5S Visual Workplace [PDF]

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5S

The five pillars of Visual Workplace System

Analysis and Enhancement of Manufacturing Systems

The begining… In the daily work of a factory, routines that maintain organization and orderliness are essential to a smooth and efficient flow of activities.

5S The five pillars of Visual Workplace System

It is a system to keep the workplace organized, clean, safe and productive.

It’s name originates in 5 japanese words begining with S.

The begining… Things found in the workplace tools dirt debris

oil parts dies

documents equipment

S1 Sort Remove all items from the workplace that are not needed for current production operations.

Only what is needed, in the needed quantity, only when is needed.

S1 Sort Do I need everything in my workplace?

Are there objects I don’t use?

When in doubt, throw it out! For the items I use: • Are they in the appropriate quantity? • Are they the ones used most frequently? • Are they always in-hand?

S1 Sort

S2 Set in order Arranging needed items so that they are easy to use and labeling them so that they are easy to find and put away. A place for everything, and everything in its place.

S2 Set in order

*Delimited areas

S2 Set in order

*Shadows

S3 Shine Sweeping floors, wiping off machinery, and generally making sure that everything in the factory stays clean. The cleanest place is not the one always been cleaned, but the one that never gets dirty.

S4 Standardize The method used to maintain the first three pillars: Sort, Set in Order, and Shine.

Say what you do, and do what you say, always.

S4 Standardize Three steps to making Sort, Set in Order, and Shine activities a habit are: Decide who is responsible for 3S conditions maintenance activities.

Integrate 3S maintenance duties into regular work activities.

Check how well 3S conditions are begin maintained.

S5 Sustain Making a habit of properly maintaining correct procedures.

The hard thing is not getting there, but staying there.

Common Types of

to 5S

What’s so great about Sort and Set in order? Why clean when it just gets dirty again? Sorting and Setting in order will not boost output. We already implemented Sort and Set in order. We did 5S years ago. We’re too busy for 5S activities. Why do we need to implement the Five Pillars?

S5 Sustain Roles in Implementation Management • Educating on 5S • Creating implementation teams • Provide resources • Supporting 5S efforts • Encourage worker involvement • Promote efforts

Your Role • • • •

Continuous learning on 5S Helping educating coworkers Being enthusiastic about 5S Helping promote 5S implementation efforts

S5 Sustain Tools and techniques to sustain 5S implementation: Slogans

Posters

Storyboards

Maps

Pocket Manuals

Dept. Tours

Newsletters 5S Months

Benefits from Visual Workplace

ZERO ZERO ZERO

…changeovers bring product diversification.

…defects bring higher quality. …waste brings lower costs.

…delays bring reliable deliveries. …injuries promote safety.

…breakdowns bring better equipment availability. …complaints bring greater confidence and trust.

The five pillars of Visual Workplace System 3Shine 1Sort 2Set in order

4Standardize

5Sustain

5S. The five pillars of Visual Workplace System References HIROYUKI, Hirano (1995) 5 Pillars of the Visual Workplace: The Sourcebook for 5S Implementation. Productivity Press, USA.

SOCCONINI Luis, BARRANTES Marco (2005) El proceso de las 5’s en acción. Grupo Editorial Norma, México.

5S images from Graham Scutt www.grahamscutt.com.uk

Analysis and Enhancement of Manufacturing Systems