for all areas needing new

layouts

9 Clements 11/18/05 Tuesday, November 29, 2005 Open After doing relayout, identify cabinets/shelves

for purchase (common tooling and material for

shop aids)

10 Clements, Otera 11/18/05 Friday, December 02, 2005 Open Investigate cost of supplying common

expandable tooling for machinists into tool

benches for day and night shifts to use

11 Clements 11/18/05 Tuesday, November 29, 2005 Open Ask for people to volunteer things out of their

work benches and toolboxes for common

shared use, get rid of scrap

12 Clements 11/18/05 Tuesday, November 29, 2005 Open Evaluate feasibility of setting up a vending

machine to vend out nuts, bolts, clamps,

common things used by machinists not

already in vending machines. Recirc back into

machine for shared use after checking it out

13 Clements 11/18/05 Tuesday, November 29, 2005 Open Come up with a simple process to establish

key contacts on each shift to make them

responsible for issue. Sign off sheets. Put

back into locked cabinets. Tied into above

action item

14 Clements, Otera 11/18/05 Thursday, December 08, 2005 Open Identify any facility fixes that need to be done

15 Clements, Otera 11/18/05 TBD Open Implement facility fixes identified above

16 Clements, Otera 11/18/05 Friday, December 02, 2005 Open Cost the move of heat treating oven to welding

room. Do in conjunction with precision

assembly heat treating oven

2 Ritchie 11/18/05 Friday, December 02, 2005 Open Get facilities support for disconnect,

movement and surplus of machines

3 James 11/18/05 Friday, December 16, 2005 Open Contact junior colleges for donation of

machines (e.g., El Camino, Compton, etc.)

4 Ritchie, Otera 11/18/05 Friday, December 16, 2005 Open Work with facilities for replacing floor where

machines broke flooring. Include asbestos

abatement as needed

5 Laverty 11/18/05 Friday, November 18, 2005 Open Create and review new draft layout of area 50%

6 Ritchie 11/18/05 Friday, December 02, 2005 Open Implement new layout

7 Ritchie 11/18/05 Saturday, November 19, 2005 Open Move, discard, reorganize, condense cabinets

(~12)

8 Ritchie 11/18/05 Friday, January 13, 2006 Open Work with facilities (plumbers, electricians,

etc.) to re-connect machines after they are

moved

9 Ritchie 11/18/05 Friday, January 13, 2006 Open Investigate purchase of new horizontal

bandsaw/cut-off

10 Ritchie 11/18/05 Friday, January 13, 2006 Open Investigate getting better vertifical bandsaw

from machine shop consolidation activity

11 Ritchie 11/18/05 Friday, January 13, 2006 Open Investigate replacement for Nomura horizontal

milling machine with a VTL to be able to do

horizontal and vertical work including a cost-

benefit analysis

12 Ritchie 11/18/05 Friday, December 16, 2005 Open Procure raw stock storage devices with

labeling

13 Clements 11/18/05 Friday, February 03, 2006 Open Create a clean area policy including

communication/training

14 Ritchie 11/18/05 Friday, December 16, 2005 Open Replace benches with modular benches to

support ergonomic use including computers.

