introductions lean knowledge or experience no prior experience some experience able to discuss able...

IntroductionsIntroductions

• Lean knowledge or experience

•No prior experience•Some experience•Able to discuss•Able to teach others•Lean expert

Lean Manufacturing Lean Manufacturing OverviewOverview

Problem

Solving

StandardizedWork

ErrorProofing

QuickChangeover

TotalProductive

Maintenance

5S / Visual

Factory

KanbanLeanLayout

Lean Manufacturing

1 3

Introduction

Lean Manufacturing:

“least-waste” way to manufacture high quality products

TPS- Toyota Production System

Kaizen- Continuous Improvement

1 4

WhyWhyPersonal ConsiderationsPersonal Considerations

Continuous Improvement can affect you where you work and live

Job Security

• Our job security depends on the long-term health of the company.

• We must improve production efficiency, reliability, and leadtime if we are to continue to meet competitive challenges and customer expectations.

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Lean is a “steady platform for Lean is a “steady platform for change” that empowers people to change” that empowers people to

continuously look for ways to continuously look for ways to make work bettermake work better

Improvement means Change

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If you keep doing what you’ve If you keep doing what you’ve always done, always done,

you will keep getting what you you will keep getting what you always got!always got!

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5S Work Place Organization5S Work Place Organization

1S2S3S 4S

5S

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5S – What is it?5S – What is it?

A Management philosophy devoted to the A Management philosophy devoted to the proper proper arrangement and orderlinessarrangement and orderliness of of the workplace.the workplace.

5S lays the foundation for continuous 5S lays the foundation for continuous improvement (Kaizen, Lean improvement (Kaizen, Lean Manufacturing).Manufacturing).

A tool used to eliminate waste. (MUDA)A tool used to eliminate waste. (MUDA)

1 9

WasteWaste

Anything other than the minimum amount of equipment, materials, parts, space, and worker’s time which are “absolutely essential” in adding value to the product.

Eight Deadly Wastes

• Over Production

• Product Defects

• Inventory

• Excess Process

• Transportation

• Excess Motion

• Waiting

• Under-utilizing People

MUDA

InventoryMotion

OverProcessing

Correction

OverProduction

Waiting

Transportation

UnusedCreativity

5S 5S The Foundation for The Foundation for

EverythingEverything

“Good factories develop beginning with the 5Ss; bad factories fall apart beginning with the 5Ss.”

—Hiroyuki Hirano, Chairman JIT Management Laboratory, Co.,

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5S 5S The Foundation for The Foundation for

EverythingEverything The underlining principal of 5S:The underlining principal of 5S:

A place for everything and everything in A place for everything and everything in its place.its place.

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Management SupportManagement Support

5S starts from the top5S starts from the top Without the support of:Without the support of:

- Upper management - Upper management

- Middle management- Middle management

- Front line supervision- Front line supervision

YOU WILL SURELY FAIL !!!!!!YOU WILL SURELY FAIL !!!!!!

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5S5S

1S2S

3S 4S

5S

Sort

Set In Order

Shine

Standardize

Sustain

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Meaning of the 5S’sMeaning of the 5S’s SortSort - - Clearly distinguishing between what is necessary and what is Clearly distinguishing between what is necessary and what is

unnecessaryunnecessary, while disposing of the latter., while disposing of the latter. EvaluateEvaluate all items in the workplace and determine which items are all items in the workplace and determine which items are

really needed.really needed. UnderstandUnderstand why items are needed. why items are needed. KeepKeep only what’s needed. only what’s needed. Throw outThrow out what’s not needed what’s not needed.. IncludeInclude desk drawers and filing cabinets desk drawers and filing cabinets

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SortSort

Where?Where? Walkways, FloorsWalkways, Floors Storage shelvesStorage shelves CabinetsCabinets Drawers, DesksDrawers, Desks Walls, Bulletin BoardsWalls, Bulletin Boards Between Dock DoorsBetween Dock Doors Around polesAround poles On and around machinesOn and around machines

What?What? Excess materialsExcess materials Tools, fixtures, gaugesTools, fixtures, gauges Spare partsSpare parts DocumentsDocuments BrushesBrushes ClothsCloths FurnitureFurniture Seldom used equipmentSeldom used equipment

EVERYWHERE!!!!! EVERYTHING!!!!!

