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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


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


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


Technique:

Use visual techniques

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Display


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

Documents

toyota+5S