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9.09.2017

Prepared by Dr. Sule Itir Satoglu 1
Prepared by Dr. Sule Itir Satoglu
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Things to be Eliminated  Dirt in a plant includes;  Defective parts inventory 
Things to be Eliminated
 Dirt in a plant includes;
 Defective parts inventory
 Unnecessary tools and equipment
 Oil on the ground
 Unneeded carts, equipment, tables
 Inventory that time forgot!
 Dirt in an office includes;
 Unneeded reports, documents
 5S is washing out these dirt.
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Why Need 5S?  As taking shower, brushing teeth are daily routines, workplace also need
Why Need 5S?
 As taking shower, brushing teeth are daily routines,
workplace also need routine cleaning!
 People look for tools, carts at the factory.
 Office people look for files, staplers, documents etc.?
 Time lost because these are not in order!
(Hirano, 1995).
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5S  5S means orderliness, cleanliness and discipline, in short terms.  It is the
5S
 5S means orderliness, cleanliness and discipline, in
short terms.
 It is the starting point to improve the production
system performance.
 “Behind workplace successes and failures are the 5S’s”.
Prepared by Dr. Sule Itir Satoglu
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Things to be Eliminated  Tables are in a mess!  Tools just thrown or
Things to be Eliminated
 Tables are in a mess!
 Tools just thrown or forgotten around the shopfloor.
 Shelves with tools unclassified!
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Benefits of 5S (Hirano, 1995) Prepared by Dr. Sule Itir Satoglu 6
Benefits of 5S
(Hirano,
1995)
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Benefits of 5S  Product Diversification  Setup time is reduced as time spent for
Benefits of 5S
 Product Diversification
 Setup time is reduced as time spent for looking for dies,
tools and equipment decreased. Everything is well
organized and in order.
 Lower setup times enhances product diversification.
 Many types of products in small quantities produced.
(Hirano, 1995)
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Benefits of 5S  Zero waste brings lower costs  Eliminated or reduced wastes of
Benefits of 5S
 Zero waste brings lower costs
 Eliminated or reduced wastes of
 motion (searching etc)
 Space occupied due to unordered tools, equipment
 Non-value added actions (counting)
 Unneeded storage places
 Excess inventory and warehouse expenses
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Benefits through 5S  Zero injuries promote safety  Injuries expected when  stocks are
Benefits through 5S
 Zero injuries promote safety
 Injuries expected when
 stocks are piled up,
 machines/equipments are covered with oil,
 items are left into walkways.
 Lack of outlined storage areas
 Collisions when forklifts turn corner without warning
 High inventories fall over unexpectedly etc….
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Benefits of 5S  Higher Quality  Defects harder to notice in an unordered workplace.
Benefits of 5S
 Higher Quality
 Defects harder to notice in an unordered workplace.
 Clean and orderly equipment: fewer defects
 Makes workers more conscious.
 Less tool selection errors and fewer defects.
 Feelings of pride will be used for motivation due to high
quality.
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Benefits through 5S  Zero delays bring reliable deliveries  When errors and defects are
Benefits through 5S
 Zero delays bring reliable deliveries
 When errors and defects are eliminated, order can go
out on time.
 Conveying products after elimination of unnecessary
materials will be easier.
 Work is more efficient in waste-free environments.
 Absenteeism is lower at 5S shops.
Prepared by Dr. Sule Itir Satoglu
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Benefits through 5S  Zero injuries promote safety  Safety first is a good concept!
Benefits through 5S
 Zero injuries promote safety
 Safety first is a good concept!
 Place things in a safe manner.
 Maintain well defined places to put things, uncluttered
aisles etc.
 Discover mechanical failures and hazards right away, when
machines in good, clean condition.
 Clearly mark emergency exits, put warning signs for
hazardous substances & dangers.
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Benefits through 5S  Zero breakdowns bring better maintenance  Trash, dirt and dust shortens
Benefits through 5S
 Zero breakdowns bring better maintenance
 Trash, dirt and dust shortens equipment life.
 Easier to observe machines while running when they are
clean.
 Maintain and check equiment daily.
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Prepared by Dr. Sule Itir Satoglu 15
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Steps of 5S 1. Organize:  Use visual methods such as red tagging.  It
Steps of 5S
1.
