FF EE SS +2+2 F E S +2 PP ECEC AA N N CC ER P EC A N C ER ...ilovepecans.org/wp-content/uploads/2013/06/Five-S2.pdfW. ORLD . C. LASS . C. ONSULTING . G. ROUP. 3 hr Five-S--1-3 2 OOO

WORLD CLASS CONSULTING GROUP 3 hr Five-S--1-3 1

FIVE S+2

PECAN CONFERENCE

BY DENNIS BETTENCOURT

JOHN B. SANFILIPPO – PLANT MANAGER

FFIVEIVE S+2S+2

PPECAN ECAN CCONFERENCE ONFERENCE

BYBY DENNIS BETTENCOURTDENNIS BETTENCOURT

JOHN B. SANFILIPPO JOHN B. SANFILIPPO –– PLANT MANAGER

PLANT MANAGER


O O O

O O O

O O O

77 Lines Lines –– Connect The DotsConnect The Dots


O O O

O O O

O O O

Thinking Outside the Box Thinking Outside the Box


O O O

O O O

O O O



O O O

O O O

O O O



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INTRODUCTION

THE 5S+2

METHODOLOGY

IINTRODUCTIONNTRODUCTION

THE THE 5S+25S+2

MMETHODOLOGYETHODOLOGY


Do you think . . .

There is a relationship between being organized and being productive ?

Do you think . . .Do you think . . .

There is a relationship between being There is a relationship between being organized and being productive ?organized and being productive ?


Do you think . . .


Plants appearance has an impact on your morale ?



Plants appearance has an impact on Plants appearance has an impact on your morale ?your morale ?


Do you think . . .


Plants appearance has an impact on your morale ?

Morale has an effect on productivity ?



Plants appearance has an impact on Plants appearance has an impact on your morale ?your morale ?

Morale has an effect on productivity ?Morale has an effect on productivity ?


Score yourself . . .

Organized ?

Clutter ?

Cleanliness ?

Score yourself . . .Score yourself . . .

Organized ?Organized ?

Clutter ?Clutter ?

Cleanliness ?Cleanliness ?

Circle One: A B C D FCircle One:Circle One: AA BB CC DD FF


Five S+2Five S+2


Visual Factory ManagementVisual Factory Management

Five S+2Five S+2



Five S+2Five S+2

LeanLeanManufacturingManufacturing


Before Five SBefore Five SBefore Five S

Steal

Scrounge

StashScramble

Search


SUSTAINSSUSTAINUSTAIN

SHINESSHINEHINESTANDARDIZESSTANDARDIZETANDARDIZE

SETSSETET

SORTSSORTORT

5 S5 S


5S5S ++ 11SAFETYSSAFETYAFETY


SMAINTENANCESSMAINTENANCEMAINTENANCE

SAFETYSSAFETYAFETY 5S5S ++ 22


STANDARDIZESSTANDARDIZETANDARDIZE

SMAINTENANCESSMAINTENANCEMAINTENANCE

SHINESSHINEHINESAFETYSSAFETYAFETY


SETSSETET

SORTSSORTORT

5S5S ++ 22


What is 5-S?

A place for everything and

everything in it’s place . . .

What is 5What is 5--S?S?

A place for everything and A place for everything and

everything in iteverything in it’’s place . . .s place . . .


What is 5-S?

A place for everything and

everything in it’s place . . .

ORGANIZATIONAL BEHAVIOR !!!

What is 5What is 5--S?S?

A place for everything and A place for everything and

everything in iteverything in it’’s place . . .s place . . .

ORGANIZATIONAL BEHAVIOR !!! ORGANIZATIONAL BEHAVIOR !!!


Has higher productivity

Produces fewer defects

Meets deadlines better

Safer place to work

Is a great marketing tool

Has higher productivityHas higher productivity

Produces fewer defectsProduces fewer defects

Meets deadlines betterMeets deadlines better

Safer place to workSafer place to work

Is a great marketing toolIs a great marketing tool

Fact -- An Organized and Clean Factory . . .Fact Fact ---- An Organized and Clean Factory . . .An Organized and Clean Factory . . .


Cluttered spaces

Things you would not want others to see

Work-in-process bottlenecks

Excess inventory or supplies

Cluttered spacesCluttered spaces

Things you would not want others to seeThings you would not want others to see

WorkWork--inin--process bottlenecksprocess bottlenecks

Excess inventory or suppliesExcess inventory or supplies

Take “Before” PicturesTake Take ““BeforeBefore”” PicturesPictures


SUSTAINSUSTAINSUSTAIN

SORTSSORTORT

SETSETSET

SHINESHINESHINESTANDARDIZESTANDARDIZESTANDARDIZE

1 S1 S


Sort . . . means you remove all items

from the workplace not needed for

“current” production.

