Shop floor 5's

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BoonevilleACCO Brands

Lean Training

5’SAugust 2010

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Lean Training Lesson 1 5’s

5’S

THE ART OF ORGANIZATION

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Lean Training Lesson 1 Lean Training Lesson 1

Objectives What is 5’S Why 5’s Sort Set in Order Shine Standardize Sustain Why 5’s

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Lean Training Lesson 1 5’s Lean Training Lesson 1 5’s

What is 5’S? The first and most critical step in Lean The Boot Camp of Lean Manufacturing A Team that is not strong enough to sustain the 5’s

culture will not be able to sustain the Lean Culture We use a lot of the 5’s disciplines at home. A consistent way of doing business Eliminates process Variation Support consistent process flow Reduces defects

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Why does the Military have Boot Camp?

• Discipline• Cleanliness• Team Building• A place for everything• Removes those who do not want to be a

member of the team• Roles and responsibilities Everyone contributes• Prepares you to do the job• One fails everyone fails

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Things too commonly heard on the shop floor

• It’s not my job

• They know what to do,

They just won’t do it

• If this does not work out I will just go somewhere else

• I get paid either way

• I keep busy

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Training Lesson 1 5’s Lean Training Lesson 1 5’s

Why 5’s How much time a day do you spend looking for tools? How much time a day to you spend looking for parts? How much time a day do you spend looking for paper

work, cleaning supplies? How much time a day do you spend re arranging your

work cell? How much time do you spend walking around boxes,

skids, carts etc,.? How much time do you spend double or triple handling

parts?

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Training Lesson 1 5’s Lean Training Lesson 1 5’s

Cost of Searching• Employees spend an average of 36 minutes per

day searching for essential items• Searching requires energy and causes mental

stress• A clear work area means a clear mind• A clear mind allows you to focus on the quality of

the work at hand• Remember the more you keep, the harder it is to

find what you really need.

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Current 5’s1. Shove

2. Stuff

3. Stash

4. Store

5. Stage

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WHAT A

5’S PLAN

SHOULD BE

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Sort Removing the unnecessary items Only have on line what is needed No personnel items online Anything in question red tag All broken tools removed Unneeded shelves and carts removed Inventory and document tools and parts needed on line

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Set In Order Arrange items in a way they are easy to find

Arrange items so they are point of use

Footprint items so anyone can find them

Label items so everyone knows what they are / where they go

Foot print all carts pallet jacks, cleaning stations, tools, part bins, etc.,

Footprint / label parts so presentation is the same every time

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Shine Dust, sweep, Mop Safety Able to spot oil leaks Better PM Changing filters healthier environment Clean environment is a healthier Happier environment Clean environment / Better Quality

Brighter environment makes it easier to spot defects.


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STANDARDIZEDecide who owns it and who is responsible

Footprint

Train and sign off

Label

Preventative Maintenance

Delivery of parts

Everyone is assigned a role and duties

Roles and duties are communicated and posted

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SUSTAIN Implement Score card Make it tangible Assign responsibilities Owners are accountable Implement corrective actions Implement Metrics to measure C/A effectivity Audit / Publish / Reward (APB)

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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5’s What is wrong

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Who does it well

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Why 5’s• Without 5’s the work in a cell can not be performed the same way by every one all the

time• When everyone is not doing the work the same way all the time you have

VARIATION. (Variation leads to quality issues)• When everyone is not doing the same work the same way you do not have accurate

time studies because the work will take different amount s of time.• If work takes different amounts of time you do not know how much work that cell can

produce• If you do not know how much work that cell can produce you do not know how much

work to schedule in that cell• If you do not know how much work to schedule in that cell you may over schedule

and lead to Overtime• If you do not do the work consistently in that cell you do not know where the waste is• If you do not know where the waste is you can not improve the efficiency of that cell.• All improvement begins with Standard work and understanding the work in that cell• All Standard works begins with 5’s

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5’s Expectations• Everything will be in the footprint (not Just Close).• Only materials for the current job being run will be on line.• No extra parts will be kept on line• All tools will be put away• There will not be more than 1/2 hour of cartons made up• There will not be more than 1/2 hour cartons pre labeled• We will learned to perform work in the same manner including the

set ups.• Everyone will participate equally in the set up• Housekeeping list will be completed daily.• No one shall leave the line to go home until all Housekeeping is

complete• In the beginning Management shall audit the cell for conformance

Cell team will be responsible for a Corrective action for each Non conformance

• Same Corrective action may not be used twice

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Questions

Education

Shop floor 5's