SlideShare a Scribd company logo
1 of 78
Krishna Heda 5S and Visual Management
Operations Strategy
Agenda ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Objectives ,[object Object],[object Object],[object Object],As a result of attending this module, you will be able to:
Work Place Organization - Philosophy Sort Eliminate what is not needed Straighten Organize what remains Shine Clean work area Standardize Schedule cleaning and maintaining Sustain Make 5S a way of life ,[object Object],[object Object],[object Object],[object Object],[object Object]
First Impressions “ You never get a second chance to create a first impression.”
First Impression: Condition of Work Area ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
First Impression:   Work Area
First Impression:  Work Area
First Impression:  Plant Main Aisle
First Impression:  Associate’s Workstation
Material Storage
Employee Morale: Break Area
Poor Workplace Organization Means Waste ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Key Characteristics in a 5S Environment ,[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],5S: Major Benefits Can You Think of Others?
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Work Place Organization:  Visual Management ,[object Object]
Two Workplaces,  Two Ways of Communicating HURRY UP! HIDDEN WORKPLACE VISUAL WORKPLACE 7
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Visual Management: Major Benefits
Work Place Organization Philosophy - Summary ,[object Object],[object Object],[object Object]
5S   Workplace Organization The Foundation of  the Visual Workplace ,[object Object],[object Object],[object Object],[object Object],[object Object],8
SORT DIVIDE ITEMS INTO Three CATEGORIES: CATEGORIZE  NECESSARY ITEMS : * RARELY USED * OCCASIONALLY USED * FREQUENTLY USED RED TAG STRATEGY ATTACH TO ALL  UNNECESSARY ITEMS DISCARD  UNNECESSARY  ITEMS 9 NECESSARY UNNECESSARY RED TAG Category 1. Raw material 6. Dies and jigs  2. In-process stock  7. Tools and supplies 3. Semi-finished goods 8. Measuring devices 4. Finished goods 9. Documents 5. Equipment 10. Other Item name and number Quantity Units $ Value Reason 1. Not needed 6. Other 2. Defective 3. Not needed soon 4. Scrap material 5. Use unknown Disposal by: Department/Business Unit/Product Center Disposal method: 1. Discard 2. Return 3. Move to red-tag storage site 4. Move to separate storage site 5. Other Disposal complete (signature ) Posting date: Disposal date:
Sort  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Action Check Item
10 RED TAG Category 1. Raw material 6. Dies and jigs  2. In-process stock  7. Tools and supplies 3. Semi-finished goods 8. Measuring devices 4. Finished goods 9. Documents 5. Equipment 10. Other Item name and number Quantity Units $ Value Reason 1. Not needed 6. Other 2. Defective 3. Not needed soon 4. Scrap material 5. Use unknown Disposal by: Department/Business Unit/Product Center Disposal method: 1. Discard 2. Return 3. Move to red-tag storage site 4. Move to separate storage site 5. Other Disposal complete (signature ) Posting date: Disposal date:
Sort: Workbench Before Sort... After Sort...
Sort:  Workstation Before Sort... After Sort...
STRAIGHTEN 2B4659 DETERMINE LOCATION FOR NEEDED ITEMS CUTTER  INSERTS 124GF 2HJF 12HJF 12HJF 12HJF 12HJF 12HJF 12HJF 13 VISUAL LOCATIONS PW2000 FIXTURES 2A4397 3A9674 IDENTIFICATION LINES 12HJF 12HJF 12HJF 12HJF 12HJF 12HJF POINT OF  USE STORAGE
Straighten Check Item ,[object Object],[object Object],[object Object],[object Object],Action ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Straighten:   Tool Storage
Straighten: Material Storage
Straighten: Maintenance Supplies
Straighten: Common Tooling Storage
Straighten: Cleaning Supplies
SHINE CLEAN SWEEP CLEANING AS A FORM OF INSPECTION BUILD VALUE IN EQUIPMENT 17 BUILD PRIDE IN WORK AREAS ELIMINATE DIRT
Shine Check Item ,[object Object],[object Object],[object Object],[object Object],Action ,[object Object],[object Object],[object Object],[object Object]
Shine: Covers Prevent Dust
Shine: Clean Walls,  Floors, Ceilings
ASSIGN “3S”  RESPONSIBILITIES INTEGRATE “3S” DUTIES  INTO REGULAR WORK DUTIES CHECK ON “3S”  MAINTENANCE LEVEL ,[object Object],[object Object],[object Object],[object Object],[object Object],5 Minute 5S 1S organize 2S orderliness 3S cleanliness 4S standardize 5S discipline 7:30 - 7:35 xxxxxxxxxxxxx xxx x x  xxx  x xx x xx x xxx x x xxxxx xxxx x x  xxxx x xxxxxxxxxx xxxxxxxxxx xxxxxxx 5 Point Checklist 1.  xxxxxxxxxx xxxxxxxxxxxxxx xxxxcx lsdfj sdlk dkdie ldslj sdlj f lsdflj  sldkj f 2  x x xxxxxxxxxxxxxxxxx xxxx 3.  xxx xx xxxx x x xxxx x xxxxxlsdf  lsdkjei lsdkj sdlkj sdl ldf 4.  xx xxxxxx x xxxx x xxxxxxxsdlfkj sdflkj sflkjsdflkj flk  5.  xxxxx xxx x x xxx xxxx xxxxxsdf,j sdlfjk flsdf ljsd 3 3 2 3 4 3.0 2 3 2 1 4 2.4 21 STANDARDIZE A State NAME M T W T F S Su Ken Sonya Paul Ross Mell Cathy Jesse Roger Ken D. Douglas
Standardize Check Item ,[object Object],[object Object],[object Object],Action ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],5S Guidelines 5S Review Schedule
Standardize (cont.) Check Item ,[object Object],Action ,[object Object],[object Object],[object Object],[object Object]
Daily Clean-Up 22
Five Point Sorting Check 23
Five Point Straightening Check 24
Five Point Cleanliness Check 25
Standardize:  5S Trend Chart 5S Rating Trend
PROPER TRAINING  CORRECT PROCEDURES BECOME A HABIT SUSTAIN MANAGERS COMMITTED TO 5S 5 S asdfsdfs sdf sdf dsfsdfsdfsfdsdfsdf 27 “ BUY-IN”  FROM  ALL WORKERS
Sustain  Check Item ,[object Object],Action ,[object Object],[object Object],[object Object],[object Object]
Sustain: Daily Activities
60 5s Checklist for Manufacturing
60 5S Checklist for Tool Room
60 TPM Checklist
Sustain:   Periodic Reviews
1. Removing unnecessary items 2. Storage of cleaning equipment. 3. Floor cleaning. 4. Bulletin boards. 5. Emergency access 6. Items on floor 7. Aisleways - markings 8. Aisleways - maintenance 9. Storage and arrangement 10. Equipment - painting All items not required for performing operations are removed from the work area, only tools and products are present at work  stations. All cleaning equipment is stored in a neat manner; handy and  readily available when needed. All floors are clean and free of debris, oil and dirt.  Cleaning  of floors is done routinely -- daily at a minimum -- posted schedule. All bulletins are arranged in a neat and orderly manner.  No outdated, torn or soiled announcements are displayed. Fire hoses and emergency equipment are unobstructed and stored in a prominent easy-to-locate area.  Stop switches  and  breakers are marked or color-coded for visibility. Work-in-process, 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 areas, identified by painted lines. Aisles and walkways are clearly marked and can be identified at  a glance; lines are straight and at a right angles with no chipped or worn paint. Aisles are always free of material and obstructions; nothing is  placed on the lines, and objects are always placed at right angles to the aisles. Storage of boxes, containers and material is always neat and  at right angles.  When items are stacked, they are never crooked  or in danger of toppling over. All machines and equipment are neatly painted; there are no  places in the plant less than six feet high that are unpainted. Item #  and  description 5S Evaluation Form Item Score  (0 - 5) What is the team doing to improve to next level? Subtotal pg 1 Pg 1 of 2
