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5S Grinding Room

Pressweld Value Stream

11-28-12 to 12-04-12

Scope Sheet

Kaizen Event Scope / Sustainment Sheet Basic Data Kaizen Team Information

Kaizen Event Name 5S Event - Inside Grinding Room Champion Jim Campisi

Process Boundary Scope Inside Grinding Room Process Owner Cal Clark

Primary Facilitator Tony Drenik

Primary Lean Tool Used 5S Secondary Facilitator None Event Location (Facility) Watteredge - Avon Lake Team Leader (s) Chet Hollingshead Event Location (Room) Lunch Room

Team Members

Cal Clark Terry Daugherty

Jeff Roussin Tyler Moates Erika Bentley Darlene McIE

Chet Hollingshead David Pullins Tony Drenik

Kaizen Event Dates 11-28-2012 to 12-04-2012 Daily Start Time 6:00 AM

Kick Off Meeting Time 8:00 AM Team Leaders Meeting Dates 11-29,11-30 and 12-03 Team Leaders Meeting Time 4:00 PM

Team Leaders Meeting Place Lunch Room

Report Out Meeting Date 12-04-2012 Team Resources

Maintenance Purchasing - Supplies

Report Out Meeting Time 11:00 AM Report Out Meeting Room Lunch Room

Problem Statement (Must show relationship to KPI, VSM, Strategic Plan)

Connected to Pressweld VSM Need to create sustainable processes around keeping the grinding area clean, neat and organized to help maximize efficiency within the department.

Kaizen Objective (Must show relationship to KPI, VSM, Strategic Plan)

Create a sustainable process around Sort, Set in Order, Shine, Standardize and Sustain in the Grinding Room. When done all equipment and items in area should be in like new condition.

Prework Data Collection Needed

Cal - order long lead time parts needed to get equipment in like new condition Tony - take pre kaizen pictures of room and equipment

Day 1:Training

• Lean Overview

– What is Lean all about?

• Kaizen

– What is this formal process?

• 5S

– What is this LE Tool?

• Safety and Waste Analysis

– A process allowing us to SEE all of the waste

around us!!!

Day 1 Training - Why 5S?

• Gives us a process to clean and organize

the area followed by a process to maintain it

• Drives Safety

• Improves Quality, Delivery and Productivity

• Reduces Inventory

• Required for Visual Management

Sort, Straighten and Shine

can be done in parallel but

cannot be maintained without

Standardize and Sustain

5S Sustain

4S Standardize

2S Straighten

3S Shine

1S Sort

Day 2 - Sort

Break out into teams and “Go Do It”!!! Sort

thru everything and remove unneeded items

use the red tag system to discard items

Red Tag Log

Tag # VS Cell / Area

Description Reason Date Disposition

Date

57 PW Grinding Cart Not Used 28-Nov 14-Dec

56 PW Grinding Booth grating To Be Replaced 28-Nov 14-Dec

55 PW Grinding Booth grating To Be Replaced 28-Nov 14-Dec

47 PW OG Yellow Haz Mat drum

container Not Used 28-Nov 14-Dec

50 PW Grinding Plastic containers Not Used 28-Nov 14-Dec

49 PW Grinding Form Not Used 28-Nov 14-Dec

51 PW Grinding Belt Sander Not Used 28-Nov 14-Dec

52 PW Grinding Misc. Not Used 28-Nov 14-Dec

53 PW Grinding Dolly Not Used 28-Nov 14-Dec

54 PW Grinding Roller Section Not Used 28-Nov 14-Dec

59 PW Grinding Deionized water Not Used 28-Nov 14-Dec

Day 3 Straighten

Day 4 - Shine

Before and After Pics

Before

After

Significant Improvements

• Replaced ceiling tiles

• Replaced light covers

• Added 6 lights

• Painted walls

• Replaced plastic doorway safety strips

• Repaired holes in the walls and floors

• Painted floor

• Cleaned and painted dust tables

• Replaced table grates

• Designated locations in each booth for tools and supplies

• 5S cleaning supply shadowboard installed

Kaizen Newspaper

Kaizen Newspaper Kaizen Name:

5S Pressweld outside grinding and machining area

Team Leader: Cal Clark Kaizen End

Date: 11/29/12

Step # Action Step Owner Assist Start Date End Date Current Status

1 Electric Panel - Trace and ID Breakers Subash Cal 12/7/12 12/14/12

2 Tools needed for all booths Cal Tony 12/1/12 1/1/13 On order due in Jan.

3 Install hooks for all tools in all booths Dave Cal 12/3/12 12/5/12 In process of being made in house

4 Stencil number on each booth and the

booths tools Erica/Darlene Cal 12/4/12 12/5/12

5 Organize Red Tag area Snake Tony 12/4/12 12/5/12

6 Complete 5S Supplies Shadow Board Terry Tony 12/4/12 12/5/12 Supplies on order

Sustainment

Daily 5S Task List

Operator Task Shift Location # Monday Tuesday Wednesday Thursday

Clean booth - only tools and supplies on table 1st

2nd

Sweep floor 1st

2nd

Clean off saw 1st

2nd

Wash booth down top to bottom 1st

2nd

Clean top of cabinets 1st

2nd

Wipe down carts, tables, buffer and grinders

1st

2nd

Organize cabinet contents 1st

2nd

Empty trash cans 1st

2nd

Mop floor 1st

2nd

Return cleaning supplies to 5S shadow board 1st

2nd

Lessons Learned

• Need to remain flexible when the kaizen

event is taking place. There will be items

that come up that will need to be

addressed that are not planned for and we

will need to react quickly.

• Schedule events Wed – Tue to allow floor

paint drying time over the weekend.

• Communicate with department supervisors

as new opportunities arise

Next Up

• Next 5S Kaizen will be in the pressweld

area of the department.

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