Professional Documents
Culture Documents
5s
5s
IMPLEMENT 5 S SYSTEM
Zero Injuries
Improve plant safety & reduce absenteeism
Zero Defects
Increase product quality & reduce variability
Zero Delays
Increase JIT deliveries
PRINCIPLES
V isualize I nform S ignal U nify A udit L ocalize
PRINCIPLES
Visualize Inform
the adjustments, the levels, the lubrication points etc. on the equipments. with indicators, with standards, with diagrams posted in the shopfloors.
5Ss
BUILDING BLOCKS OF T.P.M.
Definitions...
SORT DISTINGUISH BETWEEN WHAT IS NEEDED AND WHAT IS NOT. SET A PLACE FOR EVERYTHING AND EVERYTHING IN ITS PLACE. SHINE CLEANING, LOOKING FOR WAYS TO KEEP IT CLEAN AND IDENTIFYING FAULTS. STANDARDISE TO STANDARDISE PROCEDURES AND AGREE WITH TEAM SUSTAIN
VISUAL MANAGEMENT IS NOT JUST SOME CLEVER TRICK TO GET PEOPLE TO PAY ATTENTION.
ITS ABOUT...
1. BEING ABLE TO FIND IT WHEN YOU NEED IT. KNOWING WHERE TO LOOK FOR IT. BEING ABLE TO SEE A PROBLEM BEFORE IT GETS WORSE.
2.
3.
YOU CANNOT EXPECT SERVICE DELIVERY TO ATTAIN THE HIGHEST STANDARDS IF WORKING CONDITIONS DO NOT SUPPORT FIRST CLASS PERFORMANCE
RED TAGGING
Red Tagging is a dynamic and visual way of determining between needed and unneeded items
Is this item needed? If it is needed, is it needed in this quantity? If it is needed, does it need to be located here? Once the items have been identified and tagged, they can be moved to the Red Tag Holding Area
THE AUCTION
At this stage we go through every item as a team and decide whether to keep it or not.
THE HEART OF VISUAL MANAGEMENT IS A SIMPLE BUT POWERFUL QUESTION. WHAT DO I NEED TO KNOW, WHAT DO I NEED TO SHARE? APPLY THIS QUESTION IN RELATION TO THE FIRST DAY OF THE EXERCISE. NEED TO KNOW
WHAT DO YOU NEED TO KNOW TO DO YOUR JOB MORE EFFECTIVELY?
NEED TO SHARE
WHAT INFORMATION DO YOU NEED TO SHARE FOR YOU AND OTHERS TO BE MORE EFFECTIVE?
OHP Screen
APPLICATION
ARRANGING LOCATIONS ON SHELF AND RACKING. PREVENTS AGE RELATED DETERIORATION ON STORED ITEMS. AUTOMATICALLY SIGNALS A LOW QUANTITY LEVEL AND ALLOWS TIME OF REFILL. OUTLINES ALLOW AT A GLANCE ADDRESS FOR TOOLS AND JIGS. AUTOMATICALLY RETURNING TOOLS TO SET ADDRESS.
4. SHADOW BOARDS.
5. SUSPENSION DEVICES.
FACTORY
WORK SITES
LINE/SECTION
PROCESS
MACHINES/EQUIPMENT DOCUMENTS
NAME BADGES? THIS STRAGETY FOR SIGNS EXTENDS TO SMALL DETAILS SUCH AS PROCESS SIGNS, MACHINE SIGNS AND EVEN NAME TAGS ON WORKERS UNIFORMS. APPLY THE TWO KEY WORDS AND 3 POINTS AND 3 KEYS.
FIRE EXTINGUISHER
Lower Level Address Triangular displays ensure information is visible from sides.
FIRE POINT
Lowest Level Address Clear labels on extinguisher indicate test and refill data.
G:\MRINSE\TPM.PPT
CURRENT
fig: V1
FUTURE
fig: V2
fig: V3
MAX MIN
fig: V4
40 30 20 50 60 30 20
40 50 60
Stage 2
Standard values are indicated on dials.
40 30 20 50 60 30 20
40 50 60
35
Stage 3
54
Standard values are indicated in color on the respective instrument, although each dial must be separately monitored.
40 30 20 50 60 30 20
40 50 60
Stage 4
One can compare to standard values with a mere glance, even from a distance.
50
60
40 30
G:\MRINSE\TPM.PPT
KEY 1
ELIMINATE SEARCHING WASTE. MAKE THINGS EASIER TO GET AND USE. MAKE SURE THERES ALWAYS THE REQUIRED QUANTITY. MAKE THINGS EASIER TO PUT BACK. MAKE THINGS UNDERSTANDABLE AT A GLANCE. AVOID PRIVATE COLLECTIONS.
KEY 2
KEY 3
KEY 4
KEY 5
KEY 6
inspection
Cleaning exposes abnormal conditions and corrects prefailure conditions
Cleanliness Maintenance
Instant Maintenance
Operator immediately restores or improves upon the abnormality or slight defect
Requested Maintenance
If unable to immediately restore or improve upon the abnormality or slight defect operator :Flags abnormality Enters flag details on abnormality / improvement sheet Once item is taken care of and its results confirmed the item should be checked off in the confirmation column and the flag retrieved
5S is about the environment we work in NOT inside the machines. Examples of defects might be - missing lights - leaking pipes - missing manifold covers - damaged pillars
Cleaning Guidelines
List cleaning tasks in an efficient sequence Agree responsibilities Indicate where, when and what is to be cleaned specify methods or tools to be used Identify any checking criteria and corrective action to be taken
the adjustments, the levels, the lubrication points etc. on the equipments.
Goals : Be able to control equipments (oil levels) without any tools. Instantaneously control that suitable material (tools, adjustment pieces, cleaning material) is available and put back in its place. Eliminate risk of mistakes during the dismantling and the re-assembling of parts. Suggestions : Guidemarks to adjust parts. Color marking to fix equipment during changeovers (fig: V1). Drawing the object on its location (fig: V2). Visualize lubrication points on the equipment or on a photography. Narrow strips in front of the fans to visualize that they are running. Plexiglass plate with marks (fig: V3). Match marks on parts likely to loosen (fig: V4). Visualization of normal operating limits on control dials (fig: V5).
Visualize
Inform
Inform
Signal
Signal
Signal
pipes.
Goals :
Instantaneously know the nature of the fluid running into the pipe (in case of dismantling or incident). Know what is the fluid direction in order to prevent problems during the dismantling. Good practices : Respect the colors code for identification (see pipes identification exhibit). Indicate by signs posted in the shopfloor, the standardization in use. Indicate by direction signs on the pipes the fluids direction.
Unify
Suggestions : Unify the oils and code them to be able to mark lubrication inlets with the type of oil to use. Make a pre-printed format for the teams meeting minutes.
Audit
Audit
Audit
Localize
shopfloor.
Goals :
Have a meeting point. Create an exchange of up and down information. Organize short meetings. Provide functional diagrams, indicators etc. to facilitate explanations when solving a problem or presenting the shopfloor to a new member. Suggestions : Have a communication space for the plant (for temporary workers, visitors). Good practices : The communication space has to be painted in blue order to identify it. Identify 3 specific parts into this space : e.g indicators / communication / business. Have a permanent self service paper board. Have a high table to facilitate taking notes or writing standing during small meetings.