5S Office Version 1 Participant Workbook [1 ed.] 9781138069251, 1138069256

Table of contents :
Cover
Title Page
Copyright Page
Table of Contents
Section 1: 5S & Lean Operations
Section 2: 5S & Organization: Each Piece of the Puzzle
Section 3: 5S & Teamwork
Appendix

Citation preview

5S Participant Workbook

A PRODUCTIVITY PRESS BOOK

www.enna.com www.productivitypress.com

Copyright 2005 Enna, Inc. All rights reserved. No part of this book shall be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission from the publisher. No patent is assumed with respect to the use of the information contained herein. Although every precaution has been taken in the preparation of this book, the publisher and author assume no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of information contained herein. For information contact: Enna Products Corporation 1602 Carolina St. Unit B3 Bellingham, WA 98229 Telephone: (360) 306-5369 Fax: (905) 481-0756 E-mail: [email protected]

The 5S Office Participant Workbook and design are trademarks of Enna Products Corporation. International Standard Book Number: 9781138069251 Distributed by Productivity Press, an imprint of CRC Press 711 Third Avenue, New York, NY 10017 2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN www.productivitypress.com CRC Press is an imprint of the Taylor & Francis Group, an informa business

Note: This publication contains the opinions and ideas of its authors. It is intended to provide helpful and informative material on the subject matter provided. It is sold with the understanding that the authors and publisher are not engaged in rendering professional services in this book. If the reader requires personal assistance or counsel, a competent professional should be consulted. The authors and publisher specifically disclaim any responsibility for any liability, loss, or risk, personal or otherwise, which is incurred as a consequence, directly or indirectly, of the use and application of any of the contents of this book.

Special Symbols: This book is organized to guide the individual through the training. In addition to the Notes section there are a number of symbols used to help the participant throughout the presentation and workshop. For your convenience these symbols are repeated at the introduction of each section of this workbook.

Suggestion: This symbol represents a suggestion or is a general statement relating to facilitation of the training. Tip: This symbol represents a tip to the Facilitator and is specific to the concept that the Facilitator is presenting. Question: This symbol represents a question that may be asked to the Facilitator or to the participants in the workshop. It is intended to foster interaction during the training.

Table of Contents Section 1 5S & Lean Operations ...............................................1 Section 2 5S & Organization: Each Piece of the Puzzle ..........19 Section 3 5S & Teamwork .......................................................39

5S & Lean Operations

Participant Workbook In this Section - Learn the context of 5S - Discover how 5S fits into improvement projects - Study the 7 Wastes of Operations - Content of the workshop Participant Workbook Provided To:

Suggestion

Tip

Question

1

5S

Notes, Slide 1:

2

Wa

Notes, Slide 1 continued:

Tip: Pay particular attention to the Facilitator when learning about a clean operation.

Question: What do people generally think of an operation that is clean?

3

Introduction Section 1: 5S & Lean Operations Section 2: 5S & the Office: Each Piece of the Puzzle Section 3: 5S & Teamwork

Notes, Slide 2:

4

Section 1

5S & Lean Operations

Notes, Slide 3:

5

5S & Organization Sort, Straighten, Sweep Standardize "Determine what excellence looks like" Using visual tools allows for Sustainment

Notes, Slide 4:

6

5S & Visual Systems Easy to Understand Fun to Setup Works better for all

Notes, Slide 5:

Question: Can you think of any kind of job that may require the need to be visual?

7

Why 5S Allows us to maintain a more organized area Able to clean less and clean easier Makes our work area more productive Makes the 7 Wastes obvious Creates a standard for improvement A way to get many people involved Low real cost, high-impact for company

Notes, Slide 6:

Question: Why are we doing 5S?

8

How 5S Eliminates Waste

Notes, Slide 7:

Tip: Focus on the 7 Wastes and what the definitions are.

9

How 5S Eliminates Waste

Notes, Slide 7 continued:

Tip: The 7 Wastes are a fundamental building block of 5S. Ask the facilitator to fully explain the wastes so that you understand them completely.

10

Defects Producing bad information, having extra information, wrong information, incomplete information, and/or having to redo work. Possible Causes: Batch Processing Input Errors Questionable product design Poor work instructions

Notes, Slide 8:

Waste Definition:

Additional Example:

11

Inventory Any material in the area other than what is immediately needed for the next process, stage, or step. Possible Causes: Long processing times Supplier dependence Individual department design Just-in-case logic Unknown market demand

Notes, Slide 9:

Waste Definition:

Additional Example:

Question: What are the three stages that inventory lives as in your company?