11. Equipment - cleanliness 12. Equipment - maintenance 13. Equipment - storage 14. Documents - storage 15. Documents - control 16. Tools & gages arrangement 17. Tools & gages convenience 18. Shelves & benches - arrangement 19. Workbench & desk - control 20. 5S control & maintenance All machines and equipment are kept clean by routine  daily care;  Controls of machines are properly labeled and critical points for  daily maintenance checks are clearly marked.  Equipment  checksheets are neatly displayed and clean. Nothing is placed on top of machines, cabinets and equipment;  nothing leans against walls or columns.  Guards and deflectors  are used to keep chips and coolant from falling to the floor. Only documents necessary to the operation are stored at the  work stations and are stored in a neat and orderly manner. All documents are labeled clearly as to content and responsibility  for control and revision. Obsolete or unused documents are  routinely removed. Tools, gages and fixtures are arranged neatly and stored, kept  clean and free of any risk of damage. Tools, gages and fixtures are arranged so they can be easily  accessed when changeovers or setups are made. Arranged, divided and clearly labeled. It is obvious where things  are stored; status and condition is recorded. Kept free of objects including records and documents.  Tools and fixtures are clean and placed in their proper location. There is a disciplined system of control and maintained at the  highest  possible level.  It is the responsibility of everyone to  maintain this system and environment. Item #  and  description 5S Evaluation Form Item Score  (0 - 5) What is the team doing to improve to next level? Pg 2 of 2 Subtotal pg 2 + Subtotal pg 1 Total 5S score : 20  =
[object Object],[object Object],[object Object],  Where Are We Now? This is World Class!
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Visual Controls vs. Visual Displays Visual Display Visual Control
Visual Controls Examples  Operator Process Control (OPC) Board Examples
Visual Display Set-up Time Equipment Performance 41 World Class Time 3:00 min Our Best Time 5:30 min Our Last Time 7:30 min
Business Unit 8500 Machine Down Time 0 100 200 300 400 500 600 W/E 10/09 W/E 10/23 W/E 11/06 H o u r s Equipment Performance 43 W/E  10/02 W/E  10/16 W/E  10/30
EAST END MAINTENANCE TEAM LABOR HOURS FOR T.P.M (LEVEL 2) TOTAL 13,915 HRS (LEVEL 2 PM’S) Equipment Performance 44
Cell Mission: To be the lowest cost producer of small machined rings while  consistently meeting customer requirements on quality and delivery.  CELL 235  TEAM MEMBERS People Organization 53 SUE NICOLE JIM CELL LEADER BRIAN CYNTHIA TOM TED PAUL
STANDARD WORK COMBINATION SHEET People Standards 54 OPERATION NAME OPERATION TIME (IN SECONDS) STANDARD WORK COMBINATION SHEET MODEL NUMBER AND NAME WORK SEQUENCE DATE PREPARED DEPT. QUOTA PER SHIFT TAKT  TIME OPERATOR NUMBER Manual Automatic Walking wwwwww TOTALS WALKING 1 2 3 4 5 6 7 Pick up blank Unload/load/switch on Measure thread diameter Put down finished piece Unload/load/switch on Unload/load/switch on Unload/load/switch on M110 L210 D310 T410 2 4 5 4 3 6 2 2 2 2 2 2 2 2 28 29 27 12 26 14 12345-67890 master cylinder Master cylinder machining 2/20 40 690
? 35-IP4 101-RTY 5664-11 831-UI WHAT IS WRONG WITH THIS METHOD OF STORAGE?  Product Organization 66
101PI 794-23O 103PI 102PI 199-IO 365-98U 199-5RT 122-O89 23-56T 101PI 101PI 794-23O 794-23O 23-56T 23-56T 102PI 102PI 365-98U 199-IO 365-98U 103PI 103PI 122-O89 122-O89 199-5RT 199-5RT SMALL PARTS STORAGE  14C Product Organization 67
KANBAN SCHEDULING BOARD  PART # 128450 PART # 145398 PART # 56701 RAW MATERIAL  WITHDRAWAL MFG.. INST. 6 CARD SYSTEM Product Organization 81
Master Cylinder 12345-678909 Pick up raw material Finished product 5 40” 40” Finished Product Raw Material L210 T420 L310 1 2 3 4 5 Inspect 6 7 Product Organization 70 M110
Visual Control Tools and Methods No. Name   Illustrations   Description Red Tag The red tag strategy helps us distinguish needed items for unneeded items in the work- shops.  Red tag teams use red tags to mark unneeded items  for removal. In the signboard strategy, we  set signs that indicate what belongs where and in what amount, so that anyone will be able to understand where things belong. A B 1  Red Tag Strategy 2  Signboard Strategy
Visual Control Tools and Methods (cont.) No. Name   Illustrations   Description 3 White/Yellow Line Indicators 4 Red Line Indicators When organizing workshops in an orderly condition,  marking out pathways and in- process storage sites with white or yellow tape makes it easy  for anyone to keep the  workshop neat. Red line indicators form part of the signboard strategy.  We set up poles next to inventory (warehouse or in-process inventory) stocks and mark the minimum allowable stock  height with a red line to show when excess inventory exists.
Visual Control Tools and Methods (cont.) No. Name   Illustrations   Description 5 Andon (alarm  lamps) 6 Kanban Andon immediately alerts necessary people to  abnormalities that occur in the factory. Kanban are administrative  tools that help us maintain Just-In-Time production. The two main types of kanban are transport kanban and production kanban. CARD F
Visual Control Tools and Methods (cont.) No. Name   Illustrations   Description These are display boards that indicate current conditions on production lines.  Data shown on these boards include pro- duction results, operating  conditions, and causes for line stops. We use these charts to find the work methods that use the best combination of people,  machines, and materials.  One of these charts should be on display at each line in the  factory. 7 Production Management Boards 8 Standard Operation Charts Standard Operation Chart Cond. _____ Prod. _____ Line stops cause _____ _____
Visual Control Tools and Methods (cont.) No. Name   Illustrations   Description Set-up display areas exhibiting defective items along with  graphic data urging Associates not to allow the same defects to  reoccur. Error prevention boards help promote independent manage- ment to reduce human errors. 9 Defective Item Displays 10 Error Prevention Error Prevention Board
More Visual Control Examples Work instructions mounted on a harness jig
More Visual Control Examples Safety instructions mounted on a wire cutting machine. Lubricate and gauge levels clearly marked
More Visual Control Examples Has the nut been tightened to the right point?
War Room
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],5S & Visual Management:  Lessons Learned
Shop Floor Work Shop  Agenda ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Shop Floor Work Shop  Agenda

