Kaizen

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WasteManagement-5smodule1.pptx
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Lean Manufacturing

Department of Industrial Engineering –

 New Mexico State University

Dr. Delia J. Valles-Rosales

What is Lean Manufacturing??

It is a set of methods and techniques developed by engineers of Toyota, and it is very popular in today´s world companies to increase the value of products through waste management.

Identify the

QUALITY

ISSUES

Eliminate

WASTE

Right

THINGS

Right

PLACE

Generate a SMOOTH FLOW

Right

TIME

Right

QUANTITY

MODULE

01

Waste Management (5s Methodology)

THE JAPANESE SYSTEM “A place for everything and everything in it’s place”

It is a methodology that seeks a work environment consistent with the philosophy of total quality, highlighting the involvement of employees in conjunction with the company.

WHAT ARE THE 5’s?

Sort (Seiri):Tidiness

Throw away rubbish and unrelated materials.

Susteain (shitsuke): Discipline

Make it a way of life. This means commitment.

Set in order (Seiton): Orderliness

Set things in proper place for quick retrievel and storage.

Standardize (Seiketsu): Standardization

Standardize the way of maintaining cleanliness.

Shine (Seiso): Cleanliness

Clean the workplace.

M.I. Alejandro Nájera Acosta

Examples:

Origion of 5S

A systematic approach to organizing, ordering, and cleaning had its origins in post-World War II Japan – probably in the mid 1950s. At the time, Japanese manufacturing companies were forced to produce with very few resources, so they developed a shopfloor method to make every scrap count while wasting nothing.

Originally, there were only four activities in the Japanese system, and later, a fifth activity was added and completed the “S” elements that are known as 5S. (Fabrizio & Tapping, 2006)

Objectives

Improve cleanliness and organization of work points.

Facilitate and ensure the activities in plants and offices.

Generate ideas aimed to improve results.

Promote the discipline.

Create best practices for manufacturing.

Create a proper work environment.

Eliminate accidents.

What is 5s?

The 5s methodology is considered the removing of non-value-added processes by developing standard methods for doing the necessary work. This methodology improves efficiency, quality, workflow, and employee safety

According to Visco, 2016, 5s is based on the Japanese words that begin with the letter “S” that stands for:

Sort,

Set in order,

Shine,

Standardize,

and Susteain.

How is it implemented?

Because key words are great for catching The five pillars are generally implemented in order to one pillar following after another. Once a company decides to move forward with 5S, it is important to make a plan appropriately.

According to Visco, 2016, some items to consider are choosing the right project leader, 5S champion, team members, the size of the area to address, timeframe, and ultimate goal.

.

Project

Leader

5S Champion

Team

members

Size of the area

Timeframe

Ultimate

goal

A leader who understands 5S and has experience managing and implementing the different steps

This is the person responsible for the area of attention

make sure everybody get involved whit the 5S implementation.

Selecting a small area is more effective, and all of the necessary work can be completed.

Option 1: Close down the area until the work is done

Option 2: Close the area for a few hours every week until the work is completed

It is fundamental to determine the objectives before proceeding

1. Prevention

2. Space optimization

3. Workplace organization:

a. Process

b. Material

4. Visual Control

5. Quality Improvement

6. Reflects abnormalities

7. Cleaning

8. Responsibility

9. Positive attitude

This system provides great benefits in process control such as:

BENEFITS

Typical 5S Benefits

Data collecting is an integral part of the 5S program and can be used to track and correct many workplace inefficiencies.

Managers can use this data to take actions and make corrections so the company objectives are achieved and all-around facility processes are improved.

Safety and moral

Product quality

Equipment life

Increases

Decreases

Injures

Production costs

Downtime

Defects

Supplier Mistakes

Underutilized workers

Inventory storage costs

Underutilized floor Space

Tools/inventory searches

Step

Is this item necessary to do this job? Do we really need these items?

