6S Overview

Workplace Organization and Standardization

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Lean Building Blocks

Continuous Improvement

Pull/Kanban Continuous Flow Teams

30%
Total Productive Maintenance SMED/Quick Changeover
50%
Rapid Improvement Event Quality at Source Point-of-Use
15% Value
6S System Visual Standardized Work Stream
Mapping

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What is 6S?

The 6S’s are:

• Sort
• Set in Order
• Shine
• Standardize
• Safety
• Sustain

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What is the Goal of 6S?

• A workplace that is: • 6S results in:

– Safe – Improved control
– Stable – Improved efficiency
– Consistent – Improved visibility
– Predictable – Fewer accidents
– The foundation for all other
improvement activities • And thus…
– Reduced waste
– Reduced cost

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How do We Get Started on the Project?

• Decide on an area
• Determine the purpose of the area
• Measure the process
• Create a metric board
• Implement 6S
• Measure your progress

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What is a Spaghetti Chart?

• A layout showing equipment and personnel

and their movement through the area

Pallet

Worker

Mobile Equipment

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Spaghetti Diagram - Transportation & Motion

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Before and After: Gasket Table and Large Hand Tools

Before

After

Before
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Example 6S Inspection Checklist
6S Routine Audit Form
Audit Date: Area Audited:

Auditor(s):

Scoring Legend Good Marginal Poor If ite m is no t im ple m e nte d in the

a re a , s c o re ze ro a nd inc lude in the
4-5 2-3 0-1 fina l to ta l Score
6S Category Item Safety
Are safety guards/alarms in place and visible? 0
Are employees wearing the proper PPE and following safe practices? 0
Is anything blocking an entrance way, fire extinguisher or pathway? 0

TY
FE
Are there any trip hazards (hoses, electrical cords, etc.) in the area? 0

SA
Are there potential hazards in the area? 0
Are labels and warning signs legible? 0
Are chemicals properly labeled and stored? 0
Total: 0

Have all unnecessary items been removed? 0

Are unneeded items stored appropriately? 0

T
R
SO Are personal belongings properly stored? 0
Are there obsolete, worn, broken, out-of-service items, equipment, tooling, 0
Total: 0

Is there a visually marked/specified place for everything? 0

ER

Is everything in its specified place? 0

D

Are proper amounts and restock limits for supplies clearly identified? 0
R
O
IN

Are storage areas for tools, tooling, supplies, etc. straightened and orderly
0
T
SE

according to some standard of organization?

Are items put away after use? 0

Total: 0

Are cleaning materials and tools easily accessible? 0

Are equipment and work stations kept clean and free of oil, grease, dirt and
0
debris?
Are designated walkways/stairs free of dirt, oil, grease and dust? 0
E
IN
SH

Are floors, walls and shelves clean and in good repair? 0

Is lighting in the area good? 0
Are all connections, hoses, wires, belts, covers, lids, in place and tight? 0
Are labels and signs clean and easily readable? 0
Total: 0

Are 6S standards clearly stated? 0

ZE

Are 6S responsibilities clearly defined and assigned? 0

DI
R
DA

Are procedures and other work instructions available? 0

N
A

Are 6S activities incorporated into work schedule? 0

ST

Are internal checks in place to ensure compliance with established standards? 0

Total: 0
Is the 6S program discussed as part of unit meetings? 0
Are 6S performance charts/documentation visible and improving? 0
IN
A

Are tools in place to maintain 6S? 0

ST
SU

Are 6S practices routinely embraced by area personnel? 0

Overall, is the area maintaining 6S rules and disciplines? 0
Total: 0
Overall Score 0

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6S Example Radar Chart
Scores Safety
Safety 0 0
Sort 0
Set In Order 0
1
Shine 0
Standardize 0
2
Sustain 0
Overall Score 0
Sustain Sort
3

Standardize Set In Order

Date of Audit:
Shine

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Sort

• What do you need? What doesn’t belong here?

– Go through the items in the area
– Identify what is needed in the work area
– Eliminate or sort out what is not needed
– Keep only the quantities that are needed for
a given amount of time

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Sort Examples: Before and After Pictures

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Sort Examples: Before and After Pictures

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What is the Process for Sort?

• Determine the criteria for sorting the area

• Make 6S tags and create a 6S tag holding area
• Assign someone responsibility for the 6S tag area
• Begin identifying what needs to be sorted out
• Move items to the 6S tag area for disposition

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6S Tag Example

6S TAG
Date _____
Location _____________
Completed by ___________

Reason for 6S Tag:

 Safety Issue
 Defect
 Not Required/Scrap
 Obsolete

Action to Take:
 Discard
 Move to 6S Tag Area
 Transfer to _____________

Comments:
____________________________________
____________________________________
____________________________________

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What Criteria Should We Use for Sort?

