7/29/2019 6S_Course

1/25

6S

To Create a Workplace suited for

Visual Control and LeanProduction

7/29/2019 6S_Course

2/25

The Six Ss

Is not Six Sigma

A highly disciplined process that focuses ondeveloping and delivering near-perfect productsand services

6S is Sort, Straighten, Shine (Scrub), Safety,Standardize, Sustain

5-S in Japanese factories

Focus: orderliness

6th S added in some US companies Safety Combines orderliness with safety / ergo

Overall intention: CLEAN, SAFE, ORDERLY

First step on Lean Journey

7/29/2019 6S_Course

3/25

Visual Factory/Office

1st Level: See the Shop/Office

Basic 6S

90% never get beyond this point

2nd Level: See the work

In 5 Seconds, can you see whats going

on?

7/29/2019 6S_Course

4/25

6S

Think of 6-S as a repeating action sequence:

1: SORT OUT - get rid of whats not needed

2: STRAIGHTEN - organize what belongs

3: SCRUB - clean up, see and solve problems

4: SAFETY - make the work area safe 5: STANDARDIZE - assign tasks, track visually

6: SUSTAIN - keep it up (audit and insist)

Remember

This applies to all areas (value-adding andadministrative)

Basic "6-S is part of establishing any cell

7/29/2019 6S_Course

5/25

Sort

GET RID OF WHATS NOT NEEDED

Start with a red tag campaign

Tag everything that looks disorderly or unsafe

Be ruthless (90% of the time you'll be OK, you'll

get over the 10%) If in doubt throw it out

If still in doubt, send it to a red tag area forresolution

You should be removing truckloads of items betough (sometimes youll need to ask forforgiveness later!)

7/29/2019 6S_Course

6/25

Straighten

ORGANIZE WHAT BELONGS Create a place for everything

Meet with shop/office personnel on whatshould be where

Deal with the open red tags from the "SortOut" step:

Organize parts and material

Resolve things you were afraid to throw out

Write off or sell off obsolete materials

7/29/2019 6S_Course

7/25

Straighten

7/29/2019 6S_Course

8/25

Straighten

7/29/2019 6S_Course

9/25

Straighten

7/29/2019 6S_Course

10/25

Straighten

7/29/2019 6S_Course

11/25

Scrub

CLEAN UP, SEE AND SOLVE PROBLEMS

Make the work area absolutely clean

Clean everything (equipment, floors, walls)

Paint everything (equipment, floors, walls)

Look for problems Leaks?

Loose or missing items

Unsafe conditions

Causes of messes or problems

Quality issues

Solve problems (root cause), take correctiveaction (prevent)

7/29/2019 6S_Course

12/25

Scrub

7/29/2019 6S_Course

13/25

Safety

MAKE THE WORKPLACE SAFER Look for unsafe conditions

Look for potential for unsafe acts

Look for difficult tasks (are they

ergonomic?) Try the jobs yourself where could you

get hurt?

List the opportunities

Resolve them

Put creativity before capital and put

safety first!!!

7/29/2019 6S_Course

14/25

Safety

7/29/2019 6S_Course

15/25

Standardize

ASSIGN TASKS AND MANAGE VISUALLY

Who will do what to keep the area clean,safe and orderly?

Agree on daily and weekly tasks

Establish a visual management system forthese tasks

Can you tell at a glance if the taskshave been done?

7/29/2019 6S_Course

16/25

Standardize

7/29/2019 6S_Course

17/25

7/29/2019 6S_Course

18/25

Sustain

KEEP IT UP (AUDIT AND INSIST)

Develop audit checklists for office and forshop floor

Assign the audit role to someone outside

the area Track the audit results (a bit of friendly

competition?)

Hold yourselves accountable for sustaining

7/29/2019 6S_Course

19/25

Sustain - Maintain The Gains

Create checklist for entire

area & all items within thearea

Use checklist daily orweekly as appropriate

Once a year haveExaminers performindependent review

Fix and clean daily

Continue to train &heighten awareness

Remember you are WorldClass! Act like it.

7/29/2019 6S_Course

20/25

Sustain - 6S Scorecard0 = No evidence that 6S is being

considered for implementation1 = Some evidence of 6S being

started

2 = 6S is partially implemented

(some gains are evident)

3 = 6S has been implemented but

not self-sustaining4 = 6S has been implemented & is

self-sustaining (standard

throughout)

5 = 6S is entrenched; efforts have

resulted in high achievements6 = Out-of-the-box; Area is doing

extraordinary things, above &

beyond the norm

7/29/2019 6S_Course

21/25

Sustain - 6S Scorecard0 20 = Some organization,

needs much improvement21 40 = Signs of 6S in place,

good organization, needs

more time to mature

41 60 = 6S implemented,

signs of maturing, not self-sustaining

61 80 = 6S implemented,

system is self-sustaining

81 100 = 6S is entrenchedwith high achievements

100+ = Extraordinary, over-

and-above, outside-the-

box

7/29/2019 6S_Course

22/25

Visual Management

Make normal / abnormal conditions obviouswith

Floor and surface marking

Shadow boxes

Samples Visual indicators

Obstacle height limits

Lights and sounds

Arrows, zones, stickers Scoreboards

Labels and tags

7/29/2019 6S_Course

23/25

For Shops Remove unnecessary items

All cleaning material stored in a neat manner Floors clean of debris, oil and dirt

Bulletin boards updated, straight and neat

Easy access to emergency equipment, highly visible

Items on floors are in clearly marked areas Aisles are clear and kept free of material

Storage of boxes is square, neat, orderly

Machines, tools, equipment kept clean

Nothing on top of machines or cabinets

Documents and binders stored in a neat manner

Tools, jigs, fixtures, details are labeled, shadowed, identified,easy to reach

Shelves, benches, desks kept free of unused objects, includingfiles and documents

7/29/2019 6S_Course

24/25

For Offices Remove unnecessary items, minimum personal items

Cleaning equipment stored in a neat manner Floors clean and free of debris and dirt

Bulletin boards are updated, straight and neat

Easy access to emergency equipment, stored in a prominent manner

Nothing on the floor but furniture, CPU, recycle bin and garbage can

Office layout posted at each entrance, name and task/position outsidecubicle/office

Office equipment and furniture is functional and in good repair

Paper, cabinets, and bins squared up, centered and at right angles, PCwiring is routed and secured/clamped

Desks, surfaces, cabinets, chairs cleaned weekly Nothing on top of overheads or cabinets, nothing leaning against walls

or columns, everything labeled

Documents and binders stored in a neat and orderly manner

Shelves, cabinets, desks kept free of unused objects, including files anddocuments

7/29/2019 6S_Course

25/25

Acknowledgements

Lean Thinking by James Womack andDaniel Jones

Toyota Production System by TaiichiOhno

Simpler Business System,

www.simpler.com