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Sort and JITSort and JIT

Corresponds to the Just-In-Time principle:Corresponds to the Just-In-Time principle: Keep only what is needed.Keep only what is needed. Only in the amounts needed.Only in the amounts needed. Only when it’s needed.Only when it’s needed.

Remove all items not needed for current Remove all items not needed for current production.production.

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Sort – Problem AvoidanceSort – Problem Avoidance

The plant becomes crowded and hard to work in.The plant becomes crowded and hard to work in. Cabinets, lockers and shelves required for unneeded Cabinets, lockers and shelves required for unneeded

items get in the way of communication and place items get in the way of communication and place unwanted walls between employees.unwanted walls between employees.

Time is wasted searching for parts, tools and fixtures.Time is wasted searching for parts, tools and fixtures. Unneeded inventory and machinery are costly to Unneeded inventory and machinery are costly to

maintain.maintain. Excess stock on hand hides problems on the Excess stock on hand hides problems on the

production floor.production floor. Unneeded items and equipment make it harder to Unneeded items and equipment make it harder to

improve the process flow.improve the process flow.

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SortSort

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SortSort

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Meaning of the 5S’sMeaning of the 5S’s Set In Order Set In Order Organize the necessary items so that they can be used and returned Organize the necessary items so that they can be used and returned

easily.easily. Sort first so we don’t waste time straightening things we don’t need.Sort first so we don’t waste time straightening things we don’t need. Organize all needed itemsOrganize all needed items

- Locate items where they most needed.- Locate items where they most needed.- Identify where to return items when not in use.- Identify where to return items when not in use.

- Identify items and their storage locations.- Identify items and their storage locations. Make the order of things clearly understood at first glance.Make the order of things clearly understood at first glance. Eliminate all wasted time and motion.Eliminate all wasted time and motion.

Set In OrderSet In Order

Provide a convenient, orderly and safe place for everything…and keep it there!

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Keep tools close to where they are needed

Can we achieve requirements more

simply? …incorporate tools


121 123122

123122121

120

Make locations obvious

Label names and addresses

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Marking Color CodeMarking Color Code

Work AreaWork Area -- WhiteWhite

AislesAisles -- YellowYellow

WIPWIP -- BlueBlue

Scrap/Non-ConformingScrap/Non-Conforming -- RedRed

Finished PartsFinished Parts -- GreenGreen

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Meaning of the 5S’sMeaning of the 5S’s ShineShine

Clean floors, equipment, and furniture in all areas of the workplace.Clean floors, equipment, and furniture in all areas of the workplace. During and after the straightening process, the work place must be During and after the straightening process, the work place must be

scrubbed.scrubbed. Make things clean , neat and orderly.Make things clean , neat and orderly.

- Sweeping floors.- Sweeping floors.- Wiping off machinery, tools, computers - Wiping off machinery, tools, computers

and furniture.and furniture. - Use the cleaning process to inspect for - Use the cleaning process to inspect for sources of dirt, oil, sources of dirt, oil, trash, etc.trash, etc.

ShineShineMonitor and restore

the condition of equipment and the workplace during

cleaning

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Meaning of the 5S’sMeaning of the 5S’s StandardizeStandardize

Maintaining and improving the standards of the first three Maintaining and improving the standards of the first three S’sS’s

The first three S’s have been doneThe first three S’s have been done- Sort- Sort- Set In Order- Set In Order- Shine- Shine

Maintain and improve the first three S’s.Maintain and improve the first three S’s.-Eliminate causes of dirt leaks and spills.-Eliminate causes of dirt leaks and spills.

-Create systems to keep things neat and organized.-Create systems to keep things neat and organized.

StandardizeStandardize

Establish standards of cleanliness and procedures for routinely maintaining

workplace condition

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Problems when Standardize is Problems when Standardize is not implemented wellnot implemented well

Conditions go back to the old and Conditions go back to the old and undesirable levelsundesirable levels

At the end of the day piles of unneeded At the end of the day piles of unneeded materials are left over.materials are left over.

Tool storage areas become disorganizedTool storage areas become disorganized

The purpose of Standardize is to prevent setbacks in the first three. To make implementing them a daily habit.

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Standardize EverythingStandardize Everything

Beyond the CleaningBeyond the Cleaning Work methodsWork methods Data processingData processing ReportsReports CleaningCleaning FormsForms TrainingTraining ToolsTools

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Meaning of the 5S’sMeaning of the 5S’s SustainSustain

Achieving the discipline or habit of properly maintaining the Achieving the discipline or habit of properly maintaining the correct 5S procedure. correct 5S procedure.

