Workplace Organization Standardization

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5S Workplace Organization andStandardization


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Overview of ModuleOverview of Module

Introduction to 5S

Workplace Scan

Sort

Set in Order

Shine

Standardize

Sustain


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Introduction - What is 5S?Introduction - What is 5S?

The 5S system is a systematic employee involved approach

with five universal principles that supports and sustains an

organized and standardized workplace.

It Promotes:

Safety

Productivity

Quality

Control

5S is employee involvement and buy in


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Employee Involvement ...

All you need is one


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IntroductionIntroduction

Spend time looking for a file?

Spend time looking for a tool?

Wonder which document is the latest version?

Spend time looking for a pen or pencil you were just using?

Wonder how others perform this process?

Fill in for peers and wonder how they did their work?

Do You Ever . . .


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Introduction Visual Business LevelsIntroduction Visual Business Levels

5S

Shared Information

Shared Standards

Build Standards in the Workplace

Warn about Abnormalities

Prevent

Abnormalities

Stop Abnormalities

Visual

Control

VisualDisplay

5S

5S Provides the Foundation to Build a Visual Work lace


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Introduction Benefits of 5SIntroduction Benefits of 5S

5S activities support high performance in the workplace

Safety an organized and clean work environment prevents accidents

Productivity an organized workplace reduces the amount of time in search fortools, material, direction and information. A clean workplace reduces unplanneddowntime because you can spot problem areas before breakdown.

Quality an organized and clean workplace gets contaminants out of products andreduces defects.

Image an organized and clean workplace is a good reflection of pride andownership.

Control an organized workplace is good control for quality and productivity


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Introduction List of 5SIntroduction List of 5S

1) Sort Keep only what is needed

2) Store Arrange and identify for ease of use

3) Shine Clean regularly to identify problems immediately

4) Standardize Deviation becomes automatically observed

5) Sustain Set discipline, plan, schedule, train way of life

5S is the groundwork for improvement


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IntroductionIntroduction

Sort

Standardize

Sustain Set in Order

Shine

5SCycle


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Workplace Scan

Getting Started


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Workplace ScanWorkplace Scan

Definition of Target Area

Area Map of Target Area and Flow Diagram

Before Photographs of Target Area

Workplace Scan Display

Basic Elements


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Container Changeover parts

Tools Spareparts

Kind of Things to Look for: MessConsequences: no overview, double work, loss of time, problems with colleagues and managers



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Kind of Things to look for: Machine stoppageConsequences: Delay of delivery, costs for repair, problems with part disposition, overtime



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Kind of Things to Look for: Auxilary Material

Consequences: Costs for supplies, costs for purchasing, additional costs for deposit



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Kind of Things to Look for: Line stoppage

Consequences: Delay of delivery, costs for repair, problems with part disposition, overtime



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shrinkage Waste

Rework maculature

Kind of Things to Look for: Shrinkage, Rework

Consequences: costs for material and lost labor, additional work, loss of capacity



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Handling of Material

Handling of tools

Defect Machine Parts

Too many Defects

Kind of Things to Look for: Production process not under control

Consequences: Bad quality, low efficiency, additional costs



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Kind of Things to Look for: Stocks too high

Consequences: Lack of space, too high assets, additional transportation costs, difficulties to keep overview



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Friction

Wear ??% Man ??% Soiling ??%

Abration

Heat

Pressure

Rupture

Misbehaviour

Lack of Knowledge

Lack of Training

No Motivation

Thoughtlessness

Dust

Chips

Bonding

Acids / Caustics

Paint / Oil / Grease

What Stops Machines?

Wear 25% Man 33% Soiling 42%


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Clearly Define the Boundaries of theTarget Area

Record Name of Area

Tape off the Target Area

Record Primary Purpose of the Area

Identify Stakeholders

List all the Functions of the TargetArea

Production Function Storage

Transport of Supplies

Inspection

Maintenance and Cleaning

Definition of Target AreaDefinition of Target Area


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The Area Map shows the present location of work stations, supplies, product, andpersonnel in the target area. The flow diagram or spaghetti diagram is drawn onthe area map to show the physical flow of activity in the area.

