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Monday, September 3, 2012
Lean 101: 5S Workplace Organization (Part 2 of 2)
In last week’s blog, we learned that 5S is the
foundation for a disciplined approach to the workplace. 5S provides many
benefits including improved quality, employee empowerment and morale, safety
and efficiency improvements.
How to implement 5S at your facility?
First step is to Sort the items that are needed from those that are not needed in
the workspace. Create a space for items to be disposed (quarantine or scrap
area). Common method is red-tagging items for disposal to make them easy to
identify. Typical criteria used to sort items include:
- Frequency of Use
- Is item used hourly or daily? Store item at the workspace.
- Used weekly? Store near the workspace.
- Used Monthly or less than once per month? Store a more distant location.
- Used once a year or less? Dispose of item.
- Condition
- Is item broken or damaged? If so, dispose
- Is it worth fixing?
- Applicability
- Is item at all useful?
- Is it really needed to perform my job function?
- Can other team member use the item? Use a cross-functional team to evaluate keep/dispose status of items.
Straightening the workspace is the second step. The goal is to
create “a place for everything and everything in its place”, everything has a
clearly designated name and place to eliminate need to look for items. The goal
is to design a quick retrieval and storage system. The key to Straightening is visual management
Common tools used in Straightening include:
- Shadow board
- Organized floor space, defined areas outlined with tape and labeled
- Labeled shelves / racks
- Signs / Flags labeling aisles, for example in a warehouse or supermarket
Once the work area has been sorted and straightened, the area is Shined (cleaned) to create a bright productive work environment. The two keys to Shine
are assigned individual cleaning responsibilities and frequency of cleaning
activities. This ensures cleaning takes place as required by specified
individuals – there is not confusion around who should do it and when. Time may
be set aside at the beginning or end of shift to sweep around the work area.
Wipe down of work station between product batches may be required to prevent
cross-contamination. Shine not only positively impacts employee morale, but
also improves product quality!
Standardization refers to visual management and 5-S
standardization. It is often referred to as the “5S Job Cycle” because it
establishes periodic revisit to the 5S activities for each area. The manner in
which 5S activities are carried is also standardized. For example, red tag is
used the same way across the company, use of a common checklist for 5S audits,
common cleaning practices. Standardization is critical to the last 5S step –
Sustain.
Sustain is the individual
discipline in maintaining an organized workplace, and the culture in the
company to facilitate and encourage the discipline. How can 5S be sustained?
Build regular 5S audits into your standard operating procedures. Integrate 5S
maintenance into annual performance assessments. Create a rewards system or
contests to encourage participation in 5S activities and maintenance.
Safety in the workplace for the employee must be considered
and evaluated each step of the way in 5S. In the Sort stage, consider using a
different color tag to highlight environmental, health and/or safety (EHS)
concerns. Through straightening and shine, resolve the highlighted EHS issues
from Sort. Incorporate EHS into the standard 5S audits to ensure continuous
review and improvement of safety in the workplace. Include safety metrics in
communications, into annual performance assessments and in rewards systems in
the company. Creating a culture of safety is an integral part of the Lean and
5S culture.
What will you do today to start a culture of safety and
organization?
What does your company do to maintain a lean culture?
Monday, August 27, 2012
Lean 101: 5S Workplace Organization (Part 1 of 2)
The foundation to creating a lean culture of continuous improvement is an organized workplace. To clearly identify any form of waste in business processes, the clutter must be removed from the workspace. 5S is the foundation for a disciplined approach to the workplace. The term “5S” comes from the Japanese method for workspace organization and housekeeping. Each step in the system starts with the letter S. Safety is the sixth “S” which has been added to ensure a safe workplace is created. The term “6S” or “5S+Safety” are often used to include Safety in the original Japanese system. Steps are outlined below with the English translation:
 |
| 5S Cycle |
1. Sort: Remove what is not needed
2. Straighten: “A place for everything and everything in its place”
3. Shine: Cleaning
4. Standardize: Visual management and standardization
5. Sustain: Discipline to maintain and build upon improvements through 5S process
6. Safety: Identify and eliminate safety hazards
2. Straighten: “A place for everything and everything in its place”
3. Shine: Cleaning
4. Standardize: Visual management and standardization
5. Sustain: Discipline to maintain and build upon improvements through 5S process
6. Safety: Identify and eliminate safety hazards
Why perform 5S? What are the benefits?
o Business Efficiency! It takes MUCH LESS time to find items you use regularly. For example, the “catch-all” drawer in the kitchen cabinets where all phone numbers and small tools get lost for months and years. How long does it take to find anything in there? With a clean, organized drawer that contains only the necessities, any item can be found in a snap! Same goes for business processes - first step to lean operations are organized work spaces.
o Empowerment! By having team members take ownership for their own workspaces, they feel empowered to make decisions and take action to improve the quality of their work.
o Safety! By removing clutter and broken or damaged items, the workspace becomes safer to work in. Eliminate opportunities for slips, trips and injuries
o Morale! Employees take pride in the quality of their work and the appearance of their workspaces. Get your teams on the right track by providing these tools.
o Quality! Reduced opportunity to damage product because clear space is delineated to place product, no stray tools to fall on product, and product status is clearly identified as accepted / in-process / rejected / quarantined.
Stay tuned for the second installment of this blog to learn how to implement 5S at your workplace!
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