01:

SORT - Tidiness

Warehouse

Offices

Shelves

Production areas

The objective of this step is to assess facility inventories, equipment, tools, needless items, redundancies, and hazardous can be sorted from the work area.

In this step, workers must be trained, so SORT becomes an integral part of work routines.

Remove all items that are not needed in our work area.

Recognize the area of ​​opportunity

Define the criteria for selecting unnecessary items (see 5s check list)

Identify the selected objects

Evaluate the selected objects

https://www.graphicproducts.com/articles/what-is-5s/

This helps you to identify objects that must be removed from the workplace.

So, when you see something you think may need to be relocated, you put a red tag on it. In this sense, everybody will know that this particular item must be evaluated and define its place

Front Side

Back Side

Necessary objects

Damaged objects

Obsolete objects

Extra/Additional objects

Organize

¿Is this useful?

Fix up

Yes

No

Identify

Remove

¿Is this useful to someone?

No

Transfer

¿HOW TO USE 5S RED TAGS?

Step

Would a new person in this work area know where this item belongs?

02:

SET IN ORDER– Orderliness

Once sort has been completed, 5S leaders move forward to a better system of organization.

The objective of the “Set in Order” step helps an area to find the right and permanent storage for every item.

Define maximum and minimum quatities

Group things that can are use for the same task.

Store things that will have the same similarities

Avoid storing things that ere in used in a close place

https://in.pinterest.com/pin/331014641369141203/

This is considered the easiest way to quickly and visually identify the proper placement of tools, materials, and equipment

For instance, drawers of tools can be labeled with their contents, so workers know what they have based on what they need

Draw lines to limit acess to working places

Use colors

Document the method used for organizing your working place

This is useful for marking work areas as well as locations for raw materials, tools, etc. This makes things easier for workers and visitors to have a good idea of space because it shows every area of a facility including the work cells of any kind.

.

Best practices do not specify exactly which color of type should be used in your facility.

However, tape colors should be chosen to ensure they are easy to see for everyone in the facility.

Step

Are there items in the area that need to be cleaned?

03:

SHINE – Cleanliess

This particular step refers to the cleaning and maintenance that workers include into their daily routines.

Therefore, workers must have a schedule for cleaning periods, and they have to have access to the right cleaning supplies to put Shine in action.

Inspection and maintenance are two tasks that should be included in the daily Shine ritual.

Step

Are the methods/processes in place to keep the first three Ss maintained and ongoing?

04:

STANDARDIZE – Standarization

Standardize helps to create uniformity in the workplace so 5S duties are fully integrated into daily, weekly, and monthly work schedules. this pillar establishes what each employee knows what he/she needs to do, when he/she needs to do it, and exactly how to do it. There is no room for uncertainty.

JOB DESCRIPTION PERSONNEL START TIME
Sweep Sweep and dust workplace from top to bottom James 10:15 PM
Wash Clean contaminants Nick 10:30 PM
Empty Garbage Properly dispose of work-area garbage collected in cans Matt 10:45 PM

5S SHINE DUTIES (Friday Swing-shift)

Step

Are items reverting back to the unorganized way they were?

05:

SUSTAIN – Discipline

This final step helps to maintain the facility´s system for the life. However, the four previous steps should have already implemented into daily operations to guarantee complete success in the last S Sustain.

Five suggestions to keep the program working well:

Assign the time to do it.

Start from the top.

Create a reward system.

Get everyone involved.

Let them see it.

https://www.researchgate.net/publication/324202036_Case_study_concerning_5S_method_impact_in_an_automotive_company

https://www.researchgate.net/publication/334507299_Implementation_of_5S_in_Jute_Mill_A_Case_Study

https://www.researchgate.net/publication/329350609_A_Case_Study_How_5S_Implementation_Improves_Productivity_of_Heavy_Equipment_in_Mining_Industry

CASE STUDIES

THANK YOU

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