Organize:
 Use visual methods such as red tagging.
 It can help gain additional space and eliminate broken
tools and excess material - inventory.
Picture source: www.strategosinc.com/5s_elements.htm
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5S’s  Seiri (Organization)  Seiton (Orderliness)  Seiso (Cleanliness)  Seiketsu (Standardized Cleanup)
5S’s
 Seiri (Organization)
 Seiton (Orderliness)
 Seiso (Cleanliness)
 Seiketsu (Standardized Cleanup)
 Shitsuke (Discipline)
Prepared by Dr. Sule Itir Satoglu
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Steps of 5S 1. Organize:  Distinguish (sort) between what is needed and and what
Steps of 5S
1.
Organize:
 Distinguish (sort) between what is needed and and
what is unneeded (Hirano, 1995).
 Involves evaluating the necessity of each item.
 Discard the items unneeded.
 Unneeded items occupy space and increase the risk of
error.
Prepared by Dr.
Sule Itir Satoglu
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Steps of 5S: Organize- Red Tagging www.gemba.com Prepared by Dr. Sule Itir Satoglu 18
Steps of 5S: Organize- Red Tagging
www.gemba.com
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Steps of 5S 2. Orderliness  Organizing required items so that they can be found
Steps of 5S
2.
Orderliness
 Organizing required items so that they can
be found and used easily whenever
needed.
 It determines location of each item.
 No time spent to look for items.
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Example (Hirano, 1995) Prepared by Dr. Sule Itir Satoglu 21
Example (Hirano, 1995)
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Orderliness: Determine Locations  Workers simply look at each item  Estimate the frequency of
Orderliness: Determine Locations
 Workers simply look at
each item
 Estimate the frequency
of use
 Then select a location.
 After a few days, they
can review and revise
their locations.
www.strategosinc.com/
5s_elements.htm
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Example (Monden, 1993) Prepared by Dr. Sule Itir Satoglu 20
Example (Monden, 1993)
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Orderliness in the Factory (Hirano, 1995) Category Orderliness Target Spaces Floors, walkways, operation areas,
Orderliness in the Factory (Hirano, 1995)
Category
Orderliness Target
Spaces
Floors, walkways,
operation areas, walls,
shelves, warehouses
Products
Raw materials, parts for
machining, in-process
inventory, assembly
parts, finished products
Equipment
Machines, equipment,
tools, dies, carts,
conveyance tools, work
tables, cabinets, chairs. 22
Prepared by Dr. Sule Itir Satoglu
Orderliness: Color Coding  A visual technique to match the items more easily.  The
Orderliness: Color Coding
 A visual technique to match the items
more easily.
 The two items with the same color are
matched.
 Probability of mismatch is reduced!
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Ordrliness: Determine Locations  A typical workstation  www.strategosi nc.com/5s_elem ents.htm Prepared by Dr.
Ordrliness: Determine Locations
 A typical
workstation
 www.strategosi
nc.com/5s_elem
ents.htm
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Sule Itir Satoglu
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Orderliness Prepared by Dr. Sule Itir Satoglu 27
Orderliness
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Sule Itir Satoglu
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Orderliness: Painting Strategy www.strategosinc.com/5s_elements.htm Prepared by Dr. Sule Itir Satoglu 29
Orderliness: Painting Strategy
www.strategosinc.com/5s_elements.htm
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Orderliness: Determine Locations www.dugganinc.com Prepared by Dr. Sule Itir Satoglu 26
Orderliness: Determine Locations
www.dugganinc.com
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Orderliness: Painting Strategy  By painting, boundaries for the location and space for each item
Orderliness: Painting Strategy
 By painting, boundaries for the location and space for
each item identified
 They encourage recoil, that is the proper return of an
item, as shown below.
 They also tend to prevent people from placing other
(wrong) items in a designated space.
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Orderliness: Painting Strategy (Hirano, 1995) Prepared by Dr. Sule Itir Satoglu 30
Orderliness: Painting Strategy
(Hirano, 1995)
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Orderliness: Painting Strategy (Hirano, 1995) Prepared by Dr. Sule Itir Satoglu 31
Orderliness: Painting Strategy
(Hirano, 1995)
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Orderliness: Painting Strategy Prepared by Dr. Sule Itir Satoglu www.dugganinc.com 33
Orderliness: Painting Strategy
Prepared by Dr. Sule Itir Satoglu
www.dugganinc.com
33
Steps of 5S 3. Cleanliness:  Sweeping the floor  Cleaning the tools and equipment
Steps of 5S
3.
