PERFORMANCE
EXCELLENCE
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What is 5S ?
■ An essential step required for Waste Elimination
Systematic
Organization Orderliness Cleanliness Cleanup
Cleanup
Standardization/Perseverance
“Shitsuke”
■ An integral step in Kaizen
■ A required element to achieve Lean-site Manufacturing.
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5S Performance Excellence Model
Systematic-Systematic
Organization
Improved Quality
Customer Expectations Improved Safety
Reduced costs
Consistent Deliveries
Improved Product/ Service
Standardizing Options
Control
Self-Discipline-
Control
Sorting Visual
Placement
Scrubbing clean
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The Five Elements of 5S
Self-Discipline/Control- Systematic Systematic
Ensuring that Systematic Organization- Identifying what
Organization, Visual items are required and which
Placement & Cleanliness are not.
are maintained.
Standardizing Control-
Maintain and continually
improve the previous
improvements.
Sorting Visual Placement-
Items should be easily
Scrubbing Clean-Keep the area free from debris, retrievable, easy to get, and
dirt, oil, items not needed. visual-easy to see.
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Expanding the Strategy
Performance Excellence
6 Sigma Kaizen
• Disciplined Methodology • Philosophical Approach
• Technical Approach • Common Sense Approach
(Quantitative) (Qualitative)
• Data Driven - Statistical • Data Driven - Observation
• Customer Focus • Operational Focus
• Reduce Variation • Waste Elimination 5S
• Focus on Large Impact • Incremental Change
• Larger/Longer Projects • Smaller/Shorter Projects
Complimentary
Complimentary Tools
Tools Driving
Driving Continuous
Continuous Improvement
Improvement
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Comparative Analysis
6σ Improvement Methodologies Kaizen/Lean
• Similar in Structure
Measure Evaluate
- Data Collection • Improvements measured against - Baseline Process Performance
- Determine Process Potential / Goals established process - Establish Target
• Team oriented
Evaluate Decide
- Root Cause / Vital Few -Compare solutions
- Statistical Analysis - Choose
• Similar improvement tools
Improve & Verify • Measure effectiveness of improvements Act
- Implement Improvement • Maintain new performance level -Communicate
- Validate Improvement • Standardize & Proceduralize - Implement improvement
- Control
Standardize
- Standardize / Leverage Measure
- SPC Results - Validate improvement
- Update Procedures • More Efficient Processes - Standardize
- Update Procedures
Focus
- Reduce Process Variation Focus
- Identify Critical Cause and Focus Comparison - Eliminate Waste 5S
Resources for Maximum Impact • Both are Effective Improvement - Seek Incremental Process Changes
Mechanisms
• CPI/6s best applied to large complex Summary
Summary
- Common Sense Approach based on
- Technical Approach based on Statistical problems Observation
Analysis • Kaizen/Lean best applied to achieve - Applicable to all types of processes
- Requires Significant Data Collection
- Best applied to Manufacturing Processes
incremental changes and eliminate wastes. - Defined improvement strategy
- Typical Projects 1 week
- Typical Projects 1-3 Months
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Why 5S
Look Familiar ?
■ Overproduction
9 ■ Delays (waiting time)
Wastes
■ Transportation
■ Process
■ Inventories
■ Motions
■ Defective products
■ Untapped Resources
■ Mis-used Resources
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Think Break
The Nine types of wastes
Give an example of each type of waste.
■ Overproduction ______________________________ 9
■ Delays (waiting time)__________________________ Wastes
■ Transportation _______________________________
■ Process_____________________________________
■ Inventories__________________________________
■ Motions ____________________________________
■ Defective products ____________________________
■ Untapped Resources __________________________
■ Mis-used Resources ___________________________
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Elimination of Waste
5 S Element Waste/ Improvement Item Deliverable
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5S
Implementation
Plan
Systematic
Organization Progressive
Standardization
Enhancements
Cleanliness
Visual Placement
Step 6
Verification of Effectiveness
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Removing “Red Tagged” stuff
What Stuff would you “Red Tag” in these pictures ?
Think Break
Picture A__________________________________________________________
Picture B _________________________________________________________
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Think Break
In the following pictures, identify some of the “finding wastes “ ( assume you work in a
distribution center and you have to fill an order with product located in the following
pictures).
Finding Wastes
___________________ ___________________ _________________
___________________ ___________________ _________________
___________________ ___________________ _________________
___________________ ___________________ _________________
Everything has a useable place
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Some evidence of standardized work areas
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Visual Color System Implementation
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Cleanliness involves cleaning every aspect of
the Organization and the removal of dirt,
dust,oil, scraps on the floor, & garbage.
Key Deliverables
Increased
Efficiency
Increased
Safety
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Measurem ent
Im provem ent 5S
Tem plate
Identify w aste
9 Waste Radar Chart
% of Waste Before 5S
% of Waste After 5S
n oit at r o p s n a r T
s s e c or P n oit c u d o r p r e v O
001
09
08
07
06
05
04
03 d e p p at n U
02 s e cr u o s e R
01
0
s y al e D
y r ot n e v nI
d e s u - si M n oi t o M
s e cr u o s e R
t c u d o r P e vit c ef e D
The Nine Wastes
O ve rp ro d u ctio n D e la ys T ra n s p o rta tio n In ve n to ry M o tio n P ro c e s se s D e fe c tiv e U n ta p p e d M is - U s e d
P ro d u c ts R e s o u rc e s R e s o u rc e s
100
90
80
% of Wasteof Waste
70
60
Percentage
50
40
30
20
10