Area Map and Flow DiagramArea Map and Flow Diagram

1) Use flip chart, Markers, and Post-it notes

2) Outline shape of target area on flip chart

3) Use Post-It Notes to indicate larger items such as equipment & desks

4) Draw in smaller equipment and items or use smaller Post-It notes

5) Draw in lines and arrows of the people flow with a black marker

6) Draw in lines and arrows of materials delivery with a blue marker

7 Draw in lines and arrows of roduct flow with a reen marker

Directions


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Training and EducationTraining and EducationTarget: Every apprentice is fully trained in 5S

Teamwork

Problem solving story

Visual

Standards


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Sort

Keep only what is neededKeep only what is needed

S tSSort


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SortSort

Separate the immediate needed items from the un-needed

Purpose:

Clear workplace of items that are not used on a regular basis

in order to improve visibility and work flow

Method:

Use Tagging Tactic to visually identify unneeded items

and

include every employee that is a shareholder in the area

Standardize


Shine

5S

Cycle


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SortSortSteps for Tagging:

1. Determine the criteria for tagging

Recommend two levels of tagging (Green and Red)

9 A Red tag indicates that the item is to be moved to

the holding area to be evaluated

9 A Green tag is used when someone sees that an item

is Red Tagged and believes it should not be moved

9 If the item has a Green Tag, it is not to be moved

2. Prepare a Tag Holding area

3. Design Tags (Make tags as simple as possible

Can include: Name of Person Tagging, date, Item name, item category

Reason for tagging (Green tags should include name of persontagging for clarification of reason)

4. Set a date and time to Tag unneeded items

5. Tag unneeded items

6. Moved tagged items out of the target area into the holding area

7. Record all items tagged

M k d f t ith t


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Mark defects with tags

TPM

MehrErfolgmit

Nummer:

Mangel

3


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RED TAG Holding Area


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Set In Order

Ensure that every item within the workplace has its proper place

Set In OrderSet In OrderSort

Sustain Set in Order5S


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Set In OrderSet In Order

Purpose:

Method:

Decide and organize the workplace in a way that it is easy for anyone to find

and use items within the workplace.

Also, make it obvious when items are not in the correct location

Use the guiding principle: A place for everything and everything in its place

Decide where and how to kee thin s and ut them there

Standardize


Shine

5S

Cycle

S t I O d StS t I O d St


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Set In Order - StepsSet In Order - Steps

1. Analyze Current Situation

Analyze Part/Material Usage

9 Who uses, How many, How

often

Analyze Tool Usage

9 Place most used tools closest

to operator

Set In Order StepsSet In O de Steps


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2. Organize and Improve all other items for ease of use

Storage Methods and Places

Determine a location and quantity for everything

needed

ResponsibilityResponsibility


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ResponsibilityResponsibility

Take on responsibility of something

Set In Order StepsSet In Order Steps


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Set In Order StepsSet In Order Steps

A Place for Everything and Everything in its Place

3. Decide where and how to keep things Make everything easy to find

Keep things off the floor

Every item should have an address and name



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4. Make it Obvious where things belong Use Visual Techniques

9 LINES

9 Labels

9 Signboards


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ShineShineSort



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ShineShine

Purpose:

Method:

Clean everything inside and out to spot problems early

and to keep workplace in top operating condition at all times

Schedule basic cleaning of workspace

A Clean workplace helps to identify abnormal conditions

Standardize Shine

5S

Cycle

How to ShineHow to Shine


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How to Shine . . .How to Shine . . .

Create Plans for cleaning and lubrication

Determine cleaning and lubricating methods

Perform initial cleaning of everything

Replace worn wires, hoses, and tubing

ShineShine


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ShineShine

Create plans for cleaning and lubrication

Use a color coded method for cleaning assignments

Identify how each area will be cleaned

Schedule and document cleaning schedule

ShineShine


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ShineShine

Determine cleaning and lubricating methods


Examine equipment while cleaning and lubricating

What kind of cleaning supplies will be required

Are maintenance tags available

Is area maintenance log up to date

Are maintenance work order for tagged defects available


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Checklist of Machine Surroundings


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Control table

- Are the measuring tools at

their Place?

- Is the control table clean?

- Are the specifications actual?

Shrinkage / Rework

- Are the containers at the

right place?

- Are the containers marked?

Material preparation

- Is the correct quantity ofmaterial at the place?

- Are the containers and palets

in good condition ?

Disposal

- Are the bins correctly set?

- Are they emptied?

- Are the ashtrays emptied?- Chip- and waste container o.k?

- Emulsion container tidy?

Working area around the

machine clean?

- Are the marks on the floor

visible and o.k.?

- Is everything at its place?

