A Strategy For Performance Excellence

A STRATEGY FOR
PERFORMANCE
EXCELLENCE
1
 2000, QualityToolBox.com, LLC, all rights reserved
What is 5S ?
■ An essential step required for Waste Elimination
Systematic
Organization Orderliness Cleanliness Cleanup
Cleanup
“Seiri” “Seiton” “Seiso” “Seiketsu”

“Seiketsu”
Standardization/Perseverance
“Shitsuke”
■ An integral step in Kaizen
■ A required element to achieve Lean-site Manufacturing.
2
5S Performance Excellence Model
Systematic-Systematic
Organization
Improved Quality
Customer Expectations Improved Safety
Reduced costs
Consistent Deliveries
Improved Product/ Service
Standardizing Options
Control
Self-Discipline-
Control
Sorting Visual
Placement
Scrubbing clean
3
The Five Elements of 5S
Self-Discipline/Control- Systematic Systematic
Ensuring that Systematic Organization- Identifying what
Organization, Visual items are required and which
Placement & Cleanliness are not.
are maintained.
Standardizing Control-
Maintain and continually
improve the previous
improvements.
Sorting Visual Placement-
Items should be easily
Scrubbing Clean-Keep the area free from debris, retrievable, easy to get, and
dirt, oil, items not needed. visual-easy to see.
4
Expanding the Strategy
Performance Excellence
6 Sigma Kaizen
• Disciplined Methodology • Philosophical Approach
• Technical Approach • Common Sense Approach
(Quantitative) (Qualitative)
• Data Driven - Statistical • Data Driven - Observation
• Customer Focus • Operational Focus
• Reduce Variation • Waste Elimination 5S
• Focus on Large Impact • Incremental Change
• Larger/Longer Projects • Smaller/Shorter Projects
Complimentary
Complimentary Tools
Tools Driving
Driving Continuous
Continuous Improvement
Improvement
5
Comparative Analysis
6σ Improvement Methodologies Kaizen/Lean
• Similar in Structure
Measure Evaluate
- Data Collection • Improvements measured against - Baseline Process Performance
- Determine Process Potential / Goals established process - Establish Target
• Team oriented
Evaluate Decide
- Root Cause / Vital Few -Compare solutions
- Statistical Analysis - Choose
• Similar improvement tools
Improve & Verify • Measure effectiveness of improvements Act
- Implement Improvement • Maintain new performance level -Communicate
- Validate Improvement • Standardize & Proceduralize - Implement improvement
- Control
Standardize
- Standardize / Leverage Measure
- SPC Results - Validate improvement
- Update Procedures • More Efficient Processes - Standardize
- Update Procedures
Focus
- Reduce Process Variation Focus
- Identify Critical Cause and Focus Comparison - Eliminate Waste 5S
Resources for Maximum Impact • Both are Effective Improvement - Seek Incremental Process Changes
Mechanisms
• CPI/6s best applied to large complex Summary
Summary
- Common Sense Approach based on
- Technical Approach based on Statistical problems Observation
Analysis • Kaizen/Lean best applied to achieve - Applicable to all types of processes
- Requires Significant Data Collection
- Best applied to Manufacturing Processes
incremental changes and eliminate wastes. - Defined improvement strategy
- Typical Projects 1 week
- Typical Projects 1-3 Months
6
Why 5S
Look Familiar ?
•To eliminate the wastes that result from

“uncontrolled” processes.
• To gain control on equipment, material & inventory
placement and position.
• Apply Control Techniques to Eliminate Erosion of
Improvements.
• Standardize Improvements for Maintenance of
Critical Process Parameters.
7
The Nine types of wastes.
■ Overproduction
9 ■ Delays (waiting time)
Wastes
■ Transportation
■ Process
■ Inventories
■ Motions
■ Defective products
■ Untapped Resources
■ Mis-used Resources
8
Think Break
The Nine types of wastes
Give an example of each type of waste.
■ Overproduction ______________________________ 9
■ Delays (waiting time)__________________________ Wastes
■ Transportation _______________________________
■ Process_____________________________________
■ Inventories__________________________________
■ Motions ____________________________________
■ Defective products ____________________________
■ Untapped Resources __________________________
■ Mis-used Resources ___________________________
9
Elimination of Waste
5 S Element Waste/ Improvement Item Deliverable
Systematic Elimination of finding. Reduced Costs

