Presentation 6 S STARTER Training

7/28/2019 Presentation 6 S STARTER Training

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6S Basics

TRAINING FORSTARTER


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PPB

(Monthly)

COB

(Daily)

Visual Factory-Information

Gathering/Organization

PAB

(Hourly)

Information Center(Plant-wide Reporting)

From

Each

Department

Department Reporting

PAB = Process Analysis Board

COB = Certified Operation BoardPPB = Process Performance Board


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8 WASTES

Defect / Correction Overproduction

Waiting

Not utilizing employee talents

Transportation / material movement

Inventory Motion

Excessive processing


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Sort

Straighten

Shine

Standardize

Sustain


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There are basically three

different types of workplaces...


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1S

4S

3S

2S

5S

Sort

Straighten

Shine

Standardize

Sustain


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1S

Sort

Segregate What Is Needed, Needed

Later, and Not Needed

Discard What Is Not Needed

Segregate Needed Items By Frequency

of Use


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Where to Perform


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C

E

N

G-

L

E-

X

X

X

(--

)File completed Tag at ____________

5S

---RE

DTAG

Enter #

in

box

Ent

er #

in

box

Ent

er #

in

box

Item Name

&/or Description:

Department: Value per Item:

Classification: 1. Raw Material

2. Work-in-Process3. Component

4. Finished Product

5. Machine / Equipment

6. Mold / Jig7. Tool / Fitting

8. Other______________

Reason: 1. Unnecessary

2. Defective

3. Leftover Material

4. Unknown

5. Other______________

Action: 1. Eliminate

2. Return

3. Move to Red Tag

Storage

4. Other_______________

Completed:

Tag Attached:

Year_____ Month_____ Day____

Action Taken:

Year_____ Month_____ Day_____


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Sort


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2S

Straighten


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Small

Crescent

WrenchSmall Claw

Hammer

Flat Tip

Screwdriver

Large

Crescent

WrenchLarge Claw

Hammer


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Stage 1 Stage 2 Stage 3 Stage 4


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Before

After


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Before

After


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Before

After


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Before

After


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3S

Shine


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Why Shine?


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Shine Targets


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5S A t{Enter Location here}Location Being Audited:

(place cursor in red c orner for INSTRUCTIONS)


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5S Assessment

Score Sheet

5S Observed Condition Improvement Action

0

Storage of cleaning equipment: A ll cleaning equipment

stored in a neat manner; handy and readily available when

needed0

Items on floor: Work-in-proc ess, tools and any other

material are not left to sit directly on the floor. Large items

such as tote boxes are positioned on the floor in clearly

marked area, identified by painted or taped lines.

0

Storage and arrangement:: Boxes, containers , andmaterials are always stored neat and at correct work angles

convenient to the operators where appropria te. When

items are stacke d evenly or in a manner that would not

cause them to toppling over. Storage areas are provided

for all necessary items at POUS (Point-Of-Use Storage).

No items are placed on top of machines, cabinets, and

equipment. Unidentifie d items can not lean against walls

or columns.

0

Operating equipment/machinery: Each piece of

equipment/machinery has guards and deflectors that

prevent debris from falling uncontained to the floor.0

Document storage: Only documents necessary to the

operation are stored at the workstations and are stored in a

neat and orderly manner.0

Tool and gauges arrangement: Tools, gages and fixtures

are arranged neatly and stored, kept clean and free of any

risk of damage.0

Workbench and desk control: Kept free of objects

including records and documents (unless in use). Tools and

fixtures are clean and placed in their proper location.0

Information boards: PPB, COBs, and PABs are arranged

in a neat and orderly manner. No outdated, torn, or soiled

documents are displayed0

Emergency access: Fire hoses and emergency

equipment are unobstructed and stored in a prominent easy-

to-locate area with proper identification. E-Stop switches

and breakers are marked or color-coded for immediate

visibility.

0

Aisle ways marking: Aisles and walkways are clearly

marked and can be identified at a glance; lines are straight

and at right angles where appropriate with no chipped, worn

floor marking.

0

Equipment maintenance: Controls of machines are

properly labeled. Critical points for daily maintenance

checks are clearly marked. Equipment check sheets are

clean, neatly displayed and completed daily.

0

Tool and gauges convenience: Tools, gages and fixtures

are arranged so they can be easily accessed when needed. 0

Shelves and benches arrangement: Arranged, divided and

clearly labeled it is obvious where things are stored; status

and condition is recorded0

Equipment cleanliness: All machines and equipment are

kept clean by routine daily care. 0Floor cleaning: All floors are clean and free of debris, oil

and dirt. Cleaning of floors is done routinely -- daily at a

minimumposted schedule.0

5S control and maintenance: There is a disciplined

system of control and it is maintained at the highest

possible level. It is the responsibility of every one to

maintain this system and environment. Do cumentation exist

indicating cleaning responsibility for each team member in

the work area.