More Related Content

What's hot

How to implement 5S - Japanese technique presentation by netpeckers managemen...
How to implement 5S - Japanese technique presentation by netpeckers managemen...How to implement 5S - Japanese technique presentation by netpeckers managemen...
How to implement 5S - Japanese technique presentation by netpeckers managemen...Iskcon Ahmedabad
 
Application of 5S in a Warehouse by Supriya Basu
Application of 5S in a Warehouse by Supriya BasuApplication of 5S in a Warehouse by Supriya Basu
Application of 5S in a Warehouse by Supriya BasuSupriya Basu
 
Introduction to 6S
Introduction to 6SIntroduction to 6S
Introduction to 6STim McMahon
 
5S Presentation for beginners and professionals for implementation
5S Presentation for beginners and professionals for implementation5S Presentation for beginners and professionals for implementation
5S Presentation for beginners and professionals for implementationsudarshan jadwal
 
Presentation - introduction to 5S
Presentation - introduction to 5SPresentation - introduction to 5S
Presentation - introduction to 5SJan Sabat
 
5S - A step-by-step approach to implement 5S at your workplace
5S - A step-by-step approach to implement 5S at your workplace5S - A step-by-step approach to implement 5S at your workplace
5S - A step-by-step approach to implement 5S at your workplaceAnanth Palaniappan
 
5 S Presentation Basic Training
5 S Presentation   Basic Training5 S Presentation   Basic Training
5 S Presentation Basic Trainingflevko
 
5 s training shop floor 4
5 s training shop floor 45 s training shop floor 4
5 s training shop floor 4dottinger
 
5S AWARNESS TRAINING PROGRAM
5S AWARNESS  TRAINING  PROGRAM5S AWARNESS  TRAINING  PROGRAM
5S AWARNESS TRAINING PROGRAMDEEPAK SAHOO
 
5S Facilitator Guide
5S  Facilitator Guide5S  Facilitator Guide
5S Facilitator GuideRhonda Kovera
 

What's hot (20)

5S Training
5S Training5S Training
5S Training
 
implementation of 5s
implementation of 5simplementation of 5s
implementation of 5s
 
How to implement 5S - Japanese technique presentation by netpeckers managemen...
How to implement 5S - Japanese technique presentation by netpeckers managemen...How to implement 5S - Japanese technique presentation by netpeckers managemen...
How to implement 5S - Japanese technique presentation by netpeckers managemen...
 
Application of 5S in a Warehouse by Supriya Basu
Application of 5S in a Warehouse by Supriya BasuApplication of 5S in a Warehouse by Supriya Basu
Application of 5S in a Warehouse by Supriya Basu
 
5 s
5 s5 s
5 s
 
Introduction to 6S
Introduction to 6SIntroduction to 6S
Introduction to 6S
 
5 S
5 S5 S
5 S
 
5 s training pack
5 s training pack5 s training pack
5 s training pack
 
5S Presentation for beginners and professionals for implementation
5S Presentation for beginners and professionals for implementation5S Presentation for beginners and professionals for implementation
5S Presentation for beginners and professionals for implementation
 
Visual Management
Visual Management Visual Management
Visual Management
 
Presentation - introduction to 5S
Presentation - introduction to 5SPresentation - introduction to 5S
Presentation - introduction to 5S
 
5S - A step-by-step approach to implement 5S at your workplace
5S - A step-by-step approach to implement 5S at your workplace5S - A step-by-step approach to implement 5S at your workplace
5S - A step-by-step approach to implement 5S at your workplace
 
5S For The Office by Operational Excellence Consulting
5S For The Office by Operational Excellence Consulting5S For The Office by Operational Excellence Consulting
5S For The Office by Operational Excellence Consulting
 
5 S Presentation Basic Training
5 S Presentation   Basic Training5 S Presentation   Basic Training
5 S Presentation Basic Training
 
5 s training shop floor 4
5 s training shop floor 45 s training shop floor 4
5 s training shop floor 4
 
5S AWARNESS TRAINING PROGRAM
5S AWARNESS  TRAINING  PROGRAM5S AWARNESS  TRAINING  PROGRAM
5S AWARNESS TRAINING PROGRAM
 
5 S
5 S5 S
5 S
 
5s Lean Presentation
5s Lean Presentation5s Lean Presentation
5s Lean Presentation
 
5S Facilitator Guide
5S  Facilitator Guide5S  Facilitator Guide
5S Facilitator Guide
 
5S - Lean Manufacturing Methodology
5S - Lean Manufacturing Methodology 5S - Lean Manufacturing Methodology
5S - Lean Manufacturing Methodology
 

Viewers also liked

5S Implementation Presentation
5S Implementation Presentation 5S Implementation Presentation
5S Implementation Presentation Pranav B. Gujjar
 
Visual Management: Leading with what you can see
Visual Management: Leading with what you can seeVisual Management: Leading with what you can see
Visual Management: Leading with what you can seeRenee Troughton
 
5S: Awareness & Implementation
5S: Awareness & Implementation5S: Awareness & Implementation
5S: Awareness & ImplementationMira Anuar
 
"Visual management & 5S " in Lean T.P.S (Workshop slides)
"Visual management &  5S " in Lean T.P.S (Workshop slides)"Visual management &  5S " in Lean T.P.S (Workshop slides)
"Visual management & 5S " in Lean T.P.S (Workshop slides)Zeeshan Syed
 
5s Method In 100 Slides Slideshare
5s Method In 100 Slides Slideshare5s Method In 100 Slides Slideshare
5s Method In 100 Slides Slideshare5scom
 
Kaizen Philosophy
Kaizen PhilosophyKaizen Philosophy
Kaizen Philosophypratik207
 
Kaizen Seminar Presentation
Kaizen Seminar PresentationKaizen Seminar Presentation
Kaizen Seminar PresentationOrange Slides
 
5S: A Workplace Organization Method
5S: A Workplace Organization Method5S: A Workplace Organization Method
5S: A Workplace Organization MethodNanette Bajador
 
Poka yoke (mistake proofing)
Poka yoke (mistake proofing)Poka yoke (mistake proofing)
Poka yoke (mistake proofing)Animesh Khamesra
 

Viewers also liked (20)

5s presentation
5s presentation5s presentation
5s presentation
 
5S Implementation Presentation
5S Implementation Presentation 5S Implementation Presentation
5S Implementation Presentation
 
5S: A Lean Transformation Tool
5S: A Lean Transformation Tool5S: A Lean Transformation Tool
5S: A Lean Transformation Tool
 
Visual Management: Leading with what you can see
Visual Management: Leading with what you can seeVisual Management: Leading with what you can see
Visual Management: Leading with what you can see
 
5S: Awareness & Implementation
5S: Awareness & Implementation5S: Awareness & Implementation
5S: Awareness & Implementation
 
Visual Management by Operational Excellence Consulting
Visual Management by Operational Excellence ConsultingVisual Management by Operational Excellence Consulting
Visual Management by Operational Excellence Consulting
 
Poka Yoke
Poka YokePoka Yoke
Poka Yoke
 
Visual Controls - Mieruka
Visual Controls - MierukaVisual Controls - Mieruka
Visual Controls - Mieruka
 
"Visual management & 5S " in Lean T.P.S (Workshop slides)
"Visual management &  5S " in Lean T.P.S (Workshop slides)"Visual management &  5S " in Lean T.P.S (Workshop slides)
"Visual management & 5S " in Lean T.P.S (Workshop slides)
 
5s Method In 100 Slides Slideshare
5s Method In 100 Slides Slideshare5s Method In 100 Slides Slideshare
5s Method In 100 Slides Slideshare
 
Kaizen Philosophy
Kaizen PhilosophyKaizen Philosophy
Kaizen Philosophy
 
Visual Control and Management : Manufacturing Management
Visual Control and Management : Manufacturing ManagementVisual Control and Management : Manufacturing Management
Visual Control and Management : Manufacturing Management
 