Develop a habit of practicing the first four S’sDevelop a habit of practicing the first four S’s Make 5S a way of life.Make 5S a way of life.

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DefinitionsDefinitions Sort - Sort - Clearly distinguishing between what’s necessary Clearly distinguishing between what’s necessary

and what’s unnecessary, while disposing of the latter.and what’s unnecessary, while disposing of the latter.

Set In OrderSet In Order - - Organize the necessary items so that Organize the necessary items so that they can be used and returned easily.they can be used and returned easily.

ShineShine - - Clean floors, equipment, and furniture in all Clean floors, equipment, and furniture in all areas of the workplaceareas of the workplace

Standardize - Standardize - Maintaining and improving the Maintaining and improving the standards of the first three S’sstandards of the first three S’s

Sustain -Sustain - Achieving the discipline or habit for properly Achieving the discipline or habit for properly maintaining the correct 5S maintaining the correct 5S

procedure. procedure.

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Benefits of 5S’sBenefits of 5S’s

How will we, as a group, benefit from 5S?How will we, as a group, benefit from 5S? Reduced WasteReduced Waste Improved SafetyImproved Safety Easier MaintenanceEasier Maintenance Higher QualityHigher Quality Improved ProfitabilityImproved Profitability

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Benefits of 5S’s Con’tBenefits of 5S’s Con’t

How will you, as an individual, benefit?How will you, as an individual, benefit? You can take pride in a 5S workplaceYou can take pride in a 5S workplace Your co-workers will respect you and your Your co-workers will respect you and your

work space.work space. You can also keep a positive mental attitudeYou can also keep a positive mental attitude

5S CREATES A BETTER PLACE TO WORK5S CREATES A BETTER PLACE TO WORK

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RED TAG STRATEGYRED TAG STRATEGY

Initiate first round of Red TaggingInitiate first round of Red Tagging Select members from various areasSelect members from various areas Select a manager to lead the teamSelect a manager to lead the team First session should be plant wideFirst session should be plant wide

Identify Red Tag TargetsIdentify Red Tag Targets Inventory, equipment, supplies, toolingInventory, equipment, supplies, tooling Office areas are not exempt from red taggingOffice areas are not exempt from red tagging


Red Label No.______

Item_________________

Quantity______________

Location_____________

Date_______Clearance Date________

Purpose______________

____________________

____________________

Sopwith Ltd..

ARMSTRONG

B.S.A.

Hillman

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Define Red Tag criteriaDefine Red Tag criteria Determine what criteria will be used to distinguish Determine what criteria will be used to distinguish

a needed item from an unneeded itema needed item from an unneeded item Example: Save only the items needed to make the Example: Save only the items needed to make the

next day, next week’s or next month’s production next day, next week’s or next month’s production schedule.schedule.

Make Red TagsMake Red Tags Determine information to be recorded on tagsDetermine information to be recorded on tags Determine material to be used for red tagsDetermine material to be used for red tags

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Conduct Red Tag SessionConduct Red Tag Session Explain the red tag criteria to all teamsExplain the red tag criteria to all teams Make sure you have a good cross-section of people tagging Make sure you have a good cross-section of people tagging

items in order to prevent the “I MIGHT NEED THAT” items in order to prevent the “I MIGHT NEED THAT” Syndrome Syndrome

Red tag the entire plant as rapidly as possibleRed tag the entire plant as rapidly as possible Evaluate the red tag itemsEvaluate the red tag items Review the material that has been taggedReview the material that has been tagged Dispose of the truly unnecessary inventory, equipment and Dispose of the truly unnecessary inventory, equipment and

other itemsother items Discard any material which is still tagged after a predetermined Discard any material which is still tagged after a predetermined

amount of timeamount of time All tags must be completed and returnedAll tags must be completed and returned

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RED TAGGING HINTSRED TAGGING HINTS

Record information about all tags used on a Red Tag Log Record information about all tags used on a Red Tag Log where you can track disposition easilywhere you can track disposition easily

Make sure everyone understands what is to be tagged and Make sure everyone understands what is to be tagged and whywhy