• Questions to ask:
– Is it used in this area?
– Do you know what this is?
– Is it really needed?
– How often is it used?
– Who uses it?
– If the item is removed, will it really matter?
– Does it take up a lot of space?
– Is it in the way where it is?

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Set in Order

• A place for everything and everything in its place

• Procedure:
– Find the best location (look for ways to minimize motion,
transportation, and inventory)
– Set size limits on what will be kept in the area
– Safety first
– Create models/templates to help define where items will go

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How Do We Decide Where to Put Things?

• Where is it used? How close is it?

• How frequently is it used?
• Is it accessible? Is it easy to put back?
• Is it safe? Is it too big or too heavy to move?
• Is the location ergonomic?

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Set in Order

Missing items
are visible

Excess items
are obvious

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Set in Order Examples: Before and After Pictures

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Set in Order Examples: Before and After Pictures

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Set in Order Examples: Before and After Pictures

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Set in Order: Labeled Tool/Equipment Positions

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Everything Has a Place, Everything in its Place!

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Shine

• Clean up the area

• Clean both the inside and outside
• Look at ways to prevent dirt, dust, and
contamination from occurring
• Make shine a daily part of the operation
• Inspection as cleaning

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What is the Shine Procedure?

• Identify the area that is to be shined and who will

be responsible for that area
• Determine how the area will be cleaned
• Make sure you have the right tools and supplies in
place
• Begin the process of cleaning
• Use this as an opportunity to inspect equipment
and to perform maintenance as necessary

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Inspect Things During Shine

• Is everything in its proper place?

• Do any parts or equipment need to be replaced?
• Are there any repairs necessary?
• Check everything!

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Lean, Clean and Ready to Use!

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Standardize

• Create procedures and rules to maintain the

Sort/Set/Shine
– Set 6S tag procedure
– Identify who will be responsible for the 6S tag area
– Identify area responsibilities and set aside time for daily 6S
activities
– Make sure visual controls are in place that identify material,
location, and quantity
– Set a schedule for cleaning and maintenance activities

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Guidelines for Standardize

• Make standards obvious and easy to see from a distance

• Ensure information is on or near the operation or object
it relates to
• Make standards understandable by anyone
• Use checklist and audit sheet
• Ensure that 6S standards accomplish their purpose: an
organized, orderly, clean, safe, and efficient workplace

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Visual Controls

• Simple signals that provide an immediate understanding of

a situation or condition
• Efficient, self regulating, and worker-managed
• Examples include:
– Pictures, diagrams
– Color-coded dies, tools, pallets
– Lines on the floor to delineate storage areas, walkways, work areas
– Improved lighting

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Visual Controls Example

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Andon Examples

• A visual management tool that highlights the status of

operations in an area at a single glance and that signals
whenever an abnormality occurs
• May indicate production status (for example, which
machines are operating), an abnormality (for example,
machine downtime, a quality problem, tooling faults,
operator delays, and material shortages), and needed
actions, such as changeovers
• May also be used to display the status of production in
terms of the number of units planned vs. actual output

Source: Lean Lexicon

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Andon Examples

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Safety

• Ensure your work area is free of hazardous conditions

– Avoid injuries and unsafe work practices
– Safety is everyone’s responsibility! Incorporate it into your
workplace layout and organization
– Check points for your workplace:
• Are safety guards/alarms in place and visible?
• Are aisles clear and emergency exits signs in place?
• Are there any potential hazards in the area?
• Are personnel following safe practices?
• Visual Aids/Warning Labels - Are labels and warnings legible?
• Are chemicals properly labeled and stored?

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Safety Examples: Before and After Pictures

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Sustain

• Ensuring future compliance

– Follow rules that you set:
• Develop habits that are easily repeatable and unforgettable
• Involve workers and employees in this process
• “MAKE THE STANDARD VISIBLE” - use visual displays and
visual controls whenever and wherever possible.
– Check points for this process:
• Are 6S performance measures visible and improving?
• Do you have a daily inspection routine and is it followed?
• Are 6S related problems identified and corrected?

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Sustain

• Create conditions or structures that help SUSTAIN a

COMMITMENT
– Allow time in the schedule for 6S activities
– Structure for how and when 6S activities will be implemented
– Support: acknowledgment, leadership and resources
– Rewards and recognition for the effort involved in establishing
and sustaining 6S
– Satisfaction and enjoyment

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We Need to Shift Our Thinking

• Change our definition of normal

• Understand the 30 second rule
• Know the “one is best” concept
• Move from individual to group ownership
• Ensure that 6S is an essential part of daily work
• Move from “fix-it” to "control-it" thinking
• Enable workers to manage and control their area

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6S - Information Flow

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