Reduction of part selection errors. Improved Quality
Organization Increased Product Options
Sorting-Visual Elimination of finding. Reduced Costs

Elimination of nonconformances. Increased Safety
Placement Elimination of motion. Improved Quality
Reduction of part selection errors. Increased Product Options.
Scrubbing Clean Increased safety. Increased Safety

Preventive maintenance. Improved Quality
Increased equipment knowledge.
Standardization Increased equipment life. Improved Quality

Higher morale. Consistent Delivery
Control Clean environment. Improved Safety
Increased visibility of nonconformances.
10
5S
Implementation
Plan
Step 1 Step 2 Step 3

Step 4
Develop Specific Develop Communication
Step 5
Establish 5 S
Develop 5 S Training Plan
Implementation Plan Plan Implement 5 S
Implementation Team
Systematic
Organization Progressive
Standardization
Enhancements
Cleanliness
Visual Placement
Step 6
Verification of Effectiveness
11
Removing “Red Tagged” stuff
What Stuff would you “Red Tag” in these pictures ?
Think Break
Picture A__________________________________________________________
Picture B _________________________________________________________
12
Think Break
In the following pictures, identify some of the “finding wastes “ ( assume you work in a
distribution center and you have to fill an order with product located in the following
pictures).
Finding Wastes
___________________ ___________________ _________________
___________________ ___________________ _________________
___________________ ___________________ _________________
___________________ ___________________ _________________
Everything has a useable place
13
Some evidence of standardized work areas
•Clear, shiny aisle ways

•Color coded areas
•Slogans, banners
•No work-in-process ( WIP )

•One-Piece Flow
•Standardized Work Sheets
14
Visual Color System Implementation
• Develop a map identifying the “access ways”(aisles, entrances, walkways etc.)

and the “action” areas.
• Perform any necessary realignment of walkways, isles, entrances.
• Assign an address to each of the major action areas.
• Mark off the Walkways, Aisles & entrances from the action areas Table 1.0
• Apply flow-direction arrows to aisles & walkways Table 1.0
• Perform any necessary realignment of action areas.
• Mark-off the inventory locations Table 1.0.
• Mark-off equipment/machine locations Table 1.0
• Mark-off storage locations( Cabinets,shelves,tables) Table 1.0
• Color-code the floors and respective action areas per Table 1.0.
15
Cleanliness involves cleaning every aspect of
the Organization and the removal of dirt,
dust,oil, scraps on the floor, & garbage.
Key Deliverables
Increased
Efficiency
Increased
Safety
A clean Systematic Organization results in increased safety and

efficiency.
16
Measurem ent
Im provem ent 5S
Tem plate
Identify w aste
9 Waste Radar Chart
% of Waste Before 5S
% of Waste After 5S
n oit at r o p s n a r T
s s e c or P n oit c u d o r p r e v O
001
09
08
07
06
05
04
03 d e p p at n U
02 s e cr u o s e R
01
0
s y al e D
y r ot n e v nI
d e s u - si M n oi t o M
s e cr u o s e R
t c u d o r P e vit c ef e D
The Nine Wastes
O ve rp ro d u ctio n D e la ys T ra n s p o rta tio n In ve n to ry M o tio n P ro c e s se s D e fe c tiv e U n ta p p e d M is - U s e d
P ro d u c ts R e s o u rc e s R e s o u rc e s
B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r
100
90
80
% of Wasteof Waste
70
60
Percentage
50
40
30
20
10

A Strategy For Performance Excellence

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

A Strategy For Performance Excellence

Загружено:

Авторское право:

Доступные форматы

A STRATEGY FOR

“Seiri” “Seiton” “Seiso” “Seiketsu”

•To eliminate the wastes that result from

Systematic Elimination of finding. Reduced Costs

Sorting-Visual Elimination of finding. Reduced Costs

Scrubbing Clean Increased safety. Increased Safety

Standardization Increased equipment life. Improved Quality

Step 1 Step 2 Step 3

•Clear, shiny aisle ways

•No work-in-process ( WIP )

• Develop a map identifying the “access ways”(aisles, entrances, walkways etc.)

A clean Systematic Organization results in increased safety and

B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r B e fo re A fte r

Вам также может понравиться