5 s ppt
5 s ppt5 s ppt
5 s ppt
 
5S, Kaizen, PokaYoke
5S, Kaizen, PokaYoke5S, Kaizen, PokaYoke
5S, Kaizen, PokaYoke
 
Kaizen Seminar Presentation
Kaizen Seminar PresentationKaizen Seminar Presentation
Kaizen Seminar Presentation
 
5S Techniques by Operational Excellence Consulting
5S Techniques by Operational Excellence Consulting5S Techniques by Operational Excellence Consulting
5S Techniques by Operational Excellence Consulting
 
5S: A Workplace Organization Method
5S: A Workplace Organization Method5S: A Workplace Organization Method
5S: A Workplace Organization Method
 
Kaizen training
Kaizen trainingKaizen training
Kaizen training
 
Poka yoke (mistake proofing)
Poka yoke (mistake proofing)Poka yoke (mistake proofing)
Poka yoke (mistake proofing)
 
Poka Yoke Final Ppt
Poka Yoke  Final PptPoka Yoke  Final Ppt
Poka Yoke Final Ppt
 

Similar to 5S Workshop &Visual management - Krishna Heda

Similar to 5S Workshop &Visual management - Krishna Heda (20)

5s's housekeeping 1995
5s's housekeeping 19955s's housekeeping 1995
5s's housekeeping 1995
 
5S for Enhancing Productivity, Quality, and Safety at the Workplace
5S for Enhancing Productivity, Quality, and Safety at the Workplace5S for Enhancing Productivity, Quality, and Safety at the Workplace
5S for Enhancing Productivity, Quality, and Safety at the Workplace
 
5 S Intro
5 S Intro5 S Intro
5 S Intro
 
5S Training
5S Training5S Training
5S Training
 
5 s and lean manufacturing
5 s and lean manufacturing5 s and lean manufacturing
5 s and lean manufacturing
 
5S present.pptx
5S present.pptx5S present.pptx
5S present.pptx
 
Corus 5S Lean Presentation
Corus 5S Lean PresentationCorus 5S Lean Presentation
Corus 5S Lean Presentation
 
Housekeeping - 5 step Programme
Housekeeping - 5 step ProgrammeHousekeeping - 5 step Programme
Housekeeping - 5 step Programme
 
dokumen.tips_5s-basic-training-ppt.ppt
dokumen.tips_5s-basic-training-ppt.pptdokumen.tips_5s-basic-training-ppt.ppt
dokumen.tips_5s-basic-training-ppt.ppt
 
5S training manual
5S training manual5S training manual
5S training manual
 
3816121 5 s
3816121 5 s3816121 5 s
3816121 5 s
 
5S & Safety
5S & Safety5S & Safety
5S & Safety
 
5 s
5 s5 s
5 s
 
5 s
5 s5 s
5 s
 
5 s
5 s5 s
5 s
 
5 s
5 s5 s
5 s
 
KAIZEN Updated 030507
KAIZEN Updated 030507KAIZEN Updated 030507
KAIZEN Updated 030507
 
5 s presentation-converted
5 s presentation-converted5 s presentation-converted
5 s presentation-converted
 
5S Improvement
5S Improvement5S Improvement
5S Improvement
 
The5SMethodologySortSetShineStandardizeSustaininQualityManagement..ppt
The5SMethodologySortSetShineStandardizeSustaininQualityManagement..pptThe5SMethodologySortSetShineStandardizeSustaininQualityManagement..ppt
The5SMethodologySortSetShineStandardizeSustaininQualityManagement..ppt
 

Recently uploaded

Grade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdf
Grade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdfGrade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdf
Grade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdfJemuel Francisco
 
call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️
call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️
call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️9953056974 Low Rate Call Girls In Saket, Delhi NCR
 
How to do quick user assign in kanban in Odoo 17 ERP
How to do quick user assign in kanban in Odoo 17 ERPHow to do quick user assign in kanban in Odoo 17 ERP
How to do quick user assign in kanban in Odoo 17 ERPCeline George
 
Difference Between Search & Browse Methods in Odoo 17
Difference Between Search & Browse Methods in Odoo 17Difference Between Search & Browse Methods in Odoo 17
Difference Between Search & Browse Methods in Odoo 17Celine George
 
Earth Day Presentation wow hello nice great
Earth Day Presentation wow hello nice greatEarth Day Presentation wow hello nice great
Earth Day Presentation wow hello nice greatYousafMalik24
 
ANG SEKTOR NG agrikultura.pptx QUARTER 4
ANG SEKTOR NG agrikultura.pptx QUARTER 4ANG SEKTOR NG agrikultura.pptx QUARTER 4
ANG SEKTOR NG agrikultura.pptx QUARTER 4MiaBumagat1
 
Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)
Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)
Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)lakshayb543
 
Concurrency Control in Database Management system
Concurrency Control in Database Management systemConcurrency Control in Database Management system
Concurrency Control in Database Management systemChristalin Nelson
 
4.16.24 21st Century Movements for Black Lives.pptx
4.16.24 21st Century Movements for Black Lives.pptx4.16.24 21st Century Movements for Black Lives.pptx
4.16.24 21st Century Movements for Black Lives.pptxmary850239
 
Global Lehigh Strategic Initiatives (without descriptions)
Global Lehigh Strategic Initiatives (without descriptions)Global Lehigh Strategic Initiatives (without descriptions)
Global Lehigh Strategic Initiatives (without descriptions)cama23
 
AMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdf
AMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdfAMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdf
AMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdfphamnguyenenglishnb
 
4.18.24 Movement Legacies, Reflection, and Review.pptx
4.18.24 Movement Legacies, Reflection, and Review.pptx4.18.24 Movement Legacies, Reflection, and Review.pptx
4.18.24 Movement Legacies, Reflection, and Review.pptxmary850239
 
How to Add Barcode on PDF Report in Odoo 17
How to Add Barcode on PDF Report in Odoo 17How to Add Barcode on PDF Report in Odoo 17
How to Add Barcode on PDF Report in Odoo 17Celine George
 
Virtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdf
Virtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdfVirtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdf
Virtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdfErwinPantujan2
 
AUDIENCE THEORY -CULTIVATION THEORY - GERBNER.pptx
AUDIENCE THEORY -CULTIVATION THEORY -  GERBNER.pptxAUDIENCE THEORY -CULTIVATION THEORY -  GERBNER.pptx
AUDIENCE THEORY -CULTIVATION THEORY - GERBNER.pptxiammrhaywood
 
Procuring digital preservation CAN be quick and painless with our new dynamic...
Procuring digital preservation CAN be quick and painless with our new dynamic...Procuring digital preservation CAN be quick and painless with our new dynamic...
Procuring digital preservation CAN be quick and painless with our new dynamic...Jisc
 
Proudly South Africa powerpoint Thorisha.pptx
Proudly South Africa powerpoint Thorisha.pptxProudly South Africa powerpoint Thorisha.pptx
Proudly South Africa powerpoint Thorisha.pptxthorishapillay1
 

Recently uploaded (20)

Grade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdf
Grade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdfGrade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdf
Grade 9 Quarter 4 Dll Grade 9 Quarter 4 DLL.pdf
 
call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️
call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️
call girls in Kamla Market (DELHI) 🔝 >༒9953330565🔝 genuine Escort Service 🔝✔️✔️
 
How to do quick user assign in kanban in Odoo 17 ERP
How to do quick user assign in kanban in Odoo 17 ERPHow to do quick user assign in kanban in Odoo 17 ERP
How to do quick user assign in kanban in Odoo 17 ERP
 
