|
The free newsletter of
Lean Manufacturing
Strategy
Books & Videos
Value Stream & Process Mapping
Cycle Counting
Warehouse Planning
Human Side of Lean Video
|
 |
Elements of 5S
5S Fast & Simple
|
The First Step--Clean Out The Junk
Sorting through objects in the workplace is the first step. Everything that moves should have
a tag-- tools, parts, furniture and personal objects. While the procedure is simple, the
decisions are sometimes agonizing.
Who Decides?
This can be a delicate issue. Generally, let the person who uses or owns the item decide.
When several people within the work group use the item, negotiation may be required.
|
 |
-
Allocate a central "Red Tag Area" where items go that cannot be
simply thrown in the trash.
-
Include disposal instructions if necessary.
-
Appoint a review board for questionable items. (You may not need an item but someone else
may.)
|
|
|
-
Allocate a "Yellow Tag" location near the workplace.
-
Review on a specific date.
-
Store occasionally necessary items in out of the way locations.
|
 |
|
|
The Second Step--Clean, Polish & Paint
 With only
essential items remaining, it is time to clean and paint. In some 5S programs, cleaning and
painting are considered separately. Either way, it is likely to be done over time.
The first cleaning leaves some dirt and oil. The next cleaning looks better and third
cleaning will prepare for painting. All floors, equipment, and almost every surface should get
paint.
Guidelines for Shine
-
Each work team should establish their own measure of "clean".
-
Establish a regular schedule for routine cleaning and deep cleaning.
-
The entire team participates. This is not something for a special janitorial crew.
-
Ensure that each crew has adequate cleaning supplies and equipment.
|
 |
The Third Step--Determining Locations
After Sort and Shine, "Set" determines and identifies the location of each item. The methods
for determining such locations may be elementary and intuitive or formal and elaborate. Often
the elementary methods work quite well, especially during in the early phases. Workers simply
look at each item, visualize its use, estimate the frequency of use and then select a location.
After a few days, they can review and revise their locations.
Locations should be identified at both a micro and sub-micro level. String diagrams can
assist at the micro-level. Principles of
Ergonomics and
Principles of Motion Economy can assist at the sub-micro level. Horizontal and vertical reach zones help to
determine the best sub-micro location. The heaviest and most frequently used items should be in
the nearest reach zones.
Once people develop awareness, their body sense will alert them to excessive reaching,
walking or awkward positions. They learn to "SET" items instinctively.
|
   Reach Zones To Determine Location
Typical Workstation
"String Diagram" for Material Flow
|
Boundaries
Boundaries identify the designated and location and space for each item. They
encourage
recoil, that is the proper return of an item, as shown below. They also tend to prevent people
from placing other items in a designated space. When combined with addresses and nameplates, boundaries are a powerful tool for ensuring that
every item returns to its proper place, every time.
|
The barrel should be here.
|
A missing barrel is not obvious.
|
A boundary designates the proper location.
|
|
Clearly, something is missing.
|
An address informs us what Is missing.
|
A complete address on the barrel & location, encourages return.
|
The Fourth Step--Standardize
At minimum, standardize the 5S activities shown at the right. In some programs,
standardization is used as an opportunity to standardize normal work activities and develop work
instructions.
Standardize 5S Activities
-
Aisle Marking
-
Cleanliness Standards
-
Color Schemes
-
Cleaning Schedules
-
Signage
|
 |
|
|
