Creating World Class Organization Through 5S and Visual Management @ 3rd Annual Lean Conference, 2015 @ AMA Ahmedabad
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This presentation was presented @ 3rd Annual Lean Conference, 2015 @ AMA Ahmedabad
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Creating World Class Organization Through 5S and Visual Management @ 3rd Annual Lean Conference, 2015 @ AMA Ahmedabad
- 1. Presentation Title: Creating World Class Organization through 5S & Visual Management Presented on 2nd Feb 2015 @ 3rd Annual Lean Conference, AMA, Ahmedabad
- 2. Creating World Class Organizations Through 5S & Visual Management
- 3. 5S is a set of steps to create a more productive workshop
- 4. 5 Step to reduce or eliminate waste • Searching • Waiting • Wandering • Wondering • Delays • Extras • Waste/Scrap 8 Type of Waste Transportation Motion Waiting Inventory Over processing Rejection Over production Human Potential
- 5. × Cleaning and janitorial work to satisfy management. × Imposing standards at workplace. × Silver bullet to productivity gains. Foundation to achieve employee engagement , waste reduction, improve workflow, and safety. Empower workforce. There will not be immediate influx of ROI when you implement 5S, but it trickles down slowly, in different forms & ways. “There is not an end, it’s a journey”
- 6. 5S Pictures
- 7. 5S Pictures
- 8. 5S Pictures
- 9. s 1st S - SEIRI Sorting Out
- 10. 1. Touch everything 2. Evaluate everything with a standard set of decision making rules 3. Tag it 4. Set tagged items in tag area 5. Record all items in a Red tag Register Remove all unessential items from the workplace
- 11. Tools Red Tag Red Tag Register Red Tag Area
- 13. • Identify a home for everything that will be easy to find and put away (PEEP) • List everything that’s left from sorting step • Create a master list of everything include as much in formation on it as possible • Agree on a location for these items, 1. How to keep them, 2. How many to keep, 3. Use Visuals to locate them 2nd S: Set in Order
- 15. s 3rd S - SEISO Spic and Span
- 16. • Keep everything in top condition. So, when someone need something, it's ready • Designate areas of space to different person • Remove unnecessary items • Sweep & wipe down with tools Shine
- 17. Example of Seiso
- 19. • Take the pictures • Create a map of that locates where everything is stored • 5S team maintains a job list and schedule 5S activities Establish Visuals for everyone to maintain the condition
- 22. • Clear deliverables & communication • Score Keeping • Continuous improvement with cyclic mini-5S events Tools: • Training and Awareness of 5S • Dedicated 5S team • Clear 5S Map and Responsibilities/Ownership You are setting the standards to what you must live by
- 23. 5S Benefits to Customer & Employees Customer • Win customer confidence by bringing them to factory • Delight the Customer • Customers always expect lower price. 5S is one way to make it possible • Faster Response to queries/ requests • Improves on time delivery • Higher demands are met Employees • Improve employee involvement • Lower Absenteeism • Build Employee pride • Working smarter not harder • Higher employee Satisfaction
- 24. 5S Benefits – Improves, Reduces Improves • Productivity • Quality • Process Reliability • Work Standardization • Work Culture • Daily & Shift Start Times • Simplified work Environment • Profitability & Efficiency by reducing time wasted looking for tools and Equipment • Safety Reduces • Transportations • Cost • Machine Down time • Changeover Time • Lead Time • Waste • Inventory • Rejects/ Rework • Breakdowns • Waste in materials, Space & Time
- 25. How to implement 5S Define Scope • Where?-Identify where exactly boundary starts and ends • Who?- Define the 5S team and participants with the visuals
- 26. • What?- Define the 5S job responsibility with required resources? • When?-Settle down a plan for 5S activities with targetdates and checklist for routine How to implement 5S Define Scope
- 27. How to implement 5S ? Collect Baseline Data • Use pictures of Before and After (Inside - outside, Above-under)
- 28. • Time Study • Cost & Quality of Inventory How to implement 5S Spaghetti Diagram Floor Plan Usage Use Data
- 29. 5S - SEITON
- 30. 5S-SEITON
- 31. 5S - SEITON
- 32. Thank You