12

Processing Activity that adds no value to the product or service from the viewpoint of the internal/external customer. Possible Causes: Redundant activities No communication Unnecessary or excessive reports Next customer s needs

Notes, Slide 10:

Tip: This is the hardest waste to find. However, the solution is simple. If you think about it, if it is truly a waste of processing, then the ultimate solution is to find a way to not do it.

Waste Definition:

Additional Example:

13

Waiting Is created when materials, information, machines, or approvals are not ready for the person. Possible Causes: Intranet failures Work load variance Quality issues Too much work

Notes, Slide 11:

Waste Definition:

Additional Example:

Question: What are some times that you have waited? What are you waiting for?

14

Tip: Try purposely waiting rather than doing something. It is hard to wait.

Motion Any movement that does not add value to the product or service. Possible Causes: Lack of process design No standard work methods Design of work area Too much clutter in an area

Notes, Slide 12:

Waste Definition:

Additional Example:

15

Transportation Moving information, paperwork, drawings, or ma from one process to another process. Possible Causes: Batch processing systems WIP storage for jobs Layout of the facility Job staging Utilization of office

Notes, Slide 13:

Waste Definition:

Additional Example:

16

Overproduction Making more components/products than the next process (or internal/external customer) requires. Possible Causes: Just-in-case logic Focus on equipment only Setup times for processing jobs Keep-working environment Demand issues in each dept.

Notes, Slide 14:

Tip: Operations should look at ways to only produce what is truly needed. Anything more will result in loss of efficiency and effectiveness.

Waste Definition:

Additional Example:

Question: Why is overproduction so detrimental to an organization?

17

5S & Lean Operations Most, if not all, of the essential tools of Lean have the 5S as the key building blocks. Examples: OEE 3P Design of Flow Lean Accounting Office Kaizen

Notes, Slide 15:

18

5S & Organization: Each Piece of the Puzzle

Participant Workbook In this Section - The meaning behind 5S - Applying 5S in your area and environment - The five elements of 5S - Guide for participants through the proper sequence of learning 5S

Suggestion

Tip

Question

19

Five words begin with "S"

Notes, Slide 17:

Question: How many S’s were there originally and which company founded the term?

20

Sort Ask yourself if you really need these things.

As a rule, if you have doubt ’Red Tag’ it.

Notes, Slide 18:

Tip: When sorting, make two categories: 1) what is needed for the job, and 2) everything else.

Sort Action Defined:

Additional Example:

21

Sort: The Red Tagging Step Two Sorting Categories: 1. What you need 2. What you do not need Each team will have an area expert to properly categorize items for other members to take to the Red Tag Area. What should we do with the articles... Throw it out? Have a company auction? Donate or give away? Recycle?

Notes, Slide 19:

22

Straighten Focus on placing items in the proper places.

What is left needs a place.

Notes, Slide 20:

Straighten Action Defined:

Additional Example:

23

Decide Where to Place Items

Notes, Slide 21:

Tip: Look at the above illustration. What workstation solutions can you find that minimize the waste of motion?

24

Example of Straighten Why do office supply stores position items on shelves the way they do? Can this apply to what we do?

Notes, Slide 22:

Tip: Try to reach for anything in your work area. The goal of Straighten is to eliminate reaching.

25

Point-of-Use

Ask yourself where the item needs to be used.

Focus on placing the item so that it is within your natural range of motion.

Notes, Slide 23:

26

Items Have Homes Are these illustrations good examples of Straighten?

Notes, Slide 24:

Tip: Use Straighten to get working, rather than just preparing to work.

27

Sweep Ask yourself why items get dirty.

How about cleaning to inspect, not just cleaning?

Notes, Slide 25:

28

Sweep Clean enough to identify root problem Move beyond just having a clean area Clean to discover how not to clean

Notes, Slide 26:

Tip: Remember, we are cleaning to...

Sweep Action Defined:

Additional Example:

Question: Why are we cleaning during this workshop?

29

Sweep Cleaner work environments increase the quality of our work.

Notes, Slide 27:

Tip: Combining ideas together will find solutions to reducing and even eliminating the need for sweeping.

30

Standardize Ask yourself how to create a work area free of checklists.

Once you see it, you know what needs to be done even without years of experience.

Notes, Slide 28:

Question: Can you think of an example of good standardization?

31

Standardize: Examples

Notes, Slide 29:

Standardize Action Defined:

Additional Example:

32

Tip: When creating a standard, incorporate symbols, colors, and/or physical characteristics.

