Upload
hussain-al-ahmed
View
34
Download
3
Embed Size (px)
DESCRIPTION
A presentation about 5S which is one of the basic lean six sigma principles. This presentation can be used to kick off 5S activities. 5S Stands for:1. Sort2. Set-in-Order3. Shine4. Standardize5. Sustain
Citation preview
7/17/2019 5S Workplace Organization: A lean transformation tool
1/32
www.zulfadev.com 2015 Zulfa Managment Consulting. All Rights Reserved.
Zulfa Management Consulting
To get closer
www.zulfadev.com
@zulfa.team @zulfateam
[email protected]+966 59 084 2622
Hussain Yasin Al Ahmed
Management Consultant
@hussain_alahmed
@hyahmed
7/17/2019 5S Workplace Organization: A lean transformation tool
2/32
Imagine: A fire fighter with
a broken water hose
2
7/17/2019 5S Workplace Organization: A lean transformation tool
3/32
or a surgeon with
dirty instruments
3
7/17/2019 5S Workplace Organization: A lean transformation tool
4/32
or an
astronautwho
forgot the
hand tools on
earth
4
7/17/2019 5S Workplace Organization: A lean transformation tool
5/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
ImageIt makes the place organizedand always ready for client
or executives visits
5SOverview and Benefits
A method to improve and sustain workplace organization.
One of the basic stones for successful lean transformation.
It applies to every industry and every job function.
TimeIt saves precious time lookingfor material, tools, equipment
or information and increases
overall efficiency
PrideIt makes employees proudof their workplace and
willing to show it to others
HSEA clean and ergonomicallyorganized workplace is more
healthier and much safer for
employees and visitors
5
7/17/2019 5S Workplace Organization: A lean transformation tool
6/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
5SWorkplace Organization
Sort
Clearly distinguishwhat is needed,
what should be kept
and what should be
thrown out.
When in doubt,
move it out
Set in Order
Organize thenecessary things
making it easier for
anynone to find and
use them.
A place for
everthing and
everthing in itsplace
Shine
Clean equipmentand workplace
requrlay. Paint them
as needed and
inspect them whilecleaning.
A clean place is
safer and more
productive
Standardize
Develop standardsfor sorting, setting in
order and shining.
Enforce them and
follow up.
The seceret of
success is
consistency ofpurpose
Sustain
Make it a daily habitand a way of life
through discipline,
auditing and
recognition.
Motivation is what
gets you started,
habit is what keepsyou going
6
7/17/2019 5S Workplace Organization: A lean transformation tool
7/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
SortRed tagging
Define a Red Tag Team and a leaderand train them on 5S
Seperate the unneededitems from theneeded ones
Attach a red tag to the uneeded items
Move them to a temporaryholding area
Set the time to hold in temporary area
Review the items after the defined time
Give away, sell or throw the remainingitems
1
2
3
4
5
6
7
Red Tag Temporary Holding Areas
Red Tags
7
7/17/2019 5S Workplace Organization: A lean transformation tool
8/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
How often is it used? What to do with it?
Never Give, sell or throw away
Once or twice a year Store in a distant place
Once a month Store near your work area
Once a week Store near the the workstation
Once a day or more Keep near you or your workstation
SortIf in doubt, throw it out
NoUnused
NoDuplicates
NoUncessary !NoJust-in-Case
8
7/17/2019 5S Workplace Organization: A lean transformation tool
9/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
Set in OrderA simple exercise
Focuson the next slide for 5 seconds
9
7/17/2019 5S Workplace Organization: A lean transformation tool
10/32
12345
7/17/2019 5S Workplace Organization: A lean transformation tool
11/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
Set in OrderA simple exercise
Nowon the next slide, tell us
what was removed?
11
7/17/2019 5S Workplace Organization: A lean transformation tool
12/32
12
7/17/2019 5S Workplace Organization: A lean transformation tool
13/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
Set in OrderA place for everything, and everything in its placeWhats missing from this tool kit?
13
7/17/2019 5S Workplace Organization: A lean transformation tool
14/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
Set in Order
If it moves, it needs a home
Organize whats left after sorting.
Physically reconfigurethe area.
Make it visualand self explanatory.
