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5 Pillars of the
Visual WorkplaceAn introduction to 5 S
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Content
1. The visual workplace vision2. What is 5S?
3. Benefits of 5S
4. Expectations
5. Conclusion
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1. The visual workplace vision
Waste is easily discovered
Zero defect is normal
Standard procedures are clear
Abnormalities are immediately detected
There is nothing extra or unneeded.
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The visual workplace vision
Clean workplaceClean workplace
and easyand easy
recognizable limitsrecognizable limits
Easy access toolingEasy access tooling
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Machine StatusMachine StatusClearClear workinstructionsworkinstructions
The visual workplace vision
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It is a tool to:- improve workplace safety- reduce waste
- Improve work flow- ensure quality
2. What is 5S?
It is NOT about just having a clean factory.
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hitsuke - Sustain
The different steps...
S eiri - Sort
eiton - Set in order
eiso - Shine
eiketsu - Standardise
S
S
S
S
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Pillar 1 : Sort Out
- Organisation -
Eliminate what is unneededWhen in doubt, throw it out
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Pillar 1 : Sort Out
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Technique: Red-Tagging
Identifying all unneeded items and remove them
Pillar 1 : Sort Out
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Pillar 2 : Set in order
Determine a location for everything
- Set limits & locations -
Make it obvious when something is not in order
Improve lay-out and product flow
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Technique: Signboarding & Color Painting
39632
2658
Labels1963
1
A
Item ID1963
Shelf ID
Pillar 2 : Set in order
Using SignsUsing Signs
TMME 6th European Suppliers Conference
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Limits
MAX
MIN
MAX
Displays
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In Japan,
12 colors are used as a standard
Using ColorUsing Color
Pillar 2 : Set in order
OKNOK
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Pillar 3 : Shine
Cleaning works preventively
Cleaning detects abnormal conditions
Clean everything and keep it clean
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Technique:
Define periodic and systematic cleaning activities
(Eliminate all dirt, dust and scrap)
- A clean and safe environment will be stimulating for everybody -
Adapt cleaning as an inspection
Pillar 3 : Shine
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Pillar 4 : Standardise
Prevent fall-back of 3S, standardise 3S and maintain 3S
Create guidelines and make these obvious
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Create standard operations (define best way ofworking):
Machining OperationsAssembly Operations
Maintenance Operations
Changeover Operations
Cleaning Operations
Pillar 4 : Standardise
Technique:
Use visual techniques
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Display
Pillar 4 : Standardise
Standard operation Sheet Jan-02
NLocation Method Criteria Action Time WhoShift Day Week 2 wks Mo
1 Lub tank Wipe no lub Fill o 2 A2 Hyd tank Wipe no leak Tag o 2 A3 Mc body Brush no dirt o 1 A4 Mc base Brush no dirt o 3 A5 Liquid Wipe no leak Tag o 4 A6 Tank Wipe oil free o 1 A7 Oil pan empty oil free o 2 A8 Motor Wipe dust free o 1 A
9
Machine Status
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Pillar 5 : Sustain
- Self-discipline -
Make a habit of maintaining established procedures
Assure that everyone follows the rules
Continue 5S
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Technique:
5S Patrols, 5S Audits
X
X
X
SORTED
SETLIMITS
SHINE
SHARE
CHECK
5S CHECKLIST
X
X
Training sessions & communication boards
Pillar 5 : Sustain
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Were too busy!
Why clean daily when it gets dirty again?
We already have a nice factory!We did 5S years ago!
We do not need 5S, were making enough money already...
This is good for Japanese...
The output will not increase with this!
So, what are the benefits?So, what are the benefits?
Th b fi
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Higher Quality
Lower costs
Reliable Deliveries
Improved Safety
Higher Availability
rate
Reduction of Defects
Reduction of Waste
Reduction of delays
Reduction of Injuries
Reduction ofBreakdowns
5S
The benefits:
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4. Expectations
Active management participation
Adequate follow-up
Involvement from top-management
Necessary resources
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5. Conclusion
More severe market requirements
Tighter deadlines
Flexible manufacturing process
Foundation = 5SFoundation = 5S
an easy step-by-step approach without big investment
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There is nothing magical about it
Just use common sense
Thank you
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