TOTAL FLOW MANAGEMENT

visual-factory

What is 5S?

5S is an approach originally developed in Japan for better housekeeping. Now it is being utilized for keeping better workplace. It includes 5 steps which are to be followed sequentially. To be precise, 5S is an approach for managing workplace. Following Japanese terms collectively are as called 5S

5s

5S” or "Lean 5S" is a method to promote a safer, cleaner, and better-organized workplace – often a factory, but the 5S method can be applied to almost any work environment:

  • Office space – from cubicles to mail rooms to library space
  • Computer or server rooms, including online files and folders as well as physical objects
  • Work bench areas
  • Warehouses, storage sheds and outdoors storage areas
  • Hospitals and health care facilities

What are the 5S?

  • 1S – Seiri – Sorting – calls for the elimination of unnecessary items that have collected around work areas
  • 2S – Seiton – Set in Order – focuses on effective storage and organization methods that resists clutter and aids long-term productivity
  • 3S – Seiso – Shine – focuses on importance of cleaning in workplace with a view of employee health, morale and safety
  • 4S – Seikestu – Standardize - creates a workplace where employees can confidently pursue their daily work with common understanding of the working methods
  • 5S – Shitsuke – Sustain – focuses on self-discipline and methods of sustaining the efforts put in all other S’s to extract maximum effectiveness on regular basis

How to Implement 5S?

  • Identify a work area to make a Model 5S Workplace
  • Conduct initial Seiri – identity unwanted – rarely used – frequently used item, and mark them by tagging
  • Arrange only required work and items in a systematic manner – concept of PEEP (place for everything & everything in place)
  • Conduct cleaning of the workplace and promote cleaning by workplace users
  • Standardise activities and workplace through – colour coding, cleaning checklist, standard operating procedure for the workplace
  • Make the workplace as much visual as possible
  • Make auditing plan, train operators and workers about the best practices of workplace management
  • Plan for horizontal deployment in whole factory with reference of the Model Workplace
implement-5s

Direct Benefits of 5S:

  • Quick retrieval – less time wasted searching for misplaced items
  • Health and safety – reduces the risk of injuries, in both the short and long term
  • Lesser Breakdown – cleaner equipment may mean fewer malfunctions or breakdowns
  • Improved Productivity - standardized workflow results in quicker operations
  • Improved Morale – workers0 and employees can take greater pride in a clean and orderly workplace

Indirect Benefits of 5S:

  • Both fewer injuries, and fewer long-term illnesses, lead to a reduction in lost time, compensation, and scrambles to train workers to cover for colleagues
  • Less time spent searching for misplaced tools or parts means higher productivity
  • Cleaner equipment may mean less downtime for repairs or maintenance, and also savings on replacement parts
  • Optimized workflow leads to higher productivity due to time savings
  • Optimized workflow leads to higher productivity by reducing process errors and re-work
  • A cleaner workplace may result in cost savings for janitorial staff
  • Obsolete equipment or parts may be sold
  • Reduced inventory – whether equipment, spare parts, or raw materials – may result in reduced warehouse costs

VISUAL FACTORY

What is Visual Factory?

Visual Factory is a manufacturing facility that is visually managed through Visual Controls and Visual Displaces. In a visual factory, one can get quicker insights of the status of the workplace and work being done. Creating a visual factory allows the management to make informed decisions promptly and employees to develop a sense of ownership of the workplace.

How to create a Visual Factory?

4 Phases of Visual Factory:

4-phase-factory
  • Use of red tags and red tag area
  • Floor and work area marking
  • Regular cleaning in workplace
  • Implementation of PEEP
  • Periodic 5S assessment
  • How to do the job (SOP)
  • Show how things are used
  • Show where things are stored
  • Show performance status
  • Use of Andons
  • Identifying what to measure
  • Measuring unit
  • Measuring frequency
  • Use of Kanban
  • Mistake Proofing
  • identifying what is and is not normal
  • Make waste obvious to everyone
  • Continual workplace improvement
  • Help make each person’s job easier
  • Involve everyone

Benefits of Visual Factory:

  • Better information sharing
  • Facilitation of worker autonomy
  • Elimination of waste
  • Continuous improvement
  • Exposure of abnormalities
  • Ability of quick response & recovery
  • Promotes mistake proofing
benefits-of-visual-factory

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