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Learn the principles of the 5S/6S philosophy and how to successfully implement

Learn the principles of the 5S/6S philosophy and how to successfully implement it in any facility LEAN 5S Lean 5S Guide | creativesafetysupply.com Creative Safety Supply is a global supplier of Safety and Lean products and manufacturer of leading brands such as LabelTac® Label & Sign Printers and SafetyTac® Industrial Floor Tapes. Additionally, Creative Safety Supply offers a wide selection of floor signs, wall signs, and other high visibility signage solutions. CSS also bridges the gap between products and knowledge, offering a range of free resources for safety professionals or employees looking to learn more about Safety, Lean Manufacturing, GHS, Continuous Improvement, and other topics. or call us at 1-866-777-1360 creativesafetysupply.com Hundreds of Innovative Products and Solutions Knowledgeable Staff Free, Fast Shipping on Orders to US & Canada *some restrictions apply, see website Free Guides, Podcasts, Infographics, Blogs and much more 1. Introduction . . . . . . . . . . . 4 2. The Five Pillars . . . . . . . . . . 5 3. Sort . . . . . . . . . . . . . . . . 6 Red Tag Strategy . . . . . . . . 7 4. Set in Order . . . . . . . . . . . . 8 Label and Sign Strategy . . . . 9 Paint and Tape Strategy . . . 11 Tool Outline Strategy . . . . . 13 5. Shine . . . . . . . . . . . . . . 14 Inspection and Maintenance . 14 6. Standardize . . . . . . . . . . . 16 7. Sustain . . . . . . . . . . . . . 18 8. Safety . . . . . . . . . . . . . . 20 9. Summary . . . . . . . . . . . . 21 11. Additional Resources . . . . . 22 CHAPTERS Lean 5S Guide | creativesafetysupply.com All contents copyright © 2015 by Creative Safety Supply. All rights reserved. No part of this document or accompanying files may be reproduced or transmitted in any form, electronic or otherwise, by any means without the prior written permission of the publisher. This ebook is presented to you for informational purposes only and is not a substitution for any professional advice. The contents herein are based on the views and opinions of the author and all associated contributors. While every effort has been made by the author and all associated contributors to present accurate and up- to-date information within this document, it is apparent technologies rapidly change. Therefore, the author and all associated contributors reserve the right to update the contents and information provided herein as these changes progress. The author and/or all associated contributors take no responsibility for any errors or omissions if such discrepancies exist within this document. The author and all other contributors accept no responsibility for any consequential actions taken, whether monetary, legal, or otherwise, by any and all readers of the materials provided. It is the readers sole responsibility to seek professional advice before taking any action on their part. Readers’ results will vary based on their skill level and individual perception of the contents herein, and thus no guarantees, monetarily or otherwise, can be made accurately. Therefore, no guarantees are made. LEGAL DISCLAIMER Lean 5S Guide | creativesafetysupply.com 4 Introduction If your company is like most organizations today, you’re searching for a competitive edge. Something that will reduce costs, increase sales, and make you more agile in a changing business environment. Well you’ve found it. Simply put, 5S is a systematic approach to workplace organization. But it’s also much more than that. 5S is about efficiency, competitiveness, and survival. It is a deceptively simple system that creates an organized and productive workplace. But it’s not just about cleaning up and eliminating toolboxes. 5S creates a workplace environment that can adapt and succeed in these turbulent times. Chaos and unproductivity are your enemies; organization and efficiency are your allies. If implemented correctly and followed diligently, 5S will lead to: • Lower costs • Better quality • Improved safety • Increased productivity • Higher employee satisfaction From the offices of upper management to the workstations in the factory, the power of this system will quickly reveal itself in your bottom line. Lean 5S Guide | creativesafetysupply.com 5 The Five Pillars Originally developed by Hiroyuki Hirano for manufacturing companies in Japan, the principles of 5S translate well to the laboratory, the repair facility, and even the corporate office. Almost any work environment will benefit from the structure and efficiency that this model provides. 5S is sometimes called the five pillars because just like the physical pillars that hold up a structure, 5S has five elements that support the effectiveness of the system. And just like the pillars of a building, if one was to weaken or fail, the entire structure would fall. The five steps/pillars of 5S are: Sort Set in Order Shine Standardize Sustain Lean 5S Guide | creativesafetysupply.com 6 The first step of 5S begins with the Sort step. Sort is the cornerstone of 5S and will help to get rid of problems such as: • Tools and materials impeding workflow • Wasted time looking for parts, tools, and products • Stockpiling unnecessary and expensive inventory • Safety hazards resulting from clutter The goal of Sort is to eliminate all of the unneeded tools and materials and to create a space that is free of clutter. This allows for a workflow free from distraction. A good rule of thumb is: “If you do not use it on a daily basis – throw it out.” Leave only the things that you absolutely need to get your job done. This includes tools, materials, and machinery. When executing the Sort step, you must be vigilant and ruthless. Doing this first step correctly will lay the groundwork and ensure a successful implementation of the 5S model. Identifying unneeded parts and tools is not always an easy task. Employees and managers get so used to the chaos that they don’t even see it anymore. 5S has an effective tool that will help you with your sort process – it’s called the Red Tag Strategy. Original Japanese word : Seiri Sort Sort is the process of removing all the items that are not needed for current production from the workspace. Lean 5S Guide | creativesafetysupply.com 7 Red Tag Strategy The Red Tag Strategy is a great way to identify all of the objects that need to be removed from the workplace. When you see something that you think may need to be removed, you literally put a red tag on it. This is a flag that lets everyone know that this item needs to be evaluated. On the red tag, indicate what action should be taken. There are a few actions that can be taken at this point: 1. Leave the item where it is 2. Relocate the item 3. Dispose of the item 4. Recycle the item 5. Place in “Red Tag Holding Area” The Red Tag Holding Area is a location where items are placed until it is determined that they should be removed from the workplace. For example, perhaps you have a tool that you haven’t seen anyone use in a long time, but you aren’t sure you should get rid of it yet. Place it in the red tag holding area with a date on it, perhaps for a month from now. If that date passes and no one has used the tool, you can safely assume it’s not needed and remove it from the workplace. When items do need to be removed from the workplace, consider donating them if they’re still in usable condition. If you determine some items are still needed, remove the red tags and find appropriate locations for storing the items based on how frequently they are used. Lean 5S Guide | creativesafetysupply.com 8 You begin the Set in Order phase of 5S only when the Sort phase is complete. This phase will be useless if there is unnecessary clutter in the workspace. The goal of Set in Order is to create a standardized and consistent way to store and retrieve tools and materials. The key here is standardization. The user must develop this system based on how often the tools and materials are accessed and the process that uses them. Some guidelines to consider: • If items are used together, store them together. • Put the frequently used items closest to the user. • If possible, devise a let-go system in which tools are attached to a retractable cord and automatically go back to stored position. • Place items so that the user’s twisting and bending is kept at a minimum when accessing them. • Arrange tools and materials in order of use. The Set in Order step utilizes uploads/s1/ guide-5s 5 .pdf