Professional Documents
Culture Documents
Kurt Fink
Corporate Manager Marketing & Public Rel.
15 years of Lean & Six Sigma experience
Objectives
Learn to SEE
Over-Production
Wait time
Defects
Transportation
Motion
Processing Unnecessary
Inventory
Over-production - Waste
Definition:
Producing more than Process 1 Process 2
Extra Defects Inventory
needed by the customer or Processing
Definition:
Cycle Time That Is Too Long Due
To Insufficient Organization
Operator Wait Time
Ex: Waiting on a machine to be fixed
Machine Wait Time
Ex: Waiting on materials from the
previous process
Transportation - Waste
Definition
Any Material Movement That
Does Not Directly Support a
Lean Manufacturing System
Parts temporarily on racks
Multiple handling
Excessive travel
Processing - Waste
Definition:
Definition:
Any Supply in
Excess of Process
Requirements
Motion - Waste
Definition:
Any Movement of
Teammates Which Does
Not Contribute Added
Value To The Product, such
as: too much walking,
stretching, bending,
reaching.
Defects - Waste
Definition:
Repair of a Product
in order to deliver
the right quality
Rework
Repair Re-inspect
In order for MFG to become a World Class
Company, we must initiate a War on
Waste
or
Implementing
History of 5S
Started by Toyota Motor Company in the 1950s
MFG Entity
Sort - Separate, red tag, remove from the workplace
any item that is not immediately needed
Set In Order Orderliness: arrange items so that
they are identified and easy to reach
Shine Cleanliness: sweep the floors, wipe off
equipment, paint walls and equipment
Standardize - Formalize activities, frequencies, and
responsibilities
Sustain - Discipline, practice, audit, and repeat these
procedures so they become a way of life
If in doubt, move it out!
Red Tag Procedure:
and
Study variables:
Distance to parts
Distance to tools
Frequency of use
Time required to take out and
put away objects
Note: Time values for each variable might be
small but think of the cumulative effect, and
impact on productivity
Designate Storage Locations
Started Completed
Work Area:
Sustain
W ork a re a che cks a re ra ndomly pe rforme d a nd the re is visua l
1 me a sure me nt of 5S pe rforma nce .
Initial 5S level has been determined, and performance is documented
2
and posted in work area.
3 Work group is routinely checking area to maintain 5S agreements.
Sort
Unneeded items have been completely disposed of
Set In Order
All tools and gauges are identified and placed in their proper location.
Supplies and raw materials are clearly marked and in their proper
location.
Location and item indicators are clearly used for tools, gauges, supplies
and raw materials. Aisles are clearly marked.
5S Audit System
What are we looking for?
Shine
Cleaning tasks include dirt preventing methods for Floors, Walls, Tools,
Fixtures, and Gauges.
Standardize
A schedule exists to maintain the first 3 steps of 5S at the highest
possible levels for the entire facility.
The first 3 steps of the 5S have become a habit for all Teammates.
All operating shifts follow the same methods to maintain the first 3 steps
of 5S.
5S Audit System
What are we looking for?
Sustain
A disciplined system of control and maintenance is in place to assure the
4 previous steps of 5S are maintained at the highest possible level.
All Teammates have been educated on the principles of 5S and Waste.
Be very specific.
Indicate what, where, who, and when.
Summarizing!
MFG Entity
Points to Remember
1. Take responsibility for your work
environment