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1) Expose waste so you can eliminate it and prevent it from recurring in the future,
2) Make your companys operation standards known to all employees so they can easily follow them, and 3) Improve workplace efficiency through organization.
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V M Steps
Organizing your workplace by using a method known as the 5 S's (sort, shine, set in order, standardize, and sustain)
Ensuring that all your required work standards and related information are displayed in the workplace
Controlling all your workplace processes by exposing and stopping errorsand preventing them in the future
V M What it does
Improve the "first-time-through" quality of your products or services by creating an environment that: Prevents most errors and defects before they occur. Detects the errors and defects that do occur and enables rapid response and CA. Establishes and maintains standards for zero errors, defects, and waste.
Improve workplace safety and employee health by: Removing hazards. Improving communication by sharing information openly Creating compliance with all work standards, reporting deviations, and responding quickly to problems.
Improve the overall efficiency of your workplace and equipment, enabling your organization to meet customer expectations.
V M Areas to focus
You can effectively gain control over your company's manufacturing or business processes by focusing on the following areas
Value-added activities (Work process and methods of operation) Information sharing Source, in-process and outgoing inspections Material quantities and flow (Storage, inventory and supplies) Health and safety
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V M Start activities
Train all involved employees about the visual management techniques
Create storage ("red tag") areas for holding materials you will remove
Arrange for tags, cleaning materials, paint, labels, marking tape, and sign materials.
Make sure that all employees understand and follow your company's safety regulations and procedures as they make changes
Reduce the number of items in your immediate work area to just what you actually need
Find another storage area for all supplies that you need but do not use every day
Decide how you will prevent the accumulation of unnecessary items in the future
Tie red tags to all the items you remove from your work area. Place the items in a temporary "red-tag storage" area for five days
After five days, move any item that you haven't needed to a central red -tag storage area for another 30 days Use a logbook to track what you do with all red-tag items
Things
Cannot be used
Unlikely to be used
Discard
Remove from factory and store else-where Store near Operation Where used Keep close at hand at all times
Can be used
Occasionally used
Often Used
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Cleaning is also a good time to inspect your equipment to look for abnormal wear or conditions that might lead to equipment failure
Keeping equipment clean and "shiny" should be a part of your maintenance process Teach the concepts of " cleaning as inspection" and "eliminating sources of contamination."
Shine your administration, sales, purchasing, accounting, and engineering areas as well
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Cleanliness steps
Step 1: Determine cleanliness targets.
Instant Maintenance
Requested Maintenance
The operator immediately restore or improves upon the abnormality or slight defect.
If unable to immediately restore or improve upon the abnormality or slight defect, the operator requests help from the maintenance department.
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Create a map of your workspace that shows where all the equipment and tools are currently located
Use the map to identify wasted motion or congestion caused by excessive distances travelled, unnecessary movement, and improper placement of tools and materials
Draw a map of a more efficient workspace, showing the rearrangement of every item that needs to be moved
Make a plan for relocating items that need to be moved so you can make your new, efficient workspace a reality
Status
Date:
Dept:
Prepared by:
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Stage 2: Easy-to-confirm Orderliness.. (Visual confirmation of where to return jigs and tools.)
Stage 3: Orderliness so simple that workers can maintain it with their eyes closed.. (We know it by heart.)
Stage 4: Just let go Orderliness. (We do dont even have to return it.)
Stage 5: Orderliness eliminates some jigs and tools (We no longer need them.)
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5S-Standardize
Make sure that team members from every work area follow the sort, shine, and set-in-order steps
Share information among teams so that there is no confusion or errors regarding Locations Delivery, Destinations, Quantities Schedules, Downtime, Procedures and standards
Have everyone write down their ideas for reducing clutter, eliminating unnecessary items, organizing, making cleaning easier, establishing standard procedures, and making it easier for employees to follow the rules.
Make your standards are known to everyone so that anything out of place or not in compliance with your procedure will be immediately noticed.
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4. Seiketsu (standardisation)
Organisation
Ways to prevent generating unneeded items Because they are not needed Why throw the items away ? Throw away unneeded items
Orderliness
Ways to prevent back sliding in orderliness condition Because they tend to revert to their previous level Why 3S conditions deteriorate ? Arrange things in an orderly fashion
Cleanliness
Ways to prevent contamination Because it becomes dirty Why sweep the floor ?
No standardization
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Three salient points of visual 5S are Anyone should be able To distinguish between normal and abnormal conditions At a glance
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Step 1
Step 3
Step 6
Step 7
Awareness revolution
Line integration
Production leveling
Standard operations
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5S-Sustain
The gains you make during the above four steps are sustained when:
The workplace is well ordered and adheres to the new procedures all your employees have agreed upon
Encourage and recognize the achievement of all work areas that are able to sustain their visual management efforts.
Visual Management Sustain evaluation Sort Are all items in the work area necessary? Have unnecessary items been red-tagged? Have red-tagged items been removed? Shine Have all ares been cleaned? Has a cleaning schedule established? Set in order Is the location for every item in the work area defined? Is every item in its defined location? Standardize Have standards been established? Are standards posted? Have comapany-wide standards been adopted in the area? Sustain Is the evaluation being completed on a regular basis? Are all schedules, such as the cleaning schedule, being followed?
Y/N
Comments
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5S Introduction steps
Step 1
Establish 5S promotion organization Establish 5S promotion plan Establish 5S campaign materials In-house education 5S implementation Red-tag strategy (for Organization)
Step 2 Step 3
Step 4
Step 5
Standardized Cleanup
Intensive Improvements
Signboard strategy (for Orderliness)
Cleanliness
Discipline
Step 6