5s And Stating Fit

Question 1

What is a 5s primer?

Answer 1

Embracing the five disciplines and developing a culture that supports them

Question 2

1S

Answer 2

Sort: comb through materials, tools and equipment, identidying what is needed and getting rid of what is not

Question 3

2S

Answer 3

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

Question 4

3S

Answer 4

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

Question 5

4s

Answer 5

Standardize- create and use clear simple work methods and standards, including processes for the first three S’s

Question 6

5s

Answer 6

Sustain- develop a culture around the principles of 5S. Communicate involve and train employees, provide regular feedback

Question 7

Sixth S

Answer 7

Physical and mental safety, affects not only accident and injury concerns but the motivational aspect of work as well

Question 8

How do some companies treat 5s?

Answer 8

As a simple housekeeping program with the mantra of a place for everything and everything in its place

Question 9

Better descriptor of 5s

Answer 9

Take care of the small things and the big things will take care of themselves

Question 10

What should Five S be?

Answer 10

A problem prevention program and a way to identify and fix problems when they are still very small thus preventing big problems.

Question 11

What did taiichi ohno teach?

Answer 11

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

Question 12

What do sweeping problems under the rug or mopping problems up cause?

Answer 12

Costly problems like faulty products, maintenance mishaps, employee injury or death

Question 13

Where could a problem like an oil leak come to light using the 5s program?

Answer 13

Various stages of 3S, the shine step depending on the discipline

Question 14

A great 5s program

Answer 14

During a regular scheduled inspection, small bits of oil are observed on a gasket, The root cause is determined and corrected

Question 15

Good 5S program

Answer 15

A drop of oil forms and maintenance is requested before it drips on the floor

Question 16

Average 5S program

Answer 16

A drop of oil on the floor brings attention to the maintenance issue

Question 17

A housekeeper focused program

Answer 17

cleaner wipes, away, evidence of the oil and nothing further is done until the machine runs out of oil and breaks down

Question 18

Second factory issue

Answer 18

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

Question 19

Scenario 1

Answer 19

Meticulous housekeeping, zero problem solving

Question 20

Scenario 2

Answer 20

Skipping protocol and procedures endangers both products and people

Question 21

Scenario 3

Answer 21

Asking why until then root cause is found

Question 22

What does successful implementation of 5s or 6s require?

Answer 22

Involving, empowering and inspiring workers to share the vision and embrace the cause

Question 23

What do these programs often involve?

Answer 23

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

Question 24

Why is the fifth S vital to the program

Answer 24

Sustain is vital because without it the program will be little more than managements latest here today gone tomorrow

Question 25

What can an organization gain with the fifth s?

Answer 25

Greater safety, quality, productivity, and a positive culture where employees feel valued and can thrive

Question 26

What does the Japanese term gemba mean?

Answer 26

Actual place

Question 27

What does gemba suggest?

Answer 27

That if you really want to know what is going on you need to go to the place where the action occurs

Question 28

Why do lean practitioners apply gemba

Answer 28

To stay in touch with what is happening on the factory floor

Question 29

Possible reasons for gemba walk

Answer 29

Learn about practices, coaching employees, or following up on issues identified in the past

Question 30

What are some general guidelines for success?

Answer 30

-have a purpose
-keep it brief
- drive out fear

Question 31

Have a purpose

Answer 31

Identify the processes, people or products to be studied

Question 32

Keep it brief

Answer 32

30 to 45 minutes should be long enough to accomplish the purpose of the walk

Question 33

Drive out fear

Answer 33

Develop a culture where employees are glad to see the gemba walker and are exited to share their ideas for improvements

Question 34

Biggest miskate made with gemba

Answer 34

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

Question 35

How can an occasional pause be helpful

Answer 35

Will give you a different perspective from walking as you observe what is happening around you

Question 36

What are the cultural differences between decision making in Japan versus American firms

Answer 36

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

Question 37

What does gemba offer leaders as part of a continuous program?

Answer 37

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