Lecture 7: 5S the Foundation of Visual Management Flashcards
Who developed the 5S system?
Sakichi Toyoda, Kiichiro Toyoda and Toyota engineer Taiichi Ohno
What does 5S stand for?
Sort Set Shine Standardize Sustain
What does 5S do?
Remove waste and improve workplace safety
How does 5S improve quality?
Abnormalities are immediately identified
What is Step 1 of 5S?
Sort
What do you do during the sort step?
Distinguish between what is and what is not needed
Which questions do you ask about the items in an area in the Sort step? (6)
- Why is this quantity required?
- Where is this item used?
- When is this item used?
- What is the purpose of this item?
- Why is it stored here?
- How is this controlled?
Red tag or not?
When an item has a defined purpose and it is used regularly
No red tag
Red tag or not?
When an item has no definite purpose or is not needed
Red tag
Red tag or not?
When an item is unsafe but needed
Red tag to be repaired or replaced
Red tag or not?
When an item is unsafe and not needed
Red tag for disposal
Red tag or not?
When you are unsure about an item’s purpose?
Red tag for a discussion
What is step 2 of 5S?
Set
What do you do during the Set phase of 5S?
Arrange all items where they are needed
What do you identify during the Set step of 5S?
The ‘home’ for all items
What are the benefits of the Set step? (2)
- Clear visual standards and abnormalities become clear
* Workplace optimised to eliminate time searching for items
What is step 3 of 5S?
Shine
What does the Shine step include?
Making sure that everything is kept in this orderly way and there is routine cleaning
What is the benefit of the shine step?
a safe working environment that is maintained to a standard
What is step 4 of 5S?
Standardize
What does the standardize step include?
Adherence to the known standard. Use visual controls to make deviations from the standard obvious.
What is the benefit of the standardize step?
ongoing consistency within the workplace area
What is step 5 of 5S?
Sustain
What does the sustain step include?
Maintaining the standard through the organization culture
Why are waste walks necessary in the sustain step?
Because by looking and seeing you can identify waste more easily
What are the benefits of the sustain step?
an organizational culture of continuous improvement
What are the 5 implementation guidelines for 5S?
- Identify project area
- Train your people
3 Take photos of the project area - Identify the teams
- Make the time available
What is important when starting a 5S project?
Being prepared to maintain the standard
What is visual management?
a system to recognize deviations from the standard
What are visual displays?
communicate important information but do not control the process
What are visual controls?
build visual control into the process to ensure that activities are performed according to standard
If the problem is about quality do you use Lean or Six Sigma?
Six Sigma
If the problem is about efficiency do you use Lean or Six Sigma?
Lean
What is Six Sigma centered around?
understanding where variation is coming from
What is Lean centered around?
reducing waste
