- What is 5S and Why do it?
- 5S Office Example – Training, Targets, Results
- Lean (JIT) Summary (MAAW web site)
- 5S Page (CHU)
- Waste vs Value Added (CHU)
- Visual Controls (CHU)
- SMED (CHU)
Powerpoint file – 5S Basic Training 5S examples and LEAN terms (large file 1.3M – right click to download)
Powerpoint file – web powerpoint LEAN MANUFACTURING: Why It’s Not Easy and How to Make It Work
Wow! With each improvement made, the GEMBA becomes a little brighter as waste (muda) and disorder are reduced. Recent 5S tours have been encouraging. Of course improvement opportunities were spotted and action taken; but for the most apart, we are holding on to improvements you’ve already made during 5S events, etc.
In order to keep improving (TOC step #5), it makes sense to continue follow-ups. This is the “Sustain” step of 5S. . . .and since the people who work with a process know it best, who better to review progress? Therefore, each area has been asked to implement a “5S Tour” at least weekly. Take a good look around…imagine zero waste/zero confusion!
Ten Kaizen Principles
- Get rid of all old assumptions.
- Don’t look for excuses, look for ways to make things happen.
- Say “NO” to the status quo.
- Don’t worry about being perfect – even if you only get it half right ” start NOW!
- It does not cost money to do KAIZEN.
- If something is wrong “Fix it NOW.
- Good ideas flow when the going gets tough.
- Ask “WHY” five times – get to the root cause.
- Look for wisdom from Ten people rather than one.
- Never stop doing KAIZEN.
5S – Sort, Set in Order, Shine, Standardize and Sustain
- Sort – All unneeded tools, parts and supplies are removed for the area
- Set in Order – A place for everything and everything is in its place
- Shine – The area is cleaned as the work is performed
- Standardize – Cleaning and identification methods are consistently applied
- Sustain – 5S is a habit and is continually improved
- 5S Training – More Information on 5S
- (These are really old but useful to see how it is done)
- Maintenance-April 2002
- Maintenance Event Above (before and during pictures)
- Machining-July 2002
- Machining Event Above (during and after pictures)
- Quality Assurance-July 2002
- Quality Assurance (before and after pictures)
- Tool Room-August 2002
- Tool Room (before and after pictures)
- Finishing-September 2002
- Finishing (before and after pictures)
- Stock Room-October 2002
- Plant-Wide 5S Event-December 2002
- Web slide show of the Plant-Wide 5S event on December 2002
- TOC and 5S at work at the Tap and Plug Operation
- Die and Storage Areas-March 2003
- Areas Behind the Building-May 2003
- Mini 5S event of office storage areas-May 2003
- Die Setup Area-June 2003
- Office and Office Storage Areas-March & April 2006
- Die Cast and Finishing – January 2015
ANNUAL 5S Event Schedule-Finishing, Tool Racks, Stockroom, Maintenance, Outside, Millwater, Restrooms, Vibratory, Machining, Tool Room, Quality, Die Casting, Furnace, Shipping and Office
Examples provided by: Texas Die Casting
EXAMPLES OF MUDA (waste)
- (Note: These links are to files in powerpoint)
- Missing paperwork creates muda
- Missing payroll check creates muda
- Providing operator tools increases throughput (TOC & Lean)