Sustaining & Cleaning

5S Sustainment Schedule Start Date: ______________________ Person Responsible

Specific Location

Work Area:_______________________ Frequency of Activity

Activities to Perform

Notes, Slide 30:

Question: Why is it useful to employ the 5S Sustainment Schedule?

33

Sustain

Keep asking how to simplify the issue to ensure it is sustained.

The idea: if we have less selfdiscipline it will be easier to sustain.

Notes, Slide 31:

Question: What is the ultimate goal of 5S?

34

Sustain Management shows commitment to program Everyone leads by being an example of 5S 5S is a component of every workshop Goal is to have customers tour your facility Use the Evaluating 5S Forms to assess 5S score

Notes, Slide 32:

Tip: Use your past employment experience to help develop sustaining changes. Often past examples help develop solutions. Pull examples from the past and see how the team can use them.

Sustain Action Defined:

Additional Example:

35

5S Sustainment Schedule

5S Sustainment Schedule Start Date: ______________________ April 08, 2008 Person Responsible

Sarah Janzen

©

Notes, Slide 33:

36

Specific Location

Order Entry - Desk 3

Work Area:_______________________ Order Entry Frequency of Activity

weekly

Activities to Perform

Organize & clean area, turn off HVAC before leaving.

Long-Term 5S Success Management is expected to be involved in activities Involvement of everyone 7 Wastes are an integral part of 5S Link improvement to a financial benefit

Notes, Slide 34:

Question: 5S needs the commitment of who?

37

Review & Summary

What are the 5S words? Which S is the most important? Can you relate to the need for 5S? What are the 7 Wastes? What is your responsibility?

Notes, Slide 35:

Final thoughts on this section:

38

Tip: Write down the answers to these questions to summarize this section.

5S & Teamwork

Participant Workbook In this Section Now that we have gained some knowledge we are going to put it into practice. – Learn the 5S Evaluation process – Learn the 30 Day Action Log – Learn the 5S Sustainment Schedule – Discuss the workshop format

Suggestion

Tip

Question

39

5S Teamwork Steps: 1: 5S Evaluation 2: Sort- Red Tag Activity 3: Straighten- Point of Use Storage 4: Sweep- Clean Area 5: Standardize- Visual Management 6: Sustain- Refine and Schedule

Notes, Slide 37:

40

5S Team 1. Evaluating 5S Team (2-3 people) 2. Photography Team (2 people) Take pictures of the current state Highlight key objects and areas 3. 5S Mapping Team (2-3 people) Layout where people, materials, and equipment should be located (bird s eye view)

Notes, Slide 38:

Team Assigned To:

Tip: You will change roles as you move from assessment through to making changes, but your team should stay together.

Team Members Names:

Assigned Work Area:

Additional Information:

41

5S Team

Reviewing the Forms

Notes, Slide 39:

42

5S Map 5S Map From what process to what process Department______________________ Order Entry

Inbound From ____________________________

To _______________________________ Production Planning

Name________________________________________

3/12/09 Date _____________________________

Convert to CD

Print Proof

Into PDF Flow

Connect

Info System

Enter Data

Receive Order

In Box

Improvement Areas Identified Quality

Cost Reduction

Delivery Reduction

Safety

Morale

Visuals

Inventory Reduction

Reduction

©

Notes, Slide 40:

43

5S Evaluation Review

5S Office Evaluation Review Date: ______________________ 5S Element Number I

SORT

II III IV V VI

Evaluation Area:____________________________

Evaluation Criteria Are the aisles and walkways open and clear? Is the work zone free of any spills of fluids? Is the work zone free of unnecessary articles and items? Is the work zone free of excess consumables/materials? Is the information board active? Are the areas walls and dividers free of items not used in operations?

Rank these items from 1 through 5: 5 being well done

Score (1-5)

Ideas / Suggestions / Comments

All items that are not necessary or unsafe have been removed from the area where people travel and work. Consider whether there are any chemicals, lubricants, water, oils or other materials that may be hazardous in the area and on the floor. Are items that are not needed been removed from the work zone, i.e. tools, jigs, stationary, extra items. Evaluate against how many items are in the production work zone. Assess if the materials, parts, and supplies are currently needed for operations. All announcements are displayed currently and in good presentable shape. Arrangement is straight and placed under appropriate headings. Extra items are not on the walls, dividers, or hanging of signs that are not necessary. Category Subtotal Sort Score: Subtotal divided by 6

Notes, Slide 41:

Tip: Be critical when evaluating the area; the initial evaluation serves as a baseline for further comparison.

44

Photography

Notes, Slide 42:

Tip: Lighting is key for photographs. Have the team borrow lights to make the items in the pictures really stand out.