If you want to make enemies

try to change something . . . .

Woodrow Wilson

Sort . . . means you remove all items Sort . . . means you remove all items

from the workplace not needed for from the workplace not needed for

““currentcurrent”” production.production.

If you want to make enemies If you want to make enemies

try to change something . . . . try to change something . . . .

Woodrow WilsonWoodrow Wilson


Red Tags catch people’s attention

Is this item needed?

Is it needed in the quantity?

If it is needed, does it need to be located here?

Red Tags catch peopleRed Tags catch people’’s attentions attention

Is this item needed?Is this item needed?

Is it needed in the quantity?Is it needed in the quantity?

If it is needed, does it need to be located here?If it is needed, does it need to be located here?

Attach Red Tags to Unneeded ItemsAttach Red Tags to Unneeded ItemsAttach Red Tags to Unneeded Items


Before Five S . . .Before Five S . . .












Maintenance Area . . . Maintenance Area . . . Maintenance Area . . .

Before . . . Before . . .

After Five S . . . After Five S . . .


QC Retainer Samples . . . QC Retainer Samples . . . QC Retainer Samples . . .


Work-In-Process . . . WorkWork--InIn--Process . . . Process . . .



Floor. . . Different color tileFloor. . . Different color tile




Sort (Red Tag) . . . Sort (Red Tag) . . . Sort (Red Tag) . . .


Sanitation Area . . . .Sanitation Area . . . .Sanitation Area . . . .


After . . . After . . .


Sort (Red Tag) . . . Sort (Red Tag) . . . Sort (Red Tag) . . .




Maintenance Area . . . Maintenance Area . . . Maintenance Area . . .




Receiving / Shipping Dock . . . Receiving / Shipping Dock . . . Receiving / Shipping Dock . . .




Outside Area . . . Outside Area . . . Outside Area . . .





SORTSORTSORT

SETSSETET


5 S5 S


SET. . .

A place for everything and everything in its place

The most dangerous kind of waste is the waste we do not recognize

Shigeo Shingo

SET. . . SET. . .

A place for everything andA place for everything and everything in its placeeverything in its place

The most dangerous kind of waste is the waste The most dangerous kind of waste is the waste we do not recognizewe do not recognize

Shigeo ShingoShigeo Shingo


Arrange needed items so they are:

Easy to use

Easy to find

Arrange needed items so they are:

Easy to use

Easy to find

2-S Set22--SS SetSet


Set . . . QC Retainer SamplesSet . . . QC Retainer SamplesSet . . . QC Retainer Samples




Set . . . Elevator Trays / Storage RackSet . . . Elevator Trays / Storage RackSet . . . Elevator Trays / Storage Rack






Set . . . Set . . . Set . . .


Set . . . Super SacksSet . . . Super SacksSet . . . Super Sacks




Floor Markings . . . Floor Markings . . . Floor Markings . . .


LinesLinesLines

Make It Obvious Where Things BelongMake It Obvious Where Things BelongMake It Obvious Where Things Belong


Lines On Floor . . . Lines On Floor . . . Lines On Floor . . .


Set . . . Product Separation Set . . . Product Separation Set . . . Product Separation




Colored Tiles . . . Colored Tiles . . . Colored Tiles . . .


Floor Markings . . . Colored Tiles Floor Markings . . . Colored Tiles Floor Markings . . . Colored Tiles


Before . . . . Before . . . .

After Five S+2 . . . . After Five S+2 . . . .

Set . . . Lines on Floor Set . . . Lines on Floor Set . . . Lines on Floor


Floor Markings . . . Floor Markings . . . Floor Markings . . .


Floor Markings . . . . Yellow PaintFloor Markings . . . . Yellow PaintFloor Markings . . . . Yellow Paint


Shrink Wrap Holder. . . Shrink Wrap Holder. . . Shrink Wrap Holder. . .


Floor Markings . . . . Floor Markings . . . . Floor Markings . . . .


Roasting Room . . . Floor MarkingsRoasting Room . . . Floor MarkingsRoasting Room . . . Floor Markings


Lines – Show Where Lift BelongsLines Lines –– Show Where Lift BelongsShow Where Lift Belongs




Warehouse . . . . Lane LinesWarehouse . . . . Lane LinesWarehouse . . . . Lane Lines




Lines

Labels

LinesLines

LabelsLabels

Make It Obvious Where Things BelongMake It Obvious Where Things BelongMake It Obvious Where Things Belong


Location Labels . . . .Location Labels . . . .Location Labels . . . .