Difference Between Search & Browse Methods in Odoo 17
Difference Between Search & Browse Methods in Odoo 17Difference Between Search & Browse Methods in Odoo 17
Difference Between Search & Browse Methods in Odoo 17
 
Earth Day Presentation wow hello nice great
Earth Day Presentation wow hello nice greatEarth Day Presentation wow hello nice great
Earth Day Presentation wow hello nice great
 
ANG SEKTOR NG agrikultura.pptx QUARTER 4
ANG SEKTOR NG agrikultura.pptx QUARTER 4ANG SEKTOR NG agrikultura.pptx QUARTER 4
ANG SEKTOR NG agrikultura.pptx QUARTER 4
 
Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)
Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)
Visit to a blind student's school🧑‍🦯🧑‍🦯(community medicine)
 
Concurrency Control in Database Management system
Concurrency Control in Database Management systemConcurrency Control in Database Management system
Concurrency Control in Database Management system
 
4.16.24 21st Century Movements for Black Lives.pptx
4.16.24 21st Century Movements for Black Lives.pptx4.16.24 21st Century Movements for Black Lives.pptx
4.16.24 21st Century Movements for Black Lives.pptx
 
Global Lehigh Strategic Initiatives (without descriptions)
Global Lehigh Strategic Initiatives (without descriptions)Global Lehigh Strategic Initiatives (without descriptions)
Global Lehigh Strategic Initiatives (without descriptions)
 
AMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdf
AMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdfAMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdf
AMERICAN LANGUAGE HUB_Level2_Student'sBook_Answerkey.pdf
 
LEFT_ON_C'N_ PRELIMS_EL_DORADO_2024.pptx
LEFT_ON_C'N_ PRELIMS_EL_DORADO_2024.pptxLEFT_ON_C'N_ PRELIMS_EL_DORADO_2024.pptx
LEFT_ON_C'N_ PRELIMS_EL_DORADO_2024.pptx
 
4.18.24 Movement Legacies, Reflection, and Review.pptx
4.18.24 Movement Legacies, Reflection, and Review.pptx4.18.24 Movement Legacies, Reflection, and Review.pptx
4.18.24 Movement Legacies, Reflection, and Review.pptx
 
Raw materials used in Herbal Cosmetics.pptx
Raw materials used in Herbal Cosmetics.pptxRaw materials used in Herbal Cosmetics.pptx
Raw materials used in Herbal Cosmetics.pptx
 
How to Add Barcode on PDF Report in Odoo 17
How to Add Barcode on PDF Report in Odoo 17How to Add Barcode on PDF Report in Odoo 17
How to Add Barcode on PDF Report in Odoo 17
 
Virtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdf
Virtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdfVirtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdf
Virtual-Orientation-on-the-Administration-of-NATG12-NATG6-and-ELLNA.pdf
 
AUDIENCE THEORY -CULTIVATION THEORY - GERBNER.pptx
AUDIENCE THEORY -CULTIVATION THEORY -  GERBNER.pptxAUDIENCE THEORY -CULTIVATION THEORY -  GERBNER.pptx
AUDIENCE THEORY -CULTIVATION THEORY - GERBNER.pptx
 
YOUVE GOT EMAIL_FINALS_EL_DORADO_2024.pptx
YOUVE GOT EMAIL_FINALS_EL_DORADO_2024.pptxYOUVE GOT EMAIL_FINALS_EL_DORADO_2024.pptx
YOUVE GOT EMAIL_FINALS_EL_DORADO_2024.pptx
 
Procuring digital preservation CAN be quick and painless with our new dynamic...
Procuring digital preservation CAN be quick and painless with our new dynamic...Procuring digital preservation CAN be quick and painless with our new dynamic...
Procuring digital preservation CAN be quick and painless with our new dynamic...
 
Proudly South Africa powerpoint Thorisha.pptx
Proudly South Africa powerpoint Thorisha.pptxProudly South Africa powerpoint Thorisha.pptx
Proudly South Africa powerpoint Thorisha.pptx
 