- Is the floor tidy?

??Object: 03 Name: Automatic Lath

g

ShineShine


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ShineShine

Perform initial cleaning of everything


Clean inside and out

Look at floors, walls, aisle ways, and shelves

ShineShine


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e

Replace worn wires, hoses, and tubing



Make small repairs such as replacement of hoses and tubing

Mark defects with a Red maintenance tag

Document all tagged defects in a maintenance log

Create maintenance work order for tagged defects

Keep a record of recognized defects and corrected defects

ShineShine


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Prevent Dirt and Improve Efficiency

Start with Basic Cleaning

Spot Soiling or Defect

Tag & Record Defect

Identified for Source of Improvement

Placed on Problem Solving Story Board

Standard Created

Soiling /Defect Resolved

Summary


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Goal:

Basic cleaning

of machine,Lubricating

according to plan,

Marking defects

Schedule: 1. Preparation

Advise: Only on a tidy machine will you recognize defects!

(e.g. leaks)

Advise: Only on a tidy machine will you recognize defects!

(e.g. leaks)

Cl t I t

2. Agreement

3. Action

4. Activities

after action

Summary


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Standardize

Workplace Maintained to a level that deviations are obvious

StandardizeStandardizeSort



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Purpose:

Method:

Develop systems in the Workplace at a level that deviations become obvious and

anyone can see problems when they occur.

Establish visual guidelines for the conditions of Sort, Set in Order, and Shine

Create Guidelines for maintaining the improved conditions in your workplace

Standardize Shine

Cycle

StandardizeStandardize


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How to Standardize

Establish Guidelines for Sort, Set in Order & Shine

Bring the Condition of the area to Level ofStandards Set

Make the Standards Visual

Maintain and monitor these 5s conditions

Example: Countermeasure


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Chain cleaning device



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Improve feasibility of maintenance


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Improve feasibility of maintenanceImprove feasibility of maintenance


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Transparent Covers


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Establish Guidelines for Sort, Set in Order & ShineEstablish Guidelines for Sort, Set in Order & Shine


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Typical Sort Standards

9 Amount of Inventory

9 Tools that belong in the area

9 How often to remove scrap

9 When and how to perform tagging

Typical Set In Order Standards

9 Location of aisle ways, equipment, and tools

9 Proper storage of dangerous or fragile items

9Typical Shine Standards

9 When and how to perform cleaning and maintenance tasks

9 When protective clothing is required

Standardize Make the Standards VisualStandardize Make the Standards Visual


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9 Make Temporary line permanent by painting

9 Replace temporary lines and signboards with permanent ones

9 Use color coding to aid visual orderliness

Standardize Maintain & MonitorStandardize Maintain & Monitor


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Optimum 5S conditions are not likely to occur

unless every stakeholder knows exactly

what he or she is responsible for doing,

and knows when, where, and how.


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Sustain

Training and Communication Strategies forBuilding Self-discipline

SustainSustainSort

Sustain Set in Order 5S

Cycle


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Purpose:

Method:

Build a commitment to adhere to 5S standards

and

ensure that the 5S activities become a habit

Become aware and create a plan of the concepts, activities,

And techniques of 5S

Create a Plan to Sustain the 5S System gains

Standardize Shine

Sustain How to Sustain . . .Sustain How to Sustain . . .


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Create A Plan

Ensure Management support

Train Everyone on 5S standards and their purpose Create and maintain a 5S communication board

Make 5S activities part of daily work

Continue to Improve standards and visual methods

Continue to improve total employment involvement

Sustain Create a PlanSustain Create a Plan


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Identify Standards, Guidelines, and procedures that require adherence

Identify the people who are to adhere to these standards

Determine methods

9 5S concepts and skill training

9 5S communication Board

9 Before and After photos

9 One-Point Lessons

9 Study Groups

9 Information Signboards about standards

9 Daily 5-minute 5S activities

9 Weekly 5S activities

Sustain Communication BoardSustain Communication Board


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SustainSustain


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Make 5S activities part of daily work

5-minute 5S

Everyone takes 5 or 10 minutes to Sort, Set in Order, and Shine their own work area every day.

Weekly 5SOnce a week everyone in the area sets aside 30 minutes to perform 5S activities together

This is also a good time to implement 5S improvements

When everyone is involved, the 5S system will take root in a lasting way

Changeover and Maintenance Cart


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Date post:	04-Apr-2018
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Workplace Organization Standardization

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