0

Sort

Remove unneeded equipment, tools,

furniture, etc.

Provide information on

department PPB

Review excess inventory, supplies,

parts, or materials

Identify existence of safety hazards

(water, oil, chemical, machines,

extension cords, etc.)

(place cursor in red c orner for INSTRUCTIONS)

To-Do Items

Remove unnecessary items. All items not required for

performing operations are removed from the work area.

Only tools and products are present at workstation

All team members have had

5S training

Daily 5S actions performed

Place all personal belongings

stored in a neatly mai ntained

location

Job aids are current and readily

accessible

Routine 5S Implementation Audit

is performed until sustained

Aisle ways maintenance: Aisles are always free of

materials and obstructions; nothing is placed on the lines

and objects are always placed at right angles to the aisles

where appropriate.

0.00Legend: 4.75 (GREEN)

Equipment painting: All machines and equipment are

neatly painted; equipment cleaning schedule developed

and posted for each major piece of equipment.S

hine

Standardize

Sustain

Document control: All documents are labeled clearly as to

content and responsibility for control and revision. Obsolete

Straighten

Floors, walls, stairs, and surfaces are

free of dirt, oil and grease

Equipment is kept clean and free of

dirt, oil, and grease

Cleaning materials are easily

accessible

Lines, labels, signs, etc. are cleanand not damaged

No other cleaning problems

(of any kind) are present

0

0

0

Correct location for items are

identified

Items are placed in their correct

locations

Aisle ways, workstations, equipment

locations are indicated

Items are put away immediately

after use

Inventory or WIP height and quantity

limits are obvious

Necessary information is visible

All standards are known and visible

Checklists exist for all cleaning and

TPM maintenance jobs

All quantities and limits are easily

recognizable

All necessary items can be located

in 30 seconds

5S Implementation Audit Score =


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It is important that weestablish the first 3S

before we progress to

the next 2S.


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4S

Standardize


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5S


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5S

Sustain


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January 2007 June 2007


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?


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Now, what would you do?


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Remember

5S1S

4S

3S2S

5S

Sort

StraightenShine

Standardize

Sustain


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To Create a Workplace suited for Visual Control andLean Production


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The Six Ss Is not Six Sigma A highly disciplined process that focuses on

developing and delivering near-perfect products andservices

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


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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?


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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 and

administrative) Basic "6-S is part of establishing any cell


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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 getover the 10%)

If in doubt throw it out If still in doubt, send it to a red tag area for

resolution

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


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Straighten ORGANIZE WHAT BELONGS

Create a place for everything Meet with shop/office personnel on what should be where

Deal with the open red tags from the "Sort Out" step:

Organize parts and material

Resolve things you were afraid to throw out Write off or sell off obsolete materials


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Straighten


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Straighten


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Straighten


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Straighten


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Scrub CLEAN UP, SEE AND SOLVE PROBLEMS Make the work area absolutely clean Clean everything (equipment, floors, walls)

Paint everything (equipment, f loors, walls)

Look for problems

Leaks? Loose or missing items

Unsafe conditions

Causes of messes or problems

Quality issues

Solve problems (root cause), take corrective action(prevent)


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Scrub


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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!!!


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Safety


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StandardizeASSIGN TASKS AND MANAGE VISUALLY

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

Agree on daily and weekly tasks

Establish a visual management system for these tasks

Can you tell at a glance if the tasks have been done?


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Standardize


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Sustain - Maintain The Gains


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Create checklist for entire

area & all items within thearea

Use checklist daily or weeklyas appropriate

Once a year have Examinersperform independent review

Fix and clean daily

Continue to train & heighten

awareness Remember you are World

Class! Act like it.

Sustain - 6S Scorecard


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0 = No evidence that 6S is beingconsidered for implementation

1 = Some evidence of 6S beingstarted

2 = 6S is partially implemented(some gains are evident)

3 = 6S has been implemented butnot self-sustaining

4 = 6S has been implemented & isself-sustaining (standardthroughout)

5 = 6S is entrenched; efforts haveresulted in high achievements

6 = Out-of-the-box; Area is doing

extraordinary things, above &beyond the norm

Sustain - 6S Scorecard


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0 20 = Some organization,needs much improvement

21 40 = Signs of 6S in place,good organization, needsmore 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


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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


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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, easyto reach

Shelves, benches, desks kept free of unused objects, including filesand documents


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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 orcolumns, everything labeled

Documents and binders stored in a neat and orderly manner

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


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Acknowledgements

Lean Thinking by James Womack and DanielJones

Toyota Production System by Taiichi Ohno

Simpler Business System, www.simpler.com


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