Cleanliness:
 Sweeping the floor
 Cleaning the tools and
equipment .
 No dust, oil, water and rust.
 Eliminating sources of dirt.
www.strategosinc.co
m/5s_elements.htm
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Orderliness: Painting Strategy www.dugganinc.com Prepared by Dr. Sule Itir Satoglu 32
Orderliness: Painting Strategy
www.dugganinc.com
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Prepared by Dr. Sule Itir Satoglu
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Steps of 5S 4. Standardized Cleanup  The three activities explained above will become a
Steps of 5S
4. Standardized Cleanup
 The three activities explained above will become a
routine and continue.
 The shopfloor will be kept clean by these activities.
 Standardize normal work acitivities
 Develop work instructions.
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Steps of 5S 4. Standardized Cleanup  Develop schedules: which acitivites are to be done
Steps of 5S
4. Standardized Cleanup
 Develop schedules: which acitivites are to be done
weekly, daily, continuously.
 machine clean,inspection – daily
 tool check, inventory check – daily
 degrease work area – weekly.
 red tagging – continuously.
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Eight Tools to Sustain 5S www.strategosinc.com/5s_elements.htm Prepared by Dr. Sule Itir Satoglu 39
Eight Tools to Sustain 5S
www.strategosinc.com/5s_elements.htm
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Example (Monden, 1993) Prepared by Dr. Sule Itir Satoglu 41
Example (Monden, 1993)
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Steps of 5S 5. Discipline  The decisive attitude to maintain (keep) the shopfloor cleanliness
Steps of 5S
5.
Discipline
 The decisive attitude to maintain (keep) the
shopfloor cleanliness and orderliness conditions.
 The hardest step is sustaining 5S activities.
 So that they are institutionalized.
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www.gembapantarei.com Prepared by Dr. Sule Itir Satoglu 40
www.gembapantarei.com
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Before 5S Kaynak: Wyeth Pharmaceuticals
Before 5S
Kaynak: Wyeth Pharmaceuticals

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After 5S Kaynak: Wyeth Pharmaceuticals
After 5S
Kaynak: Wyeth Pharmaceuticals
After 5S Kaynak: Wyeth Pharmaceuticals
After 5S
Kaynak: Wyeth Pharmaceuticals
After 5S Kaynak: Wyeth Pharmaceuticals
After 5S
Kaynak: Wyeth Pharmaceuticals
Before 5S Kaynak: Wyeth Pharmaceuticals
Before 5S
Kaynak: Wyeth Pharmaceuticals
Before 5S Kaynak: Wyeth Pharmaceuticals
Before 5S
Kaynak: Wyeth Pharmaceuticals
Before 5S Kaynak: The Lean Enterprise
Before 5S
Kaynak: The Lean Enterprise

9.09.2017

After 5S Kaynak: The Lean
After 5S
Kaynak: The Lean
After 5S Kaynak: The Lean
After 5S
Kaynak: The Lean
Drawer manuf. Table (Before 5S) Drawer manuf. Table (After 5S)
Drawer manuf. Table (Before 5S)
Drawer manuf. Table (After 5S)
Before 5S Kaynak: The Lean
Before 5S
Kaynak: The Lean
Messy workstation Ordered Workstation
Messy workstation
Ordered Workstation
5S for the Office Environments  Step 1: Organize – Sort  Messy Office: Transform
5S for the Office Environments
 Step 1: Organize – Sort
 Messy Office: Transform the cluttered and disorganized
office into an efficient workstation!
 First sort needed and unneeded items.
 Red tag unneeded big items, eg: furnitures, broken
monitors, PCs, etc.
 Dispose unneeded office supplies, papers, reports etc.
