A Strategy For Performance Excellence
A Strategy For Performance Excellence
A Strategy For Performance Excellence
Executive Overview
Knowledge Breakthrough
Tools Workbook
Lecture notes
Session 1.0
Introduction..... 3
Session 2.0
Session 3.0 Element 3.1
Waste Management .. 14
5S Implementation. 20 Systematic Organization... 31
Element 3.1.1
Element 3.2
Element 3.5
What is 5S ?
Standardization/Perseverance Shitsuke
Customer Expectations
Standardizing Control
Standardizing ControlMaintain and continually improve the previous improvements. Sorting Visual PlacementItems should be easily retrievable, easy to get, and visual-easy to see.
Scrubbing Clean-Keep the area free from debris, dirt, oil, items not needed.
4
4 4 4 4 4 4 4 4 4 4 4
Column chart ranking items highest to lowest 4 Cause / Effect Diagram Elimination waste 4 Emphasis on visual techniques to manage process 4 Error proofing techniques
4 Material storage technique used to control process Determine pace or beat of a process Evaluate tasks done during a process Single minute exchange of dies - Quick machine set up Integrate maintenance strategy with process Reduce inventory & cycle time thru process layout and pull production techniques
6 Sigma Disciplined Methodology Technical Approach (Quantitative) Data Driven - Statistical Customer Focus Reduce Variation Focus on Large Impact Larger/Longer Projects
Kaizen Philosophical Approach Common Sense Approach (Qualitative) Data Driven - Observation Operational Focus Waste Elimination 5S Incremental Change Smaller/Shorter Projects
Comparative Analysis
6s
Measure - Data Collection - Determine Process Potential / Goals
Improvement Methodologies Similar in Structure Improvements measured against established process Team oriented Similar improvement tools Measure effectiveness of improvements Maintain new performance level Standardize & Proceduralize
Kaizen/Lean
Evaluate - Baseline Process Performance - Establish Target
Comparison Both are Effective Improvement Mechanisms CPI/6s best applied to large complex problems Kaizen/Lean best applied to achieve incremental changes and eliminate wastes.
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.
10
9
Wastes
Overproduction Delays (waiting time) Transportation Process Inventories Motions Defective products Untapped Resources Mis-used Resources
11
Think Break
Overproduction ______________________________ 9 Delays (waiting time)__________________________ Wastes Transportation _______________________________ Process_____________________________________ Inventories__________________________________ Motions ____________________________________ Defective products ____________________________ Untapped Resources __________________________ Mis-used Resources ___________________________
12
Elimination of Waste
5 S Element Waste/ Improvement Item Deliverable
Reduced Costs Improved Quality Increased Product Options Reduced Costs Increased Safety Improved Quality Increased Product Options.
Elimination of finding. Elimination of nonconformances. Elimination of motion. Reduction of part selection errors.
Increased safety. Preventive maintenance. Increased equipment knowledge. Increased equipment life. Higher morale. Clean environment. Increased visibility of nonconformances.
Increased Safety Improved Quality Improved Quality Consistent Delivery Improved Safety
13
5S Implementation Plan
Step 1 Establish 5 S Step 2 Develop Specific Step 3 Develop Communication
Step 5 Implement 5 S
Implementation Team
Implementation Plan
Plan
Systematic Organization
Progressive Enhancements
Standardization
Visual Placement
Cleanliness
Step 6
Verification of Effectiveness
14
Removing Red Tagged stuff What Stuff would you Red Tag in these pictures ?
Think Break
Picture A__________________________________________________________
Picture B _________________________________________________________
15
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
17
Develop a map identifying the access ways(aisles, entrances, walkways etc.) and the action areas.
Cleanliness involves cleaning every aspect of the Organization and the removal of dirt, dust,oil, scraps on the floor, & garbage. Key Deliverables
19
Step 2: Allocation:
Assign resources to the specific tasks required to make 3S a habit.
5S To Do Plan
Date: 5S Team Members Company/Division Name: Page of Person Preparing This Sheet
Item #
Date Started
5S element
5S Task - Action
Person Responsible
Location/ Department
100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75 100 75
Percent Complete
25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50 25 50
20
Remember to focus on the elimination of waste. Strive to maximize yields and obtain cost reductions from existing machinery and equipment before buying solutions. Improve current systems and techniques before automation. Automating a system or practices without first having an understanding of the process will not solve underlying process problems. Perhaps the most important point to remember is that we must understand a process before we make any attempt in changing it. No Tampering is the first rule of continuous improvement. We can not tamper with a process without understanding it. By using these tools, we will all share a common and systematic approach for questioning, analyzing, proposing solutions, experimenting, and finally, implementing proven changes.
Identify waste
The problems that exist in the world today cannot be solved by the same level of thinking that created them.
Table of Contents
Section 1
Development of 5S To Do Plan: Establishment of the 5S team focused on the development, training, and implementation of the companys 5S program. Deliverable includes action plan and associated tasks with the 5S implementation. Waste Identification Map: Identification of the 9 wastes associated with production of products and services. A detailed map of each major work area is developed describing the major types of wastes in each area. These wastes are the improvement opportunities that exist prior to 5S... The overall wastes is calculated for all the work areas and identified on the 9 Waste Radar Chart
Section 2
Section 3
5S Action sheet: Establishing baseline key performance metrics in terms of key deliverables, photographs, and current conditions of the before 5S implementation phase. Deliverable includes the 5S action sheet. Red Tag Strategy: The utilization of Red Tags to visually identify items which are not needed or used infrequently..
11
14
Section 5
Visual Color Sheets: Utilization of colors to identify specific work actions, inventory locations, access areas within the work environment. Initialization begins with development of Visual Color Sheets.
17
Section 6
Visual Sign Sheets: Utilization of signs to identify machine, equipment, tooling, inventory, safety, hazard and work center locations. Sample Sign Sheets. Standard Cleaning Work Sheet: A cleaning matrix identifying the work area responsibilities, supplies, and schedules for cleaning. .. Cleaning To Do List: A action list identifying specific cleaning tasks for each work area identified on the Standard Cleaning Work Sheet.. 5S Status Report: A report identifying implementation effectiveness of each 5S steps applied. A variable metric ranging from 0-5 is established for each step implemented.. Waste Identification Map: Identification of the 9 wastes associated with production of products and services. A detailed map of each major work area is developed describing the major types of wastes in each area. These wastes are the improvement opportunities that exist prior to 5S 9 Wastes Radar Chart: After the completion of 5S, the results of the waste reduction is recorded, charted and compared to the initial 9 Waste Radar Chart.
20
23 27
30
Section 10
33
Section 2
Waste Identification Map
(Section B)
(Section C)
Over production
Delays
Transportation
Process
Inventory
Motion
Defective Product
Untapped Resources
Mis-used
Defective
Resources
P r ce ss o
70 50 40 30 20 10 60
O ve r p r d u c t o n o i 100 90 80
U n t pped a R e so u rce s
0 D e a ys l
I ve n t ry n o
M is - se d u R e so u rce s D e f c t ive P r d u c t e o
M o ton i
Untapped Resources
Before After
Before
After
Before
After
Before
After
Before
After
Before
After
Before
After
100 90
80 70 60 50 40 30 20 10 0
When To Use
How To Use It
1. Referring to the 5S To Do Plan, identify each respective area 5S will be implemented. Develop a Waste Identification Map for each area or department and complete sections A, B, C, with the necessary information. Note you may have multiple Maps for the entire 5S implementation program. 2. For each work department, fill in the equipment, access areas, storage areas, inventory locations etc. on the Map. It is best to draw these to scale. 3. Next identify the processes for each area on the Map. 4. Next, list the products and services at each applicable workstation. 5. Next, identify the product/service flow through the respective processes & work stations. 6. Establish time trials for each major activity and when completed document the time for each major activity within the department. 7. Document the type of waste and time associated with each waste at each activity, process, equipment, inventory, storage, and office location. 8. For each type of waste identified, complete the waste matrix section on the bottom of the 9 Waste Radar Chart in the before column. Note: The y-axis list % of waste, use whatever metric makes sense i.e. time, $, labor hours, productivity etc. Remember that your goal is to reduce these wastes as a result of the 5S Program.
Chart the % waste value for each type of waste on the Radar Chart. Connect each of the values on the radar chart. This is extremely important, this is your baseline metric and will be used to determine the magnitude of your improvements.
Next Step
You are now ready to move to the next step, the Action Sheet.
THANK YOU