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pleasant and safer work environment, it will also be much easier to notice leaks, spills,
breakages, etc.
However, shine is also an important part of the ongoing process where the work space and
equipment are cleaned and restored to their proper place at the end of each shift. Basic
preventative maintenance tasks like tightening, oiling, restocking are part of this. The
workstation is then ready for the next user (or the next day) and the order created in the first two
steps is preserved.
Standardize
So that the 5S project is not just a spring cleaning exercise, you will need to ensure that everyone
knows what are the current steps to follow and to establish expectations for the process.
In order for the changes to stick, you will need to conduct training, create documented
procedures, work instructions, use visual guides, checklists, and/or photos. It will be easier to
make changes if users of the system understand why they were made and ideally, they will have
been involved in making the changes in the first place.
Visual controls include the familiar tape markings and shadow boards. By assigning everything
to specific locations, you reduce time wasted looking for tools or equipment. If good visual
controls have been installed, it should be immediately obvious if a problem exists in the work
area, e.g. a missing tool.
Where there are multiple workstations for the same or similar tasks, setting them up in a standard
way will increase efficiency and make them much more interchangeable for users.
Sustain
You have to keep it going so that the old ways do not return, otherwise all that time and effort
and $$ will have been wasted. You will need to followup over a period of time until the new
way becomes entrenched.
This will be easier if the changes have made it easy to do the right thing. The design of the work
should facilitate the process, not place a burden on employees.
Sustaining the new processes is often the most difficult task. If the focus drifts away from 5S,
then the work area will drift back to the old state. Strategies include daily meetings, miniaudits, and ongoing continuous improvement efforts.
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1. Check sheet
The check sheet is a form (document) used to collect data
in real time at the location where the data is generated.
The data it captures can be quantitative or qualitative.
When the information is quantitative, the check sheet is
sometimes called a tally sheet.
The defining characteristic of a check sheet is that data
are recorded by making marks ("checks") on it. A typical
check sheet is divided into regions, and marks made in
different regions have different significance. Data are
read by observing the location and number of marks on
the sheet.
Check sheets typically employ a heading that answers the
Five Ws:
2. Control chart
Control charts, also known as Shewhart charts
(after Walter A. Shewhart) or process-behavior
charts, in statistical process control are tools used
to determine if a manufacturing or business
process is in a state of statistical control.
If analysis of the control chart indicates that the
process is currently under control (i.e., is stable,
with variation only coming from sources common
3. Pareto chart
5.Ishikawa diagram
Ishikawa diagrams (also called fishbone diagrams,
herringbone diagrams, cause-and-effect diagrams, or
Fishikawa) are causal diagrams created by Kaoru
Ishikawa (1968) that show the causes of a specific event.
[1][2] Common uses of the Ishikawa diagram are product
design and quality defect prevention, to identify potential
factors causing an overall effect. Each cause or reason for
imperfection is a source of variation. Causes are usually
grouped into major categories to identify these sources of
variation. The categories typically include
People: Anyone involved with the process
Methods: How the process is performed and the
specific requirements for doing it, such as policies,
procedures, rules, regulations and laws
Machines: Any equipment, computers, tools, etc.
required to accomplish the job
Materials: Raw materials, parts, pens, paper, etc.
used to produce the final product
Measurements: Data generated from the process
that are used to evaluate its quality
Environment: The conditions, such as location,
time, temperature, and culture in which the process
operates
6. Histogram method