Ensure they also have lighting on cabinets

15 Ritchie 11/18/05 Friday, December 02, 2005 Open Establish a centrally located cabinet for lathe

tooling

16 Ritchie 11/18/05 Friday, December 23, 2005 Open Get new vending machine for dispensable

tooling for the lathing area only

17 Ritchie 11/18/05 Friday, December 23, 2005 Open Move vending machine to lathe area

18 Ritchie 11/18/05 Friday, December 02, 2005 Open Get lathing team together to define shared

tooling to put into the vending machine

colocated with the lathing area

19 Ritchie 11/18/05 Friday, December 16, 2005 Open Identify and purchase a screen for mazak

manual lathe to vent chips from scattering

20 Ritchie, Connor 11/18/05 Saturday, November 19, 2005 Open Relocate hazardous waste flammable cabinets

that do not belong to this area

21 Ritchie 11/18/05 Friday, November 18, 2005 Open Get night shift crew to start sorting through

cabinets, empty out what is not needed. Start

cleaning up area as prework for Saturday

22 Ritchie 11/18/05 Friday, December 16, 2005 Open Work with facilities to replace burned out

lightbulbs. Investigate possibility of lowering

lamps

23 Ritchie 11/18/05 Saturday, November 19, 2005 Open Work with other areas (milling 1)to see what

they want from what is being eliminated from

this area

24 Ritchie 11/18/05 Saturday, November 19, 2005 Open Complete cleanup, identify what cannot be

done Saturday that should be created as

separate action items post event

# Actionee Date Asngd Due Date

Status

(Open or

Closed) Required Action

%

Done Desired Outcomes

1 Facilities 11/18/2005 12/31/2005 Open Remove MRB Cage Open space

2 11/18/2005 1/31/2006 Open

Remove shelves & cabinets in

inspection staging area Open space

3 11/18/2005 1/31/2006 Open

Move storage shelves against flow

tunnel wall Open space

4 11/18/2005 1/31/2006 Open

Add caging material to storage

shelves in new inspection staging area Security

5 11/18/2005 1/31/2006 Open Move inpection items to new area Open space

6 11/18/2005 2/28/2006 Open

Move center and south wall storage

shelves toward east wall Open space

7 Facilities 11/18/2005 2/28/2006 Open Move rotary blue tower (rolodex) east Open space

8 11/18/2005 2/28/2006 Open Rremove blue roller cabinet Open space

9 11/18/2005 2/28/2006 Open

Remove copy machine, conf room

table, courier shelf Open space

10 11/18/2005 2/28/2006 Open

Relocate tracker computer and

remove workbench & excess packing

materials Open space

11 11/18/2005 3/15/2006 Open

Move area control person to

inspection area and remove the area

control booth Open space

12 11/18/2005 2/28/2006 Open

Remove 3 storage cabinets outside

packaging area Open space

13 11/18/2005 2/28/2006 Open

Relocate packaging area next to

router staging area Open space

14 Team 11/18/2005 11/19/2005

Remove red-tagged "unused" sheet

metal machinery Open space

15 Movers 11/18/2005 TBD

Move red-tagged but required

machinery to M1 Open space

16 Team 11/18/2005 11/19/2005

Clean sheet metal area - pick up and

throw out unneeded "junk" Clean work area

17 11/18/2005 11/19/2005

Clean out router staging area - e.g.,

scrapped sheet metal Open space

18 11/18/2005 11/19/2005

Move crates in router staging area to

dock area Open space

# Actionee

Date

Asngd Due Date

Status

(Open or

Closed) Required Action

%

Done1 Team 5 11/18/05 Tuesday, November 29, 2005 Open Red tag cabinets by going through them.

Create the red tag log. Determine what

cabinets can be eliminated or consolidated

2 Team 5 11/18/05 Saturday, November 19, 2005 Open Go through existing cabinets and identify what

to eliminate, redistribute, scrap and/or donate

tools

3 Team 5 11/19/05 Saturday, November 19, 2005 Open Physically eliminate redundant and inefficiently

used cabinets. Move them

4 Team 5 11/18/05 Saturday, November 19, 2005 Open Scrap the bookshelf, bulletin boards and

outdated manuals

5 Team 5 11/19/05 Saturday, November 19, 2005 Open Go through cabinets, create min/max cabinets,

clear off the rock to eliminate seldom used

tools, red tag unused tools, clean, reorganize

rest of tools. Move items Saturday using

existing storage

6 Team 5 11/18/05 Saturday, November 19, 2005 Open Define and error and identification and

corrective action process

7 Team 5 11/18/05 Friday, December 23, 2005 Open Do new CAD and work station layout for all

areas

8 Team 5 11/18/05 Tuesday, November 29, 2005 Open Request ergo review of individual work

stations through health services to address

deficiencies including flat screen to maximize

efficiency

9 Team 5 11/18/05 Team 5 Open Reduce conveyance to Precision Assembly

from Towner's tower--move workable inventory

into area

10 Team 5 11/18/05 Friday, December 02, 2005 Open Examine RF work stations at Bldg 108

warehouse for potential use in precisions

Assembly

11 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Ask for people to volunteer things out of their

work benches and toolboxes for common

shared use, get rid of scrap

12 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Evaluate feasibility of setting up a vending

machine to vend out parts. Recirc back into

Precision Assembly for shared use after

checking it out

13 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Replace missing fluorescent light bulbs above

occupied work stations

14 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Clean/replace flooring tiles. (Asbestos tile)

15 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Replace bulletin board with scrolling message

board

16 Paul 11/18/05 Monday, November 28, 2005 Open Replace lead desk with unigroup table, return

and table for staging area to improve

organization

17 Paul/Norm 11/18/05 Friday, November 18, 2005 Open Ask M&P to help identify an alternative to

using typewriter for electro chemical etching so

we can throw out typewriter!

Milling-1

Milling-2

Lathe & Turn

Sheet Metal Fab Precision Assembly

All actions closed as of 5/23/06

M3 5S Lean Event

9

Tool Storage rack

Before During

Sort, Shine Time spent looking for support tooling (MUDA)

After

Set in order, standardize

M3 5S Lean Event

10

Before After

Equipment relocation to improve work flow

1. End of the day debriefs

Initial 30 day review – 6th January 06 Final review – 22nd May 2006

11

4

38

08 512

915

519

812 31

104

0

20

40

60

80

100

120

140

Planning

& Mgmt

2-Milling2 4-Sheet

Metal

Total

Open Closed

Closed,

104, 77%

Open, 31,

23%

Closed,

135,

100%

Open, 0,

0%

Team #1 Milling1 Completed all action items; moved, cleaned, installed shelving, organized

Team #2 Miling2 Accomplished ~50% action items; rest are investigative, longer term

Team #3 Lathe & Turn Got rid of lots of old cabinets

Team #4 Sheet Metal Fab Moved shelves down about 40 feet, clearing much space

Team #5 Precision Assembly About 50% of actions, rest are longer term including computers, monitors.

2. Reviews

Implementation Updates

1. Freed square footage area – 4250

12

File: PSC MPD Mech Fab 5S Lean 11-19-05_ROM METRICS AND SAVINGS.xls

• 93% reduction in motion

• Total cost benefit - $527k

• Increased employee morale and efficiency

• Reduced workplace accidents

Conclusion and Results

Space Freed By Eliminating Non-Value Added items

13

Case Study – 2 MaST - Australia

Introduction Management consultancy and training

Found in 1971, Australia

Focuses on four main skills

Applying 5S Sort (Organize)

Set (Neatness)

Shine (Cleaning)

Standardize

Sustain (Self-discipline)

Transition

Reflection and learning

Link between 5S and strategic business plan

Changes in the internal cultures of the organization

Lesson for the international group

Conclusion

5S was incorporated in strategic business plan

Increased the morale of the employees

MaST