45

5S Score

Notes, Slide 43:

Tip: We should be ready to evaluate our current state.

46

Red Tags Red Tag Register Red Tag Register Project Date: _______________________ April 7-11, 2008 Item Description

Spare File Folders Assorted Items Extra Printer Print Drums

Date Sorted

Log Number

4/2/08 4/3/08 4/4/08 4/4/08 4//4/08 4/4 /08

B001 B002 B003 B004 B004

Work Area:_______________________ Order Entry Reason for Tag

Not needed at desk. Too much stuff in area. In work area but not used.

Classification (i.e. need approval, other dept. needs to assess, throw out, etc.)

No need for approval. Need approval of management. Need product development approval.

Not needed neededd in in area area - should should be store sstored toredd elsewh tore el elsewhere. sewhee sewh Back to stores, not Red Tag Area.

Notes, Slide 44 & 45:

Tip: If you have any doubt, Red Tag it and “throw it out” of the area.

47

30 Day 5S Action Log 30 Day 5S Action Log Office Copy Room Work Area:_______________________

Start Date:______________________ 2/16/2010 Date Logged

Item Number

2/16/10 A001 2/17/10 A002

5S Problem

Suggestion to Solve Problem

Who is Responsible

Main Xerox 95 will not shutdown when running color jobs.

Need to call Xerox to address this.

Gary Fitzman

Too many unnecessary boxes of paper in storage.

Implement Kanban for paper replenishment.

Sarah Ellis

©

Notes, Slide 46:

Tip: Only place items on the 30 Day 5S Action Log that the team has agreed is an item for that list. Your team should all agree before adding an item to the 30 Day 5S Action Log. You may have to get support from other departments.

48

5S Sustainment Schedule 5S Sustainment Schedule Start Date: ______________________ April 08, 2008 Person Responsible

Sarah Janzen

Specific Location

Order Entry - Desk 3

Work Area:_______________________ Order Entry Frequency of Activity

weekly

Activities to Perform

Organize & clean area, turn off HVAC before leaving.

©

Notes, Slide 47:

Tip: Team members are expected to commit to 5S by providing innovative ways to solve problems.

49

5S Board

5S Board Work Area: _______________________________

Activity Date: _______________________________

Before 5S Office Evaluation Review

After 5S Office Evaluation Review

5S Office Evaluation Review

Scheduled Current Activities 30 Day 5S Action Log 30 Day 5S Action Log

5S Office Evaluation Review Start Date:______________________

Date: ______________________

SORT

V

SET IN ORDER / STRAIGHTEN

VI

VII VIII IX X XI XII

Evaluation Criteria Are the aisles and walkways open and clear? Is the office area free of any spills of fluids? Is the office area free of unnecessary articles and items? Is the office area free of excess consumables/materials? Is the information board active? Are the areas walls and dividers free of items not used in the operation?

Evaluate any documentation storage. How are the shelves, desks, and work surfaces arranged? How are the tools and materials stored in the area? Evaluate container and any packaging locations and tidiness. Assess order and where items are found on the floor. Easiness to access the tools, equipment, and stationary.

Score (1-5)

Rank these items from 1 through 5: 5 being well done

Ideas / Suggestions / Comments

5S Element Number

All items that are not necessary or unsafe have been removed from the area used as pathways.

I

Consider whether there are any chemicals, water, oils or other materials that may be hazardous in the area or on the floor. Are items that are not needed been removed from the work zone, i.e. monitors, scanners, stationary, extra items? Evaluate against how many items are in the processing area for work. Assess if the materials, parts, and supplies in the area are currently needed for the job. Closer to actually needed is better. All announcements are displayed currently and in good presentable shape. Arrangement is straight and placed under appropriate headings. Extra items are not on the walls, dividers, calendars, or hanging of posters that are not necessary.

II

SORT

I II III IV

Date: ______________________

III IV V VI

Evaluation Area:____________________________

Evaluation Criteria Are the aisles and walkways open and clear? Is the office area free of any spills of fluids? Is the office area free of unnecessary articles and items? Is the office area free of excess consumables/materials? Is the information board active? Are the areas walls and dividers free of items not used in the operation?