5S Workshop &Visual management - Krishna Heda

  • 1. Krishna Heda 5S and Visual Management
  • 3.
  • 4.
  • 5.
  • 6. First Impressions “ You never get a second chance to create a first impression.”
  • 7.
  • 8. First Impression: Work Area
  • 9. First Impression: Work Area
  • 10. First Impression: Plant Main Aisle
  • 11. First Impression: Associate’s Workstation
  • 14.
  • 15.
  • 16.
  • 17.
  • 18. Two Workplaces, Two Ways of Communicating HURRY UP! HIDDEN WORKPLACE VISUAL WORKPLACE 7
  • 19.
  • 20.
  • 21.
  • 22. SORT DIVIDE ITEMS INTO Three CATEGORIES: CATEGORIZE NECESSARY ITEMS : * RARELY USED * OCCASIONALLY USED * FREQUENTLY USED RED TAG STRATEGY ATTACH TO ALL UNNECESSARY ITEMS DISCARD UNNECESSARY ITEMS 9 NECESSARY UNNECESSARY RED TAG Category 1. Raw material 6. Dies and jigs 2. In-process stock 7. Tools and supplies 3. Semi-finished goods 8. Measuring devices 4. Finished goods 9. Documents 5. Equipment 10. Other Item name and number Quantity Units $ Value Reason 1. Not needed 6. Other 2. Defective 3. Not needed soon 4. Scrap material 5. Use unknown Disposal by: Department/Business Unit/Product Center Disposal method: 1. Discard 2. Return 3. Move to red-tag storage site 4. Move to separate storage site 5. Other Disposal complete (signature ) Posting date: Disposal date:
  • 23.
  • 24. 10 RED TAG Category 1. Raw material 6. Dies and jigs 2. In-process stock 7. Tools and supplies 3. Semi-finished goods 8. Measuring devices 4. Finished goods 9. Documents 5. Equipment 10. Other Item name and number Quantity Units $ Value Reason 1. Not needed 6. Other 2. Defective 3. Not needed soon 4. Scrap material 5. Use unknown Disposal by: Department/Business Unit/Product Center Disposal method: 1. Discard 2. Return 3. Move to red-tag storage site 4. Move to separate storage site 5. Other Disposal complete (signature ) Posting date: Disposal date:
  • 25. Sort: Workbench Before Sort... After Sort...
  • 26. Sort: Workstation Before Sort... After Sort...
  • 27. STRAIGHTEN 2B4659 DETERMINE LOCATION FOR NEEDED ITEMS CUTTER INSERTS 124GF 2HJF 12HJF 12HJF 12HJF 12HJF 12HJF 12HJF 13 VISUAL LOCATIONS PW2000 FIXTURES 2A4397 3A9674 IDENTIFICATION LINES 12HJF 12HJF 12HJF 12HJF 12HJF 12HJF POINT OF USE STORAGE
  • 28.
  • 29. Straighten: Tool Storage
  • 34. SHINE CLEAN SWEEP CLEANING AS A FORM OF INSPECTION BUILD VALUE IN EQUIPMENT 17 BUILD PRIDE IN WORK AREAS ELIMINATE DIRT
  • 35.
  • 37. Shine: Clean Walls, Floors, Ceilings
  • 38.
  • 39.
  • 40.
  • 42. Five Point Sorting Check 23
  • 45. Standardize: 5S Trend Chart 5S Rating Trend
  • 46. PROPER TRAINING CORRECT PROCEDURES BECOME A HABIT SUSTAIN MANAGERS COMMITTED TO 5S 5 S asdfsdfs sdf sdf dsfsdfsdfsfdsdfsdf 27 “ BUY-IN” FROM ALL WORKERS
  • 47.
  • 49. 60 5s Checklist for Manufacturing
  • 50. 60 5S Checklist for Tool Room
  • 52. Sustain: Periodic Reviews
  • 53. 1. Removing unnecessary items 2. Storage of cleaning equipment. 3. Floor cleaning. 4. Bulletin boards. 5. Emergency access 6. Items on floor 7. Aisleways - markings 8. Aisleways - maintenance 9. Storage and arrangement 10. Equipment - painting All items not required for performing operations are removed from the work area, only tools and products are present at work stations. All cleaning equipment is stored in a neat manner; handy and readily available when needed. All floors are clean and free of debris, oil and dirt. Cleaning of floors is done routinely -- daily at a minimum -- posted schedule. All bulletins are arranged in a neat and orderly manner. No outdated, torn or soiled announcements are displayed. Fire hoses and emergency equipment are unobstructed and stored in a prominent easy-to-locate area. Stop switches and breakers are marked or color-coded for visibility. Work-in-process, 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 areas, identified by painted lines. Aisles and walkways are clearly marked and can be identified at a glance; lines are straight and at a right angles with no chipped or worn paint. Aisles are always free of material and obstructions; nothing is placed on the lines, and objects are always placed at right angles to the aisles. Storage of boxes, containers and material is always neat and at right angles. When items are stacked, they are never crooked or in danger of toppling over. All machines and equipment are neatly painted; there are no places in the plant less than six feet high that are unpainted. Item # and description 5S Evaluation Form Item Score (0 - 5) What is the team doing to improve to next level? Subtotal pg 1 Pg 1 of 2
  • 54. 11. Equipment - cleanliness 12. Equipment - maintenance 13. Equipment - storage 14. Documents - storage 15. Documents - control 16. Tools & gages arrangement 17. Tools & gages convenience 18. Shelves & benches - arrangement 19. Workbench & desk - control 20. 5S control & maintenance All machines and equipment are kept clean by routine daily care; Controls of machines are properly labeled and critical points for daily maintenance checks are clearly marked. Equipment checksheets are neatly displayed and clean. Nothing is placed on top of machines, cabinets and equipment; nothing leans against walls or columns. Guards and deflectors are used to keep chips and coolant from falling to the floor. Only documents necessary to the operation are stored at the work stations and are stored in a neat and orderly manner. All documents are labeled clearly as to content and responsibility for control and revision. Obsolete or unused documents are routinely removed. Tools, gages and fixtures are arranged neatly and stored, kept clean and free of any risk of damage. Tools, gages and fixtures are arranged so they can be easily accessed when changeovers or setups are made. Arranged, divided and clearly labeled. It is obvious where things are stored; status and condition is recorded. Kept free of objects including records and documents. Tools and fixtures are clean and placed in their proper location. There is a disciplined system of control and maintained at the highest possible level. It is the responsibility of everyone to maintain this system and environment. Item # and description 5S Evaluation Form Item Score (0 - 5) What is the team doing to improve to next level? Pg 2 of 2 Subtotal pg 2 + Subtotal pg 1 Total 5S score : 20 =
  • 55.
  • 56.
  • 57. Visual Controls Examples Operator Process Control (OPC) Board Examples
  • 58. Visual Display Set-up Time Equipment Performance 41 World Class Time 3:00 min Our Best Time 5:30 min Our Last Time 7:30 min
  • 59. Business Unit 8500 Machine Down Time 0 100 200 300 400 500 600 W/E 10/09 W/E 10/23 W/E 11/06 H o u r s Equipment Performance 43 W/E 10/02 W/E 10/16 W/E 10/30
  • 60. EAST END MAINTENANCE TEAM LABOR HOURS FOR T.P.M (LEVEL 2) TOTAL 13,915 HRS (LEVEL 2 PM’S) Equipment Performance 44
  • 61. Cell Mission: To be the lowest cost producer of small machined rings while consistently meeting customer requirements on quality and delivery. CELL 235 TEAM MEMBERS People Organization 53 SUE NICOLE JIM CELL LEADER BRIAN CYNTHIA TOM TED PAUL
  • 62. STANDARD WORK COMBINATION SHEET People Standards 54 OPERATION NAME OPERATION TIME (IN SECONDS) STANDARD WORK COMBINATION SHEET MODEL NUMBER AND NAME WORK SEQUENCE DATE PREPARED DEPT. QUOTA PER SHIFT TAKT TIME OPERATOR NUMBER Manual Automatic Walking wwwwww TOTALS WALKING 1 2 3 4 5 6 7 Pick up blank Unload/load/switch on Measure thread diameter Put down finished piece Unload/load/switch on Unload/load/switch on Unload/load/switch on M110 L210 D310 T410 2 4 5 4 3 6 2 2 2 2 2 2 2 2 28 29 27 12 26 14 12345-67890 master cylinder Master cylinder machining 2/20 40 690
  • 63. ? 35-IP4 101-RTY 5664-11 831-UI WHAT IS WRONG WITH THIS METHOD OF STORAGE? Product Organization 66
  • 64. 101PI 794-23O 103PI 102PI 199-IO 365-98U 199-5RT 122-O89 23-56T 101PI 101PI 794-23O 794-23O 23-56T 23-56T 102PI 102PI 365-98U 199-IO 365-98U 103PI 103PI 122-O89 122-O89 199-5RT 199-5RT SMALL PARTS STORAGE 14C Product Organization 67
  • 65. KANBAN SCHEDULING BOARD PART # 128450 PART # 145398 PART # 56701 RAW MATERIAL WITHDRAWAL MFG.. INST. 6 CARD SYSTEM Product Organization 81
  • 66. Master Cylinder 12345-678909 Pick up raw material Finished product 5 40” 40” Finished Product Raw Material L210 T420 L310 1 2 3 4 5 Inspect 6 7 Product Organization 70 M110
  • 67. Visual Control Tools and Methods No. Name Illustrations Description Red Tag The red tag strategy helps us distinguish needed items for unneeded items in the work- shops. Red tag teams use red tags to mark unneeded items for removal. In the signboard strategy, we set signs that indicate what belongs where and in what amount, so that anyone will be able to understand where things belong. A B 1 Red Tag Strategy 2 Signboard Strategy
  • 68. Visual Control Tools and Methods (cont.) No. Name Illustrations Description 3 White/Yellow Line Indicators 4 Red Line Indicators When organizing workshops in an orderly condition, marking out pathways and in- process storage sites with white or yellow tape makes it easy for anyone to keep the workshop neat. Red line indicators form part of the signboard strategy. We set up poles next to inventory (warehouse or in-process inventory) stocks and mark the minimum allowable stock height with a red line to show when excess inventory exists.
  • 69. Visual Control Tools and Methods (cont.) No. Name Illustrations Description 5 Andon (alarm lamps) 6 Kanban Andon immediately alerts necessary people to abnormalities that occur in the factory. Kanban are administrative tools that help us maintain Just-In-Time production. The two main types of kanban are transport kanban and production kanban. CARD F
  • 70. Visual Control Tools and Methods (cont.) No. Name Illustrations Description These are display boards that indicate current conditions on production lines. Data shown on these boards include pro- duction results, operating conditions, and causes for line stops. We use these charts to find the work methods that use the best combination of people, machines, and materials. One of these charts should be on display at each line in the factory. 7 Production Management Boards 8 Standard Operation Charts Standard Operation Chart Cond. _____ Prod. _____ Line stops cause _____ _____
  • 71. Visual Control Tools and Methods (cont.) No. Name Illustrations Description Set-up display areas exhibiting defective items along with graphic data urging Associates not to allow the same defects to reoccur. Error prevention boards help promote independent manage- ment to reduce human errors. 9 Defective Item Displays 10 Error Prevention Error Prevention Board
  • 72. More Visual Control Examples Work instructions mounted on a harness jig
  • 73. More Visual Control Examples Safety instructions mounted on a wire cutting machine. Lubricate and gauge levels clearly marked
  • 74. More Visual Control Examples Has the nut been tightened to the right point?
  • 76.
  • 77.
  • 78. Shop Floor Work Shop Agenda