Color Coded Labels . . . Allergen Program Color Coded Labels . . . Allergen Program Color Coded Labels . . . Allergen Program


Ingredient Labeling . . . Ingredient Labeling . . . Ingredient Labeling . . .


Film Storage . . . Film Storage . . . Film Storage . . . Before Before

After Five SAfter Five S


Truck Signs . . . Truck Signs . . . Truck Signs . . .

Before

After Five S+2


Find “BEST LOCATION”

Locate tools in workplace based on frequency of use

Store tools together if used together

Make tools easy to remove / put back

Find Find ““BEST LOCATIONBEST LOCATION””

Locate tools in workplace based on frequency of useLocate tools in workplace based on frequency of use

Store tools together if used togetherStore tools together if used together

Make tools easy to remove / put backMake tools easy to remove / put back

Decide on Locations . . .Decide on Locations . . .Decide on Locations . . .

Implementing SetImplementing SetImplementing Set


Example . . . Tool Shadow BoardExample . . . Tool Shadow BoardExample . . . Tool Shadow Board


Tool Shadow Board Tool Shadow Board Tool Shadow Board


Tool Box Tool Box Tool Box

BeforeBeforeBefore

After 5SAfter 5SAfter 5S


Fixture Cart for Quick Change-OverFixture Cart for Quick ChangeFixture Cart for Quick Change--OverOver

BeforeBeforeBefore

After 5SAfter 5SAfter 5S


Maintenance StockroomMaintenance StockroomMaintenance Stockroom


Maintenance StoreroomMaintenance StoreroomMaintenance Storeroom






Maintenance Managers OfficeMaintenance Managers OfficeMaintenance Managers Office


Maintenance . . . Maintenance . . . Maintenance . . .



SORTSORTSORT

SETSETSET


3 S3 S


SHINE. . .

To keep the work place as clean as possible.

Don’t be too busy mopping the floor to turn off the faucet.

Author unknown

SHINE. . . SHINE. . .

To keep the work place To keep the work place as clean as possible.as clean as possible.

DonDon’’t be too busy mopping the floort be too busy mopping the floor to turn off the faucet.to turn off the faucet.

Author unknownAuthor unknown


Keep everything “clean”

Shine should be integrated into daily work schedule

Shine includes saving labor by finding ways to prevent dirt and “stuff” from piling up in factory

Keep everything Keep everything ““cleanclean””

Shine should be integrated into Shine should be integrated into daily work scheduledaily work schedule

Shine includes saving labor by Shine includes saving labor by

finding ways to finding ways to prevent dirt prevent dirt and and ““stuffstuff”” from piling up in from piling up in factoryfactory

3S - Shine3S 3S -- ShineShine


Utensil Colored SegregationUtensil Colored SegregationUtensil Colored Segregation


Shadow Board . . . Shadow Board . . . Shadow Board . . .



Sanitation . . . Sanitation . . . Sanitation . . .


Sanitation Project Board Sanitation Project Board Sanitation Project Board


Fumigation BoardFumigation BoardFumigation Board


5 S Daily Cleaning Responsibilities5 S Daily Cleaning Responsibilities5 S Daily Cleaning Responsibilities


On-Going Cleaning ScheduleOnOn--Going Cleaning ScheduleGoing Cleaning Schedule



SORTSORTSORT

SETSETSET


4 S4 S


Standardization . . .

Create the Rules and Guidelines

The only difference between a rut and a grave is their dimensions . . .

Ellen Glasgow

Standardization . . . Standardization . . .

Create the Rules and GuidelinesCreate the Rules and Guidelines

The only difference between a rut and a graveThe only difference between a rut and a grave is their dimensions . . .is their dimensions . . .

Ellen GlasgowEllen Glasgow


Five S Signs . . . Five S Signs . . . Five S Signs . . .


Color Coded Floor Markings . . .Color Coded Floor Markings . . .Color Coded Floor Markings . . .


Suggestion Action BoardSuggestion Action BoardSuggestion Action Board



SORTSORTSORT

SETSETSET


5 S5 S


Sustain . . . Means making it a habit . . . Stick to the rules !!!!!

Amateurs work until they get it right. Professionals work until they can’t get it wrong.

Author Unknown

Sustain . . . Means making it a Sustain . . . Means making it a habit . . . Stick to the rules !!!!!habit . . . Stick to the rules !!!!!

Amateurs work until they get it right.Amateurs work until they get it right. Professionals work until they canProfessionals work until they can’’t get it wrong.t get it wrong.

Author UnknownAuthor Unknown


Continuous Improvement

Value Added vs Non-Value Added

Elimination of Waste

Ergonomics

Measure Success . . .

Visual Factory Management . . .

