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This document discusses various Lean games and tools including 5S and time studies. It provides information on 5S principles of Sort, Set In Order, Shine, Standardize, and Sustain and describes levels of achievement for each. It also outlines the basic steps for conducting a time study including selecting a process to study, recording details, breaking work into elements, measuring times, and rating performance. Finally, it gives examples of applying time studies and 5S tools to a torch factory and plug factory, listing the specific activities and procedures involved.
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Lean Games that easily communicate the importance of Lean to staffs
This document discusses various Lean games and tools including 5S and time studies. It provides information on 5S principles of Sort, Set In Order, Shine, Standardize, and Sustain and describes levels of achievement for each. It also outlines the basic steps for conducting a time study including selecting a process to study, recording details, breaking work into elements, measuring times, and rating performance. Finally, it gives examples of applying time studies and 5S tools to a torch factory and plug factory, listing the specific activities and procedures involved.
This document discusses various Lean games and tools including 5S and time studies. It provides information on 5S principles of Sort, Set In Order, Shine, Standardize, and Sustain and describes levels of achievement for each. It also outlines the basic steps for conducting a time study including selecting a process to study, recording details, breaking work into elements, measuring times, and rating performance. Finally, it gives examples of applying time studies and 5S tools to a torch factory and plug factory, listing the specific activities and procedures involved.
Game Names 5s study with an puzzle game Time study & Lean Analysis of Torch Factory Application Time and Motion Study using Plug Factory 5 S Puzzle Game WHAT IS 5S ?
5S is a Japanese concept using five simple steps to create a conducive work atmosphere.
5S is a series of techniques that provide the foundation for a visual management system
5S - To create least waste way to deliver value to the customers 5S IS A WAY OF LIFE JAPANESE TERMS ON 5S
SEIRI OR SORT
SEITON OR SET IN ORDER
SEISO OR SHINE
SEIKETSU OR STANDARDIZE
SHITSUKE OR SUSTAIN
WHAT IS 5S ? 5S 5S IS A WAY OF LIFE Level Sort Identify & eliminate what is not needed 1 2 3 4 5 Necessary and unnecessary items are mixed together in the work area. Necessary and unnecessary items are separated (excess inventory, Obsolete tools & Equip) All unnecessary items have been removed from the work area. Documented method to maintain work area free of unnecessary items. Waste is immediately visible and triggers a planned response with root cause analysis and corrective action. Sort Levels of Achievement 5S IS A WAY OF LIFE Level Set in Order A place for everything and everything in its place 1 2 3 4 5 Documented method of visual sweep to identify items out of place or exceeding quantity limits. Defined process to evaluate and improve movement and motion. Tools, supplies and materials are randomly located. Designated location established for all items as needed. Designated locations are marked to make organization more visible (color, outlines, labels, numbers, etc).
Set In Order Levels of Achievement 5S IS A WAY OF LIFE
Shine Levels of Achievement Level Shine An effective, organized environment 1 2 3 4 5 No visuals are in place. Work/break areas and machinery are dirty and disorganized. Visual display of data. Work/break areas and machinery are cleaned on a regularly scheduled basis. Visual controls are in place. Machines are cleaned daily. Customers/suppliers are identified and value defined. Real time metrics and visual management are in place. Preventative maintenance is implemented. Abnormal is immediately visible and triggers a planned response with root cause analysis and corrective action. 5S IS A WAY OF LIFE
Standardize Levels of Achievement Level Standardize Develop standards and stick to them 1 2 3 4 5 No attempt is being made to document or improve current processes. Current process is known, but not documented. Current state is documented as Standard Work performed the same by all employees. Future state is documented. Implementation plan is actively worked. Area metrics are linked to OpEx metrics. Improvements are based on data and tracked for actual results. 5S IS A WAY OF LIFE
Sustain Levels of Achievement Level Sustain 5S is a way of life 1 2 3 4 5 Documented methods (Red Book) have been put into place to ensure adherence to 5S. Employees continually seek improvement opportunities. Minimal attention is spent on 5S. 5S is a scheduled event. 5S practices are evaluated on a regular basis. Procedure Observe the items Observe the Output in the figure Keep the respective essential items near by hand. Make it with less utilization of time Make sure the output is done correctly
Output Time study & Lean Assessment using Torch Factory Application Basic Steps in Time Study Select the work/method/operation/process to be studied Obtain and record the details about the operations and the operator being studied Breakdown the work into suitable elements Measure the time for each element and hence the time for the work cycle Simultaneously rate the operator performance.
Activities in Torch Factory Take the lower part of the torch. Insert the batteries and the black ring. Place the upper part in the floor. Take the upper part and place the glass. Insert the bulb holder and put the bulb. Cover the bulb with the steel ring. Put the cover for the bulb and complete the upper part. Insert the upper part with the lower part . check for the working of the torch. Time & Motion Study Using Plug Factory Procedure Taking lower cap Taking black cord grip and placing in slot Taking screw 1 and putting in hole Take Screw Driver Fixing screw 1 Putting screw driver on the table Taking Screw 2 and putting in hole Taking screw driver again Fixing screw 2 Putting screw driver on the table again Taking blue pin and putting in slot
Talking brown pin(fuse Holder) and putting in slot Taking fuse holder and inserting in the slot Taking fuse and fixing with the fuse holders Taking the top covers and placing Taking screw driver to fix the top cover Screwing the top cover Putting the screw driver on the table Placing the assembled 3 pin plug in the tray