Editor's Notes

  1. Purpose: To review agenda with participants Main Points: Agenda is self-explanatory
  2. Purpose: To identify what the participants will get out of this module Main Points: Objectives are self-explanatory
  3. Purpose: To drive home the point of how important the first impression is to our Customers and employees. Main Points: - First impressions are positively impacted by associate morale - First Impression and Employee morale are influenced by management attitude. - Leadership is critical for creating the environment.
  4. Purpose: To illustrate how the waste resulting from poor organization costs the company. Main Points: Unneeded inventory included those items we stockpile in our desks. Think of how much space can be freed up if we keep only those items we truly need, and the number we truly need. Teaching Tip: Ask: Can you think of any items that are lying around not be used? When was the last time it was used?
  5. Purpose: Introduce Visual Management to the audience. Main Points: The main objective of visual management is to provide employees, management, etc., with an understanding of what is going on in the work environment in a quick, organized manner. This will enable them act immediately when situations warrant it. One should immediately be able to tell: - Workplace organization - The work process - Schedule condition - Abnormalities Teaching Tips: Ask: What are some examples of Visual Management in your plant or department?
  6. Purpose: to show the class the difference in how info. is conveyed in a visual workplace as opposed to a hidden workplace. Main Points: In a hidden workplace, the manager has the production schedule in his back pocket. What do you think the employees reaction will be in the hidden factory to this manager request? In a visual workplace, the employee can see how they are doing relative to the schedule and take action if their is an abnormality. The result may be the same, with the employee working overtime or having to borrow a person from another department, but how the info is perceived is different Visual communications help give employees a more accurate perception of reality
  7. Purpose : Discuss benefits Main Points : Slide is self-explanatory. Training Tips: Ask: How does visual management help with JIT?
  8. Purpose: Workplace organization is necessary in order for visual controls to be effective. Main Point: The tool we use to achieve workplace organization is called 5S (read each of the 5 S’s with the brief description)
  9. Purpose: To understand that the first step to workplace organization is to get rid of unneeded items and to categorize needed items. Main Point: get rid of unnecessary items categorize needed items by frequency of use and choose storage site accordingly red tag strategy: used to identify unneeded items, give four tags to each team member or cell member to attach to things by the end of the day. Teaching Tip: Describe the process that you would use to clean out your garage: Throw out junk, put snow blower and shovel in shed
  10. Purpose: To introduce the team members to the red tag and describe its uses. Main Points: 1 red tag should be attached to all unnecessary items. Categorize each item by writing the appropriate number in the first square Note that all items tagged do not need to be discarded as can be seen under the category disposal method. Some groups are setting up red tag storage sites to move all questionable items to until a decision can be made regarding their use.
  11. Purpose : To show that all items which are needed should have a visually designated place based on their frequency of use. Main Points: Items used frequently should be located at point of use (OK to move your arms but not your legs) Items should be stored so that they are easily identified and accessible everything should have a home so that it is returned to the exact same place each time Floor markings to designate different areas and markings on tables to help unneeded items standout
  12. Purpose: To show examples of Straighten. Main Points: - Photograph of Maintenance Dept. tool storage at El Paso Plant 111 (Lear Electrical & Electronics Division). - They eliminated separate tool boxes for associates. - Results in reduced cost.
  13. Purpose: To show examples of Straighten. Main Points: Photographs of raw material storage.
  14. Purpose: To show examples of “Shine” Main Points: - Availability of cleaning supplies make the 5S process easier.
  15. Purpose: 3rd S is shine. Work areas should be cleaned, people should have the same attitude as they do to keep their homes or yards clean and neat Main Points: Clean dirt and grime off of tables, workstations, floors By cleaning things you are forced to touch them and this becomes a form of inspection, such as detecting loose bolts or broken hydraulic lines Cleaned maintained equipment will retain its value and perform better People will take more pride in working in cleaner conditions
  16. Purpose: To show examples of Shine Main Points: - Dust covers prevent tools from getting dusty and potentially causing quality problems.
  17. Purpose: To show examples of “Shine” Main Points: - Notice that the floors, walls, and ceilings are clean.
  18. Purpose: The 4th S is standardize. Maintain and monitor the first 3 S’s Main Points: While the first 3 S’s are activities, the 4th S is a state or condition which one strives for This will determine whether any improvements made in the first 3 S’s will be maintained or if it was just a one time improvement to impress visitors Begin by assigning responsibilities for doing 3S, unless everyone knows exactly what they are responsible for doing and when, where, and how to do it, 3S has little meaning Set aside a certain time, minimal (term 5 minute 5S is a loose one) to do 5S each day to make it habitual Evaluate how well the 3 S’s are being maintained using 5 point checklists To take standardize to a higher level, we must ask why do unneeded items accumulate (despite 1st S), why do tools not get put back (despite 2nd S), why do floors get dirty (despite 3rd S). Preventative sorting prevents unneeded items from being brought into the work areas in the first place, only allow what is needed to be brought in, consistent with JIT. If you don’t bring in 4 months worth of supplies, then you don’t have to find a place for them. Preventative straightening; eliminate need for tool, suspension (tool hangs from elastic cord), incorporation where tool remains a part of the work station Preventative cleaning; prevent dirt from getting on the floor
  19. Purpose: To describe how to Standardize the 5S Main Points: - Establishing a schedule and standards for maintaining the area’s Sort, Straighten and Shine to maintain a quality workplace. - Need to schedule time and resources for 5S activity - Creating a model work area to demonstrate the 5S philosophy is helpful - Utilize standard 5S check sheets/audit sheets - Perform regularly scheduled audits - It helps to get management involved - Make sure all associates understand the 5S’ Other helpful tips: Post Schedule Post Rating Standard Cell Level Boards Management walk-arounds Training Scheduling time and resources for 5S activity Check sheets
  20. Purpose: To describe how to Standardize the 5S Main Points: - Leader’s should make sure 5S becomes part of normal work activities.
  21. Purpose: To show an example of a cell 5S assignment board. Main points: This board is currently being used in some of the cells. Everyone knows when and who is responsible for sweeping up the work area each day With clear responsibilities, cleanup has a greater chance of sticking
  22. Purpose: To show an example of a quick 5 point check for the 1st S Main Points: This quick checklist will make it easy to monitor how well the 1st S is being maintained
  23. Purpose: To show an example of a quick 5 point check for the 2nd S Main Points: This quick checklist will make it easy to monitor how well the 2nd S is being maintained
  24. Purpose: To show an example of a quick 5 point check for the 3rd S Main Points: This quick checklist will make it easy to monitor how well the 3rd S is being maintained
  25. Purpose: To suggest methods to ensure improvements are sustained Main Points: -Charting improvements provides a visual record of progress - You should also capture action items, responsibility, and assign dates to complete the action items.
  26. Purpose: To show the 5th S, sustain or self discipline Main Points: Begins with training so people understand the meaning and importance of 5 S Workers buy-in and agree to support 5S activities Once 5S is implemented and people continue to do it, it becomes a habit like brushing your teeth every morning Management supports people who are performing 5S activities, and insures that people are following agreed upon procedures (e.g. putting tools back in their proper location) Teaching Tip: Ask the class for some examples of how managers or supervisors could support 5S