Continuous ImprovementContinuous Improvement

Value Added vs NonValue Added vs Non--Value AddedValue Added

Elimination of WasteElimination of Waste

ErgonomicsErgonomics

Measure Success . . . Measure Success . . .

Visual Factory Management . . .Visual Factory Management . . .

5S - Sustain5S 5S -- SustainSustain


Employee Involvement Group . . . Employee Involvement Group . . . Employee Involvement Group . . .


Five S Communication Board . . . Five S Communication Board . . . Five S Communication Board . . .


CI – Physical InventoryCI CI –– Physical InventoryPhysical Inventory

Before . . .Before . . . After Five S . . .After Five S . . .


Continuous Improvement . . .Continuous Improvement . . .Continuous Improvement . . .Walnut Dicer Machine – Internally rebuilt from scrap . . . .

Doubled plant capacity


Continuous Improvement . . .Continuous Improvement . . .Continuous Improvement . . .

BeforeAfter Five S+2

Open product chutes meant more possibility of product on the floOpen product chutes meant more possibility of product on the floor.or.


Continuous Improvement . . .Continuous Improvement . . .Continuous Improvement . . .


Reduce Floor SpillageReduce Floor SpillageReduce Floor SpillageWalnut Shelling Plant . . . . Built chute to catch spillage


Five S+2 . . .

Visual Factory Management

Five S+2 . . . Five S+2 . . .



Visuals . . . Visuals . . . Visuals . . .


Visuals . . . Visuals . . . Visuals . . .


Safety Communication Board . . . Safety Communication Board . . . Safety Communication Board . . .


Packaging Production Schedule board . . .Packaging Production Schedule board . . .Packaging Production Schedule board . . .


Scrap / Film Shrink - Weekly / YTD ScoreboardScrap / Film Shrink Scrap / Film Shrink -- Weekly / YTD ScoreboardWeekly / YTD Scoreboard


Packaging Scoreboard - Standard vs Actual . . . Packaging Scoreboard Packaging Scoreboard -- Standard vs Actual . . . Standard vs Actual . . .


1st Pass Yields . . .11stst Pass Yields . . .Pass Yields . . .


1st Pass Yield. . . 11stst Pass Yield. . . Pass Yield. . .


1st Pass Yield . . . 11stst Pass Yield . . . Pass Yield . . .


1st Pass Yield Graph . . . By Department 11stst Pass Yield Graph . . . By Department Pass Yield Graph . . . By Department

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5Number of Shell:

Name:

Weekly: Average shell count per check - 1st ShiftOctober 20 - December 05, 2008

10/20 - 10/25 10/27 - 11/01 11/03 - 11/07 11/10 - 11/15

11/17 - 11/21 11/24 - 11/28 12/01 - 12/05


1st Pass Yield Graph . . . By Employee 11stst Pass Yield Graph . . . By Employee Pass Yield Graph . . . By Employee


Daily Cracked / Packed lbs Scoreboard . . . Daily Cracked / Packed lbs Scoreboard . . . Daily Cracked / Packed lbs Scoreboard . . .


Total Team Performance . . . Total Team Performance . . . Total Team Performance . . .


10 Success Factors for Five S . . . .10 Success Factors for Five S . . . .10 Success Factors for Five S . . . .

1. 1. Make a clear link between Five S and Elimination of Waste Make a clear link between Five S and Elimination of Waste

2.2. Five S is the first step towards LeanFive S is the first step towards Lean

3.3. Five S saves by being organizedFive S saves by being organized

4. 4. Lead by exampleLead by example

5.5. Make Five S mandatoryMake Five S mandatory

6.6. Motivate and reward excellence in Five SMotivate and reward excellence in Five S

7.7. Clean as you goClean as you go

8.8. Use a Five S audit scoreboardUse a Five S audit scoreboard

9.9. Focus on Continuous Improvement and followFocus on Continuous Improvement and follow--upup

10.10. Passion owns the processPassion owns the process


NOTHING GREAT WAS EVER

ACHIEVED WITHOUT . . .

PASSION!

NOTHING GREAT WAS EVER NOTHING GREAT WAS EVER

ACHIEVED WITHOUT . . .ACHIEVED WITHOUT . . .

PASSION!PASSION!

REMEMBER

REMEMBER


Dennis Bettencourt - [email protected]

Chip Long - wccg2.com

Documents

FF EE SS +2+2 F E S +2 PP ECEC AA N N CC ER P EC A N C ER ...ilovepecans.org/wp-content/uploads/2013/06/Five-S2.pdfW. ORLD . C. LASS . C. ONSULTING . G. ROUP. 3 hr Five-S--1-3 2 OOO