Make everything easy to findand return.
Label and mark locations of movable items.
Color-code items based on location or use.
Build racks, shelves or shadow boards.
Try new ideas and be creative.
14
7/17/2019 5S Workplace Organization: A lean transformation tool
15/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
ShineA clean place is safer and more productive
Promotes SafetyDetecting and removing
sources of danger such asliquid spills, tripping
hazards, and biological
infections.
Quality InspectionHelps in checking for non
standard conditions suchas leaks, cracks and wear.
Reputation
Customers will trust peoplewho keep thier workplace
clean and organized more
than those who dont.
Improves MoralTeam members becomehappier in a clean workplace
and closer to managment
when managers are
involved in 5S.
15
7/17/2019 5S Workplace Organization: A lean transformation tool
16/32
Before 5S
Photo Credit: Hussain Al-Ahmed 16
7/17/2019 5S Workplace Organization: A lean transformation tool
17/32
After 5S
Photo Credit: Hussain Al-Ahmed 17
7/17/2019 5S Workplace Organization: A lean transformation tool
18/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
ShineGuidelines
Togethercleanthe entire area
Assign rolesandresponsibilities
Repairleaks
Tag what youcant repair
Plan propercollection method
Disposecorrectly
Paint or retouch
Provide propercleaning tools
Think of ideastominimize dirt
18
7/17/2019 5S Workplace Organization: A lean transformation tool
19/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
StandardizeThe key to success is consistency of purpose
Sorting
Setting inOrder
Shining
Visual ManagementMaking the place self-explenatory through signs, labels, colors and marks.
Continuous Improvement
Keeping the ball of improvement rolling and keep changing for better.
Utilizing TalentWhen there is a standard, it becomes easier to choose non critical things such ascolors, material, brand, etc.
SustainingClear and simple instructions help making it easier for members to keep the placeorganized and tidy.
TrainingNew members will learn faster and will get invloved immidately.
Best PracticesRecognition and knowledge sharing helps in finding best practices and adopting them.
19
7/17/2019 5S Workplace Organization: A lean transformation tool
20/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
Check this
and this
then that
CHECKLIST
1
2
3
Do this
and this
then that
PROCEDURE
PROCESS
WhichColor?
Whatshould be done and why?
Whenshould it be done and how often?
Howshould it be done and whoshould do it?
Colors, fonts, sizes, shapes, templates, etc.
Develop checklists, procedures and processes.
Remember; the first idea may not be the best one.
Material, brand, model, etc.
Find the best practice and make it a standard.
StandardizeBe consistent but not constant
Try, experiment, explore and innovate.
20
7/17/2019 5S Workplace Organization: A lean transformation tool
21/32
Be consistent, not constant
Photo Credit: Hussain Al-Ahmed
Photo Credit: Hussain Al-Ahmed
7/17/2019 5S Workplace Organization: A lean transformation tool
22/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
SustainHow to keep the improvement ball rolling?
22
Promote 5S
Get people buy-in by getting them involved in shaping the improvement path and recognizingindividual efforts and rewarding for teamwork.
FocusManagement team must lead the 5S efforts, learn the techniques, and participate in practicalactivities.
Simplify WiningCelebrate simple improvements and avoid comparisons between individuals or teams.
Develop MetricsEstablish KPIs and visually display them to create pride through positive competition and asense of achievement.
Walk The TalkGo to the workplace and observe whats happening and help before giving constructivefeedback.
Conduct Audits and ReviewsRegularly conduct assessments for the current state and create and improvement plan.
7/17/2019 5S Workplace Organization: A lean transformation tool
23/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
SustainTools for sustaining: Metrics
23
You Cant Manage
What You Cant Measure
Focus on the important goals only.
Not all goals are as important.
Establish lead measures (KPIs) that
you can act on to achieve the goals.
Lead measures should be directly
relatedto the members of the team.
Have people develop their own lead
measures to create accountability.
Show the measures and the progress
publicly and present them visually.
Simplify or automatethe measurementand data collection process.
Photo Credit: Hussain Al-Ahmed
7/17/2019 5S Workplace Organization: A lean transformation tool
24/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
SustainTools for sustaining: Zone Charting
24
Divide the shop floor or office to areas
and assign people to them.