  27. Purpose: To describe “Sustain” Main Points: Practicing New 5S as a way of life, establishing and following rules and initiating improvements daily. This is the most challenging “S” Associate spirit will improve with sustained 5S process. Periodic reviews reinforce commitment to 5S. Management commitment is important. Make 5S a way of life, but also look to improve. Benefits: Quality mindset Early warning system Continuous improvement Teaching Tips: Ask: What challenges have you encountered in trying to sustain other initiatives in your area? What works for you? Against you? Which of these aspects seems most challenging to you?
  28. Purpose: To show an example of daily activities to help Sustain a 5S culture Main Points: This PM checklist is located at the Grinder/Polisher workstation in the Materials Engineering Lab at the Philippine Engineering and Technology Center. There are 8 tasks that the operator is responsible for completing on a daily basis. Note the blue sticker on the power head. The sticker bears the name of the owner of the equipment. The number sticker corresponds to the criticality/classification of the equipment to the lab. On a scale of 1-3, or A-C, the grinder/polisher this is a 2. Teaching Tips: Ask:
  29. Purpose: To show an example of a visual tool which displays people’s status, a Skills Matrix Chart. Main Points: This chart tells everyone in the cell exactly who is capable of doing what and what their strengths and weaknesses are. Note that names don’t necessarily have to be on the chart. It can be looked at from an overall perspective of where the cell is lacking and could use improvements .
  30. Purpose: To show an example of a visual tool which displays people’s status, a Skills Matrix Chart. Main Points: This chart tells everyone in the cell exactly who is capable of doing what and what their strengths and weaknesses are. Note that names don’t necessarily have to be on the chart. It can be looked at from an overall perspective of where the cell is lacking and could use improvements .
  31. Purpose: To show an example of a visual tool which displays people’s status, a Skills Matrix Chart. Main Points: This chart tells everyone in the cell exactly who is capable of doing what and what their strengths and weaknesses are. Note that names don’t necessarily have to be on the chart. It can be looked at from an overall perspective of where the cell is lacking and could use improvements .
  32. Purpose: To suggest methods to ensure improvements are sustained Main Points: This photo shows management performing a 5S review.
  33. Purpose: To get discussion going about status of 5S at the different Lear facilities Main Points: We must realize that we cannot implement 5S and walk away. If we don’t keep it alive with periodic reviews we will loose it just as we have in the past.
  34. Purpose : To discuss the differences between Visual Displays (displaying reports) and Visual Controls (displaying information needed to perform work well, produce quality products, etc.). Main Points : Slide is self-explanatory.
  35. Purpose: To explain what should be included in visual controls. Main Point: Shown are two different examples of Operator Process Control (OPC) Boards. Current process/product operating data is posted on the boards. This information includes: Machine downtime Scrap Takt Time 5S rating Production volume Process flow charts Teaching Tips: Ask: What type of information is displayed in your facility?
  36. Purpose: To offer suggestions on how to make machine status more visual. Main points: By posting theses times by the machine, the operator can see what is expected and what they must strive for in order to reach World Class Status. Also, if your set-up is slower than it was previously you will know it. Now you can find and eliminate the cause of the slower set-up time.
  37. Purpose: An example of a performance trend of the equipment within a cell. Main points: This particular chart shows downtime of a particular area or machine. We can see if we are improving or what needs improvements.
  38. Purpose: An example of a performance trend of the equipment within a cell. Main Points:
  39. Purpose: To give an example of a team member board on display. Note the mission or purpose is also displayed on the board. Main points: This tool lets the workers in the cell and even outside workers and visitors know who works on that team and what their primary function is.
  40. Purpose: To show an example of what a Stand. Work Comb. Sheet looks like and what the info. on it tells us. Main point: This worksheet graphically shows us what the persons operation loads are, what the steps are, and whether or not they are within Takt time. This chart gives us a lot of information at just one glance and tells someone if they are going to be able to meet their production requirements.
  41. Purpose: To illustrate a poor method of storing products. Main point: Can the audience tell you what is wrong with this method of storage? -boxes not clearly marked -boxes stored to high (cant see what’s in them or the quantity left) -boxes too big (hard to move without another person or equipment)
  42. Purpose: To give an example of what a good product storage method looks like Main point: What is better about this method of storage? -boxes clearly marked (even color coded) -boxes small enough to be moved easily by one person alone -shelves are slanted to slide down next part or product when one is removed -inventory line in use (tells us when the stock is low and needs replenishment) -boxes aren’t stored too high (can see the contents and quantity left)
  43. Purpose: Main Points:
  44. Purpose: To show what a Standard Work Sheet looks like and to explain how it can help make a factory more visual. Main Points: This visually shows where all the WIP should be. By looking at the cell and your Standard Work Sheet one can tell if something is wrong (example-too much inventory or materials by a machine).
  45. Purpose : To describe some tools and methods that can be used to implement visual management. Main Points : Slides are self-explanatory.
  46. Purpose : To describe some tools and methods that can be used to implement visual management. Main Points : Slides are self-explanatory.
  47. Purpose : To describe some tools and methods that can be used to implement visual management. Main Points : Slides are self-explanatory.
  48. Purpose : To describe some tools and methods that can be used to implement visual management. Main Points : Slides are self-explanatory.
  49. Purpose : To describe some tools and methods that can be used to implement visual management. Main Points : Error Prevention Board - Display acceptance criteria, boundary alerts, etc.
  50. Purpose: To show other ways to use visual controls. Main Points: Work instructions, including photos and instructions, are mounted on a jig board so that the operator can clearly see how to assemble a wire harness. Teaching Tips:
  51. Purpose: To show other ways to use visual controls. Main Points: Safety instructions for a hand terminal press machine have been laminated and mounted at the workstation. Lubricant and gage levels are clearly marked on this machine. The numbers correspond to a daily TPM checklist item that the operator is responsible for checking. Teaching Tips:
  52. Purpose: To show other ways to use visual controls. Main Points: When the white lines are lined up, then the nut has been tightened to the right point. Teaching Tips:
  53. Purpose: To show another example of Visual Controls - War Room in the Iowa City plant. Main Points: A “War Room” is a room where all manner of current production or operating data is posted. The room is used for daily Accountability Meetings. The type of information posted: EH&S and Ergonomics Ergonomics Production scoreboards (pieces per hour, downtime, financial forecast, action plans) Shipping (number of shipments, under shipments, number of trucks, problem loads, problems caught by shipper) Injection Mold Change activity Manufacturing Operational Charts (sales, efficiency, indirect labor, overtime, scrap, supply spending) “ The Cell Leaders are the center of our universe.” Steve Lahey - Quality Manager
  54. Purpose : To review some lessons learned. Main Points : Slide is self-explanatory.
  55. Purpose: Provide the participants with an agenda of tasks to be performed during a 5S COMPASS session. Main Points: Teaching Tips: Ask:
  56. Purpose: Provide the participants with an agenda of tasks to be performed during a 5S COMPASS session. Main Points: Teaching Tips: Ask: