IntroductionUnit 4, IDA Industrial Estate,
Purcellsinch,
Kilkenny,
Ireland.
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This document has been formulated in order to explain to organizations about 5S & Visual Workplace, the requirements of the 5S & Visual Workplace in simple terms and some of the benefits of the if they are applied correctly.
We hope you find this document useful and please do not hesitate to contact us with any questions.
5S
What it means:
| Japanese | Translation / Definition | English Equivalent |
|---|---|---|
| SERI | Sort needed & unneeded items | SORT |
| SEITON | Put things in proper places, arrange | SET IN ORDER |
| SEISO | Clean the workplace | SHINE |
| SEIKETSU | Standardize the first 3 S's | STANDARDIZE |
| SHITSUKE | Make 5-S a part of the job | SUSTAIN |
1 - SORT
First, we SORT the needed from the unneeded !!!
Conducting a “Red Tag” Campaign
- Select Area and a Team, including the Area Owner
- Place a Red Tag on Every Item in the Area
- Segregate Items into:
- Used Frequently
- Used Occasionally
- Used Rarely or Never
- Make a Permanent Home for:
Frequently Used Items in the Work Area - Move Less-Frequently Used Items Outside the Area
- Remove Rarely-Used or Not-Used Items from the Area
(if they’re needed in the future they can be retrieved)
Benefits
Remove Clutter
Improve Safety
Empty Wasted Space
2 – SET IN ORDER
Second, we SET IN ORDER what we keep !!!
- Popular items belong closest to Point-of-Use
- Every item gets a fixed home
- Make it easy to retrieve, use, & return items
- Nothing but feet touch the floor
Benefits
Ease of Job Performance
Safer work-area
Better ergonomics
3 - SHINE
Third, we SHINE throughout our work-areas !!!
- Clean Everything
- Paint Everything
- Prevent dirt & grease from returning
- Clean Floors
- Make our work-areas into places where we’re proud to work!
Benefits
Begin to take Pride
in Workplace.
Become a showpiece for
company & visitors.
4 - STANDARDISE
Fourth, we STANDARDISE our 5-S & Visual Factory Systems
- We build a Plant-Wide 5-S System to our Plant-Wide Standards
Benefits
We’re all part of one Fleet
with a common purpose.
We all drive toward
World-Class Performance.
5 - SUSTAIN
Fifth, we SUSTAIN our Success !!!
- Training for all Team Members
- Consistent Management Support
- 5-S is a part of our Daily Lives
- Audit Regularly
- Make Performance Matter
Benefits
Ease of Job Performance
Safer work-area
Better ergonomics
VISUAL WORKPLACE
- What do you do here?
- What is the flow of the product?
- How well is the product flowing at this moment?
- Is production efficient or inefficient?
- What is the quality level of the various operations?
- What progress has been made to reduce inventory levels?
- To what degree is continuous improvement being practiced?
The environment at many plants is tedious because the reality of production is not visible at the point where production occurs.
VISUAL MESSAGE
“I’ll believe it when I see it.” “A picture is worth a thousand words.” “Now I see what you mean.”
Visual images send a more consistent message!- Visual communication is predominant in organizations that seek to reinforce employee autonomy.
- The emphasis is on openness, expansion of contacts, and greater cohesion.
- Visual communication, above all, is a matter of company culture, a culture where the essence is sharing.
- Companies that promote a visual workplace typically practice other forms of workforce empowerment as well.
- A visual workplace enables people to see
VISUAL METHODS
The distinctive aspect of visual communication is that it is intended for a group. This helps people to pull in the same direction.
Visual Communication can be:
- a sign
- a label
- a photograph
- a display
- a trend chart
- a color scheme
- whatever serves the purpose
A visual message is observed by everyone working in a given area, everyone who passes through the area, and everyone who comes into range of visibility.
VISUAL PURPOSE
Visual Communication should be tailored to the audience
If information is intended for cell operators, supervisors, technicians, or management, then they must be personally involved in the creation and maintenance of the visual communication.
Each objective that is posted for a factory or work cell should have the effect of mobilizing the individuals responsible for achieving that objective.
Every flag, flashing light, or caution statement must be linked to a corresponding set of actions and responsibilities.
If no one is using a visual communication, it should be removed.
VISUAL INFO.
Information Empowers Workers, Promotes Autonomy & Productivity
- Has the group defined a productivity objective?
This objective must be visible. - Are operators responsible for quality?
Quality must be visible. - Must precise work instructions be followed?
These work instructions must be visible. - Has the team developed an improvement strategy?
This strategy must be visible. - Is the customer satisfied or dissatisfied?
This satisfaction level must be visible. - What do the people in this area do?
- What are these tools for?
- Are any missing?
- What is this inventory?
- Are there any safety precautions in this area?
- What is the current status of this line?
VISUAL EXAMPLES
There is no reason to try to do everything on this chart or to limit yourself to what’s on this chart. Be creative and use what works.
The Team’s Territory
- Boundaries of Territory
- Activities, Resources, and Products
- Identification of the team
- Markings on the floor
- Markings of tools and racks
- Information and instructions
Visual Production Control
- Takt Time
- Production Schedule
- Maintenance Schedule
- Inventories and WIP
Visual Quality Control
- Quality losses
- Statistical Process Control
- Cautions and Alerts
- Monitoring Signals for Machines
General Displays
- Objectives and Results
- Mission Statement
- Concept Posters
- Improvement Activities
- Current Projects
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