Source: http://www.lean.state.mn.us/photos.htm
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5S for the Office Environments  Step-2: Set in order (orderliness)  Organized drawer 
5S for the Office Environments
 Step-2: Set in order (orderliness)
 Organized drawer
 Point of use
 Office supply station
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Before After Source: www.sigmacenter.com.tr Prepared by Dr. Sule Itir Satoglu 57
Before
After
Source: www.sigmacenter.com.tr
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5S for the Office Environments  Step-5: Sustain (Discipline)  Commitment required to sustain 5S
5S for the Office Environments
 Step-5: Sustain (Discipline)
 Commitment required to sustain 5S conditions, in the
office.
 Maintain established procedures.
 5S Circle
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5S for the Office Environments  Step-3: Clean  Clean office vs. Cluttered Office: compare!
5S for the Office Environments
 Step-3: Clean
 Clean office vs. Cluttered Office: compare!
Source: http://www.lean.state.mn.us/photos.htm
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5S for the Office Environments  Step-4: Standardize  Labeled cabinets: Labels tell exactly what
5S for the Office Environments
 Step-4: Standardize
 Labeled cabinets: Labels tell exactly what is inside.
 Color coded files: Visual system for placing files quickly
into the cabinet.
 Map of files: Anyone can easily find files.
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Office 5S Video  Cluttered Cubicles Go Lean With 5S Rules http://www.youtube.com/watch?v=AUaJ9roHj2s Prepared by Dr.
Office 5S Video
 Cluttered Cubicles Go Lean With 5S Rules
http://www.youtube.com/watch?v=AUaJ9roHj2s
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Prepared by Dr. Sule Itir Satoglu 61
Prepared by Dr. Sule Itir Satoglu
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Characteristics of a Visual Workplace clearly communicates needed information clearly reflects established
Characteristics of a Visual
Workplace
clearly communicates needed
information
clearly reflects established standards
clearly identifies behavior or process
targets
clearly is low cost and easy to use
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Visual Management :Andon  Andon refers to a signal used to call for help when
Visual Management :Andon
 Andon refers to a signal used to call for help
when an abnormal condition is recognized.
 The most common andon lights are used to
request assistance on an assembly line.
 Opel’s new production facility in Rüsselsheim
for the new Vectra autos.
 Andon systems installed at every station to help
prevent defective parts being produced, or
passed on down the line.
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Visual Workplace Distinguishing value versus waste & communicating process outcomes are all important elements
Visual Workplace
Distinguishing value versus waste &
communicating process outcomes are all
important elements of visual
management.
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Visual Management Scoreboard  A simple scoreboard provides the foundation for visual management. Process metrics,
Visual Management Scoreboard
 A simple scoreboard provides the foundation for visual
management. Process metrics, descriptions, historical
data, improvement communicated!
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Visual Management :Andon  Two cords are positioned at each work station .  If
Visual Management :Andon
 Two cords are positioned at each work station .
 If an employee pulls the yellow cord, a light and an
acoustic signal are triggered, requesting help from
other members of the team.
 Pulling the red cord stops the assembly line until the
problem has been solved.
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Visual Control  http://www.youtube.com/watch?v=7TBSr8LHm1I Prepared by Dr. Sule Itir Satoglu 67
Visual Control
 http://www.youtube.com/watch?v=7TBSr8LHm1I
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Assembly by using white gloves Easy access to the tools Alarm Button for Problems
Assembly by using
white gloves
Easy access to the
tools
Alarm Button for
Problems
5S in Meeting Rooms Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
5S in Meeting Rooms
Kaynak:
http://www.youtube.com/watch?v=nHutkkfUpDs
Prepared by Dr. Sule Itir Satoglu 68
Prepared by Dr. Sule Itir Satoglu
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5S in Offices & Working by Standing Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
5S in Offices & Working by Standing
Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
Kaynak:
http://www.youtube.com/watch?v=nHutkkfUpDs

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Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
Poka Yoke Prepared by Dr. Sule Itir Satoglu 77
Poka Yoke
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Kaynak: http://www.youtube.com/watch?v=nHutkkfUpDs
Kaynak:
http://www.youtube.com/watch?v=nHutkkfUpDs
Poka Yoke Prepared by Dr. Sule Itir Satoglu 76
Poka Yoke
Prepared
by Dr.
Sule Itir Satoglu
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Poka Yoke Prepared by Dr. Sule Itir Satoglu 78
Poka Yoke
Prepared
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Sule Itir Satoglu
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Prepared by Dr. Sule Itir Satoglu 79
Prepared by Dr. Sule Itir Satoglu
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