Clearly show photos of assigned
people in the area.
Members should audittheir areas
regularly and allow others to do so.
Managers should plan to visitdifferent
areas randomlyand give feedback.
Show photos of good work publicly in
displays or meetings.
Dont take disciplinary actions for badscores, but reward good ones.
Everyone is Accountable
Photo Credit: Hussain Al-Ahmed
7/17/2019 5S Workplace Organization: A lean transformation tool
25/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
SustainTools for sustaining: Recognition
25
Reward teams for small and continuous
improvements.
Simple and continuous recognitions
can boost motivation.
You dont have to spend money. An
applause or a thank you note will do.
Supporting new ideas and allowing trial
and error is a form of recognition
Educateemployees in new skills and
provide necessary resources.
Encourage friendly competition andfun challenges.
7/17/2019 5S Workplace Organization: A lean transformation tool
26/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
SustainTools for sustaining: Visual Displays
26
Show progress visually. It can be manual
or digital.
Spend more time analyzing and planning
for improvements than collecting data.
You dont have to spend money. A
simple white board and a marker will do.
Updating the display must be simplean
easy and done in at least in dailybasis
Discuss accountabilitiesin short quick,
routine meetings next to the display.
Be flexible with the format. The teamshould put what really matters to them.
7/17/2019 5S Workplace Organization: A lean transformation tool
27/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
SustainTools for sustaining:Auditing
27
Consistently review progress using
different audit tools.
Preform 5S self assessments and audits
at least weekly by different people.
Simplifyaudits and translate to local
languages.
Auditing should be an opportunity to
discuss barriersto improvement.
Visually present audit results and post
them in the Primary Visual Display (PVD)
Encourage knowledge sharing andcooperation between teams.
0
1
2
3
4
5
Week 1Week2
Week3
Week4
Week5
Week6
Week7
Week8
Week9
Week10
5S Weekly Score
0
1
2
3
4
5
Sort
Set in Order
ShineStandardize
Sustain
Current 5S Audit Score
Sort 3.5
Set inOrder
2.5
Shine 3
Standardize 4
Sustain 2
7/17/2019 5S Workplace Organization: A lean transformation tool
28/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
5STips for successful implementation: Take photos
28
A picure worth a thousand words. Before and afetr pictures help convey the message.
Great tool for reporting progress and training people.
Why Take Photos?
Get a good camera and learn how to use it. Smartphones good for social media and quick sharing,
but not for quality photos.
Make sure its charged and memory is cleared.
Make a home for it. Remember Set in Order.
How To Take Photos?
Take before and after photos from the same angle anduse the same camera if possible.
Capture good practices and lessons learned.
Record activities and use them on event
Store the photos in a common place.
What To Capture?
7/17/2019 5S Workplace Organization: A lean transformation tool
29/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
5STips for successful implementation: Leverage teamwork
29
It divides the work and doubles the success. Helps generating different ideas.
Effective problem solving tool.
The whole is greater than the sum of the parts.
Why Teams?
Effective communication and collaboration. Embracing and encouraging differences.
Doesnt matter who gets the credit.
Understanding the stages of team development.
What is Teamwork?
A Group of people working together to achieve acommon goal in sports, life or at work.
It can be formal or informal.
What is a Team?
1. Forming2. Storming
3. Norming4. Performing
7/17/2019 5S Workplace Organization: A lean transformation tool
30/32
www.zulfadev.com
2015 Zulfa Managment Consulting. All Rights Reserved.
5SCan you recall them?
Sort
Set in OrderShineStandardize
Sustain
30
7/17/2019 5S Workplace Organization: A lean transformation tool
31/32
Coming together is a beginning,
keeping together is progress,
working together is success
- Henry Ford
Photo Credit: Hussain Al-Ahmed
7/17/2019 5S Workplace Organization: A lean transformation tool
32/32
We hope you liked the presentation
Please share, leave a comment and like.
Our goal is to help you achieve your goals.
We strongly believe in supporting localcommunities and charities. We arecommitted to providing help anyway we can.
Zulfa Management Consulting
www.zulfadev.com
@zulfa.team @zulfateam
[email protected]+966 59 084 2622
Let us hear from you