Lean production, Kaizen & 5S

K.B.Gopalam
Aura Leadership Foundation
Hyderabad
 Lean Production
• assembly-line manufacturing methodology.
• as "to get the right things to the right place at
the right time, the first time, while minimizing
waste and being open to change".
• eliminating waste,
• improved product flow and better quality.
• deliver on demand, minimize inventory,
maximize the use of multi-skilled employees,
flatten the management structure, and focus
resources where they were needed.
 The Ten Rules of Lean
Production
1. Eliminate waste
2. Minimize inventory
3. Maximize flow
4. Pull production from customer demand
5. Meet customer requirements
6. Do it right the first time
7. Empower workers
8. Design for rapid changeover
9. Partner with suppliers
10. Create a culture of continuous improvement
 Gemba Kaizen
• Gemba means `real place' meaning the area
where value is actually added,
• Kaizen means continuous improvement.
• to reduce costs, cut out waste, improve
quality and productivity.
• without using expensive technologies.
 The Impediments
• the misconceptions regarding the theory
• that it needs to be done by workers, not
managers
• management of shop floors left to middle
managers and supervisors
• visit the shop floor ?
 1. Seiri (Clearing Up)
wastebasket is our friend.
– plenty of waste receptacles.
– a waste container was within six steps.
• of any position.
• E-bay also is your friend.
– Serviceable but unwanted equipment
– can be auctioned off.
• Three-tier classification.
– Frequently-used items at workstation.
– Regular use: near workstation.
– Rare use: keep outside the work area.
 2. Seitori (arranging)

Every tool should have a place.

Socket wrench boxes have specific
niches for each socket
Draw outlines on the wall for each tool
 3.Seiso (neatness)

• Keeping everything clean

– Continuous Cleaning
The long-handled window cleaning
sponge
• Air suction system
 4.Shitsuke (discipline)

• "Mind you keep your rifle and yourself just

so."
– Preventive maintenance as well as cleaning
must be routine.
– Build them into the work instructions.
Maintenance logs
 5.Seiketsu
(ongoing improvement)

Ongoing improvement driven by

standardization and best practice
deployment.
• Do not let friction or waste remain part of
any job by "working around" the problem
 1. SORT
• Remove all items from the workplace that
are not needed for current operations. Leave
only the bare essentials.
• Targets excess inventory, obsolete items,
quality defects, unneeded tools/equipment
• Will use red tags, local and central red tag
holding areas; Account for discarded items
• Take before and after pictures
 2. SET IN ORDER
• Arrange needed items so that they are easy
to find, use and put away.
• Consider motion economy
• Use painting, outlining and signboard
strategies, Visual 5S
 3. SHINE
• Sweeping, wiping-off equipment, painting
and assuring everything stays clean.
• Create 5S schedules for painting
• Must create cleaning inspection checklists
• Create current and future shine targets
 4. STANDARDIZE
• Method to maintain the first 3
disciplines (sort, set-in-order,
shine)
• Prevention steps for clutter-
suspension, incorporation,
elimination
• Integrate 3S duties into
regular work with 5S job
cycle charts, 5 minute 5S,
visual 5S activities
 5. SUSTAIN
• A top-down support of the ongoing 5S process.
• Must create the conditions to support 5S
• Allocate time
• Create awareness
• Provide a structure
• Show support
• Offer rewards and recognition
• Encourage training/participation
 Sort
• problems in the work "flow"
are reduced / throughput is
increased
• communication between
workers is improved
• product quality is increased
• wasted space is reduced
• wasted time looking for parts
or tools is reduced
• overstocking is avoided
 Red Tag Strategy
• a method for identifying potentially
unneeded items
• evaluating whether they are needed,
• dealing with them appropriately
• red tags are used to identify items removed
from the work area for evaluation.
 Set-In-Order
• Decide on appropriate locations
• Consider how to store tools and jigs
• Consider principles of motion waste.
• Visual controls
– Signboard and Painting Strategies
– 5S Map – Map out locations of
equipment
– Color-Coding Strategy - Distinguish use
of tools, parts, etc. by color
– Outlining Strategy – Draw outlines of
tool/jig storage locations
 Shine

1. What is to be shined?
2. Who is responsible?
3. How will it be shined?
4. What is needed to shine?
5. Implement Shine (everyone’s responsibility in a
work area)
6. 5S Schedules – Have a plan…
7. 5 Minute Shine – Quick & easy!
 Standardize
• Making It A Habit
Assigning three discipline job
responsibilities
Integrating three pillar duties into
regular work duties
Checking maintenance of the three
pillars
• Prevention
what they are responsible for doing and
exactly when, where, and how to do it.
 Sustain
o 5S Slogans
o 5S Posters
o 5S Photo Exhibits
o Story boards
o 5S Newsletters
o 5S Pocket Manuals
o 5S Department Tours
o 5S Months
o Success Stories
 Another Version
1. Sort:
Decide which things you need to accomplish your
work.
2. Straighten:
Decide what are the things you do not need. You
should get what you need in 30 seconds.
3. Sweep:
perform maintenance regularly.
4. Standardise:
Standardise the procedures.
5. Self Discipline:
Make the employees a party to the plan.