Discourage people from being defensiveDiscourage people from being defensive Be fair all areas get taggedBe fair all areas get tagged Don’t compromise; IF IN DOUBT, THROW IT OUT!Don’t compromise; IF IN DOUBT, THROW IT OUT! Necessary items can be tagged if improvements are known Necessary items can be tagged if improvements are known

or suggestedor suggested Do not put multiple tags on any one objectDo not put multiple tags on any one object Make reasonable allowances for decorative items such as Make reasonable allowances for decorative items such as

plants or family photosplants or family photos

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FormsForms

---------------------------------------------------------------------------------------------------------------

DESCRIPTION

CELL/AREARED TAG LOCATOR

TAG NUMBER

LOCATION

3. LONG TERM STORAGE 6. OTHER__________________

ACTION TAKEN DATE

DISPOSITION REQUIRED1. DISCARD 4. REDUCE INVENTORY2. IN CELL STORAGE 5. SELL/TRANSFER

TAG DATE:ITEM NAME:QUANTITY:REASON TAGGED:

3. FINISHED MAT'L 7. FURNITURE4. TOOLS 8. OFFICE MAT'L

1. RAW MATERIAL 5. SUPPLIES 9. BOOKS/MAGAZINES2. WIP 6. EQUIPMENT 10. OTHER

CELL/AREA RED TAG TAG NUMBER

CATEGORY

Item Disposition Guidance

Directions•Determine the category each tagged item belongs

•Determine required action, record on tag and Unneeded Items Log

•Take actionActionCategory

Defective •Return to supplier

•Throw away

•Repair

Used about once per week •Store in area

Obsolete •Sell

•Hold for depreciation

•Give away

•Throw away

Scrap •Remove to proper location

Trash / garbage •Throw away

•Recycle

Used less than once per month •Store where accessible in plant

Seldom used •Store in distance place

•Sell

•Give away

•Throw away

Unneeded in this area •Remove to proper location

Use unknown •Find out use

•Remove to proper location

Used at least once per day •Carry with you

•Keep at place of use

Red Tag Checklist

Directions•Examine all items in each category

•Red tag every item that may not be needed

•Enter a when a category is inspected

Search the walls, boards, etc.Items hung on walls

Bulletin boards

Signboards

Other

Raw materials

Supplies

Parts

Work in process

Finished products

Shipping materials

Look for unneeded material / supplies

Look for other unneeded itemsWork clothes

Helmets

Work shoes

Trash cans

Other

Floors

Aisles

Operation areas

Work Stations

Corners, behind/under equipment

Stairs

Small rooms

Offices

Loading docks

Inside cabinets and drawers

Search these spaces

Machines

Small tools

Dies

Jigs

Bits

Conveyance equipment

Plumbing, pipes, etc.

Electrical equipment

Wire, fixtures, junction boxes

Look for unneeded equipment

Look for unneeded furnitureCabinets

Benches and tables

Chairs

Carts

Other

Search these storage placesShelves

Racks

Closets

Sheds

Other storage areas

Unneeded Items Log#Unneeded Item Date Reason for Tagging Notes / Disposition

Workplace Scan

To identify workers, processes, and functions of the area. To plan the Workplace Scan.

Directions:

Plan the Workplace Scan by identifying who is responsible for each step and when completion is expected

•Draw an area layout

•Draw a material spaghetti chart

•Complete 5-S & Safety audits

•Take photos

•Create a workplace scan display

Scan Step Who When

Target Area Name:

Define the boundaries of the target area and tape it off.

State the primary purpose of the target area.

Record the functions of the target area.

Workplace Audit Checklist

Sustain

Stick to the rules

Area workers have not had 5-S training

5-S is not performed routinely

Personal belongings are not stored neatly

Standard Work is not available or up to date

Daily 5-S audits are not performed

Sort

Distinguish between what is needed and not needed

Unneeded equipment, tools, furniture, etc. are present

Unneeded items are on walls, bulletin boards, etc.

Items are in aisles, stairways, corners, etc.

Unneeded inventory, supplies, parts, or materials are present

Safety hazards (water, oil, chemical, machines) exist

Set in Order

A place for everything and everything in its place

Correct places for items are not obvious

Items are not in their correct places

Aisles, workstations, equipment locations are not identified

Items are not put away immediately after use

Height and quantity limits are not obvious

Cleaning, and looking for ways to keep it clean and organized

Floors, walls, stairs, and surfaces are not free of dirt, oil, and grease

Equipment is not kept clean and free of dirt, oil, and grease

Cleaning materials are not easily accessible

Lines, labels, signs, etc. are not clean and unbroken

Other cleaning problems of any kind exist

Shine

Standardize

Maintain and monitor the first three S’s

Necessary information is not visible

All standards are not known and visible

Standard Work doesn’t exists for all cleaning and maintenance jobs

All quantities and limits are not easily recognizable

Items cannot be located in 5 seconds

BEFORE AFTER

Note: Check all that apply, plan countermeasures.

Set in Order Inspection Sheet

Directions

FurnitureCabinets

Benches and tables

Chairs

Carts

Shelves

Racks

Materials / supplies / inventoryRaw material

Supplies

Parts

Work in process

Finished product

Shipping materials

Cleaning supplies

Other items

Charts, graphs, etc.

Books, checklists, etc.

Bulletin boards

Signboards

Pens, pencils, rulers, etc.

Work clothes

Helmets

Work shoes

Trash cans

Personal items

EquipmentMachines

Small tools

Dies

Jigs

Bits


Cleaning equipment


Fixtures, junction boxes, etc.

Computer equipment

•Inspect all items in entire area

•Move items to proper place

•Enter a when a category is inspected

•Search all items in the area for cleaning needs

•Use this with the Initial Cleaning Plan

•Enter a when a category is completed

Shine Inspection Sheet

Directions

Surfaces of equipment and furnitureMachines


Plumbing, pipes, sinks


Fixtures, junction boxes

Chairs

Other itemsMaterials and supplies

Trash cans

Bulletin boards

Labels and signs

Small tools

Hoses, cords, tubing, etc.

Other

Large Surfaces

Ceilings

Aisles

Work Stations

Corners, behind/under equipment

Stairs

Loading docks

Walls

Doors

Pillars and posts

Floors

Other

Carts

Shelves

Racks

Inside equipment / furniture

Machines


Closets

Drawers

Cabinets

Sheds

Tool boxes

Storage bins

Initial Cleaning Plan

Target Area

•List tasks and complete the columns belowDirections

Location Who Materials and Tools Needed

WhenTask

Current Score:Previous Score:

1 2 3 4

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

Sustain

ScoreDate:Scored By:

Set In Order

Shine

Stabilized

5S # Check Item

Are work clothes clean?

Have improvements been made to prevent things from getting Have rules been established for maintaining the first three of 5S's?

Have improvements been made to facilitate jig and tool handling?

Trash, water or oil on floors?

Are machines covered with shaving and oil?

Have the workers developed the diciplines required for maintaing the first four of 5S's?

Has 5S become a way of life?

Are all safety signs easily readable?

Are safety guards being used properly?

Has time been set aside for sustaining?

Has management and maintenance provided all of the needed support to sustain?

Is the angle and intensity of lighting adequate for the work being performed?Are workers wearing dirty or oil stained work clothes?Instead of cleaning up the messes, have people found ways toavoid making messes?

Are the first three of 5S's being maintained?

Do operators clean their machines while checking them?

Is there a person responsible for overseeing cleaning operations?Do operators routinely sweep floors and wipe equipment without being told?Is the room/are ventilated well enough to be clear of heavy dust?

Are white/yellow lines or other markers used to clearly indicate walkways and storage area?

Are jigs and tools arranged more rationally to facilitate picking them up and returning them?

Are the floors ket shiny, clean and free of debris?

Are the machines wiped clean?

Are safety guards in place?

Time and Structure

Is there an support?

Are there any unused machines or other equipment around?Are there any unused jigs, tools, dies or similar items around?Is it obvious which items have been marked as unnecessary?

Are notices kept clean and orderly?

Are shelves and other storage area marked with indicators and addresses?Do the shelves have labels showing which items go where?Are the minimum and maximum allowable quantities indicated?

Are safety signs posted?

Have specific cleaning task been assigned?

Has clealiness become a habit?

Is there proper ventilation?

Is there proper lighting?

Is equipment inspection combined with equipment maintenance?

Are there location indicators?

Are there item indicators?

Are there quantity indicators?

Are walkways and in-process inventory identified?

Area Name:

Does the inventory or in-process inventory include any unneeded materials or parts?

Unneded materials or parts.

Sort

Description

Unneded machines or other equipment.

Unneeded jigs, tools or dies?

Have unneeded items been marked?Are display boards well organized?

introductions lean knowledge or experience no prior experience some experience able to discuss able...

Documents

unneeded items

management support5s

management philosophy

work better improvement

current production

production efficiency

s lays

excess materialstools