5s And Stating Fit Flashcards
What is a 5s primer?
Embracing the five disciplines and developing a culture that supports them
1S
Sort: comb through materials, tools and equipment, identidying what is needed and getting rid of what is not
2S
Set in order- develop and organization system using visual cues like shadow boards or masking tape to identify where each tool or piece of equipment goes
3S
Shine- clean equipment, tools and workspaces, note their condition. Develop a schedule for ongoing cleaning and maintenance of all items and areas and regularly inspect
4s
Standardize- create and use clear simple work methods and standards, including processes for the first three S’s
5s
Sustain- develop a culture around the principles of 5S. Communicate involve and train employees, provide regular feedback
Sixth S
Physical and mental safety, affects not only accident and injury concerns but the motivational aspect of work as well
How do some companies treat 5s?
As a simple housekeeping program with the mantra of a place for everything and everything in its place
Better descriptor of 5s
Take care of the small things and the big things will take care of themselves
What should Five S be?
A problem prevention program and a way to identify and fix problems when they are still very small thus preventing big problems.
What did taiichi ohno teach?
Must ask why Five times in order to find root cause looking deeper and deeper ti uncover underlying problems for real improvement and change to take place
What do sweeping problems under the rug or mopping problems up cause?
Costly problems like faulty products, maintenance mishaps, employee injury or death
Where could a problem like an oil leak come to light using the 5s program?
Various stages of 3S, the shine step depending on the discipline
A great 5s program
During a regular scheduled inspection, small bits of oil are observed on a gasket, The root cause is determined and corrected
Good 5S program
A drop of oil forms and maintenance is requested before it drips on the floor
Average 5S program
A drop of oil on the floor brings attention to the maintenance issue
A housekeeper focused program
cleaner wipes, away, evidence of the oil and nothing further is done until the machine runs out of oil and breaks down
Second factory issue
found electric cabinet that had been left closed but unlatched, breaching normal safety procedures, and OSHA regulations, multi test parts made were packaged to be shipped the next morning
Scenario 1
Meticulous housekeeping, zero problem solving
Scenario 2
Skipping protocol and procedures endangers both products and people
Scenario 3
Asking why until then root cause is found
What does successful implementation of 5s or 6s require?
Involving, empowering and inspiring workers to share the vision and embrace the cause
What do these programs often involve?
Significant change and convincing workers to do things differently necessitates showing them how and why they as well as the company stand to gain by doing things differently
Why is the fifth S vital to the program
Sustain is vital because without it the program will be little more than managements latest here today gone tomorrow
What can an organization gain with the fifth s?
Greater safety, quality, productivity, and a positive culture where employees feel valued and can thrive
What does the Japanese term gemba mean?
Actual place
What does gemba suggest?
That if you really want to know what is going on you need to go to the place where the action occurs
Why do lean practitioners apply gemba
To stay in touch with what is happening on the factory floor
Possible reasons for gemba walk
Learn about practices, coaching employees, or following up on issues identified in the past
What are some general guidelines for success?
-have a purpose
-keep it brief
- drive out fear
Have a purpose
Identify the processes, people or products to be studied
Keep it brief
30 to 45 minutes should be long enough to accomplish the purpose of the walk
Drive out fear
Develop a culture where employees are glad to see the gemba walker and are exited to share their ideas for improvements
Biggest miskate made with gemba
To just wander aimlessly about the plant floor in a meet and greet session, handing out pats on the back or empty praise to employees
How can an occasional pause be helpful
Will give you a different perspective from walking as you observe what is happening around you
What are the cultural differences between decision making in Japan versus American firms
In America decisions are made without understanding all the facts, solve problems without seeing the point of the cause, meeting are filled with gut feeling and emotional hunches
What does gemba offer leaders as part of a continuous program?
Offers leaders and managers a way to stay in touch with the pulse of activities on the factory floor and make decisions that include employee input and concerns
