5S and Visual Factory

Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams

Contents
Introduction Background and History Components and Implementation Knowledge Check

2007 Superfactory. All Rights Reserved.

Introduction
5S is a method to improve and sustain workplace organization 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). These are foundational to continual improvement and a manufacturing strategy based on "Lean Manufacturing" (waste removing) concepts. Reduces clutter Reduces the time it takes to look for tools and equipment A place for everything and everything in its place Improves how the operation appears to customers always be tour ready Creates pride in the workplace Many companies have a standard that any tool must be able to be found within 60 seconds.

2007 Superfactory. All Rights Reserved.

Components and Implementation

5S and Lean Manufacturing Elements of 5S
Sort Straighten Shine Standardize Sustain Safety

Visual Factory

Implementation plan

2007 Superfactory. All Rights Reserved.

Elements of 5S
Sort Straighten Shine
Remove all unnecessary materials and equipment Make it obvious where things belong Clean everything, inside and out

Standardize
Sustain
Establish policies and procedures to ensure 5S Training, daily activities

Safety (often called 6S or 5S + 1)

A safety commitment in all activities
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The Good, Bad and the Ugly

First the Bad and the Ugly - Life Without 5S

2007 Superfactory. All Rights Reserved.

5S Examples Sort and Straighten

See the difference?

Sort - All unneeded tools, parts and supplies are removed from the area Straighten - A place for everything and everything is in its place

2007 Superfactory. All Rights Reserved.

5S Implementation
1. Begin reviewing your areas for 5S 2. Discuss 5S with each of your groups (brief group meeting) 3. Red tag sorting process (one time) 4. Brief, simple daily 5S individual activity (just look around) 5. Brief 5S checklist or procedure for each area 6. Monthly 5S audit beginning __________
Area Lead plus at least one person from outside that area Post results (I will look for them!) Review results with your group Take corrective action
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Red Tag Process

One-time activity to remove or disposition clutter To be started within two weeks of this training 1. Identify clutter, unused equipment, etc 2. Fill out and attach red tag

3. Note in red tag log

4. Red tags must be dispositioned within 30 days

2007 Superfactory. All Rights Reserved.