Score (1-5)

Rank these items from 1 through 5: 5 being well done

Category Subtotal Sort Score: Subtotal divided by 6

Only documents required for jobs are stored at the point of use. These documents are stored nicely and in an orderly fashion that is recognizable/understandable to outsiders. All locations of items are labeled, marked, and it is known if they are missing. No items are resting on walls, tucked in corners. No items are resting on equipment, cupboards, or other fixtures. Boxes, storage containers, and other items are stored in the appropriate place and orientated well for the area. Cabinets are secure and not causing any danger to the people working in the area. Nothing is sitting directly on the floor and no materials are left around the area. Items that need to be on the floor are clearly marked and positioned in designated areas clearly outlined on the floor. Materials, tools, jigs, attachments, and fixtures are organized so that they are all easily within reach. Consider this as well for any kind of tools needed for a job including cutting and measuring something.

VII VIII IX X XI XII

Evaluate any documentation storage. How are the shelves, desks, and work surfaces arranged? How are the tools and materials stored in the area? Evaluate container and any packaging locations and tidiness. Assess order and where items are found on the floor. Easiness to access the tools, equipment, and stationary.

Item Number

Work Area:_______________________

5S Problem

Suggestion to Solve Problem

Who is Responsible

Ideas / Suggestions / Comments

All items that are not necessary or unsafe have been removed from the area used as pathways.

Category Subtotal

Red Tag Register

Only documents required for jobs are stored at the point of use. These documents are stored nicely and in an orderly fashion that is recognizable/understandable to outsiders. All locations of items are labeled, marked, and it is known if they are missing.

Red Tag Register

No items are resting on walls, tucked in corners. No items are resting on equipment, cupboards, or other fixtures. Boxes, storage containers, and other items are stored in the appropriate place and orientated well for the area. Cabinets are secure and not causing any danger to the people working in the area. Nothing is sitting directly on the floor and no materials are left around the area. Items that need to be on the floor are clearly marked and positioned in designated areas clearly outlined on the floor. Materials, tools, jigs, attachments, and fixtures are organized so that they are all easily within reach. Consider this as well for any kind of tools needed for a job including cutting and measuring something.

Category Subtotal

Project Date: _______________________ April 7-11, 2008 Item Description

Date Sorted

Spare File Folders 4/2/08 Assorted Items 4/3/08 Extra Printer 4/4/08 Print Drums 4/4/08

Category Subtotal

Set in Order / Straighten Score: Subtotal divided by 6

Set in Order / Straighten Score: Subtotal divided by 6

Overall Score: 1.5

Date Logged

Consider whether there are any chemicals, water, oils or other materials that may be hazardous in the area or on the floor. Are items that are not needed been removed from the work zone, i.e. monitors, scanners, stationary, extra items? Evaluate against how many items are in the processing area for work. Assess if the materials, parts, and supplies in the area are currently needed for the job. Closer to actually needed is better. All announcements are displayed currently and in good presentable shape. Arrangement is straight and placed under appropriate headings. Extra items are not on the walls, dividers, calendars, or hanging of posters that are not necessary.

Sort Score: Subtotal divided by 6

SET IN ORDER / STRAIGHTEN

5S Element Number

Evaluation Area:____________________________

Work Area:_______________________ Order Entry

Log Number

B001 B002 B003 B004

Reason for Tag

Not needed at desk. Too much stuff in area. In work area but not used.

Classification (i.e. need approval, other dept. needs to assess, throw out, etc.)

No need for approval. Need approval of management. Need product development approval.

Not needed in area - should be stored elsewhere. Back to stores, not Red Tag Area.

Overall Score: 2.4

5S Map

5S Map

5S 5S Map

5S 5S Map Map From what process process to to what what process process From what

Department______________________ D1 Department______________________ D1Assembly Assembly

Receieve From Receieve of of materials materials From ____________________________ ____________________________

To Final Assembly To _______________________________ _______________________________ Final Assembly

Inflatable Name________________________________________ Inflatable pool pool recliner recliner Name________________________________________

2/07/09 Date _____________________________ _____________________________

Assembly Assembly

Air Air Pump Pump

5S Sustainment Schedule

Packaging Packaging

From process From what what process process to to what what process Department______________________ D1 Department______________________ D1Assembly Assembly

Finished

Receieve From Receieve of of materials materials From____________________________ ____________________________

To Final To _______________________________ _______________________________ Final Assembly Assembly

Inflatable Name________________________________________ Inflatable pool pool recliner recliner Name________________________________________

2/07/09 Date Date _____________________________

Assembly Assembly

Air Air Pump Pump

Packaging Packaging

5S Sustainment Schedule Start Date: ______________________

Finished

Person Responsible Parts Parts

Tooling Tooling

Misc Mat

In Material

Parts Parts

Tooling Tooling

Improvement Areas Areas Identified Identified Improvement Quality Quality

Cost Cost Reduction Reduction

Delivery Delivery

SSaaffeettyy

Work Area:_______________________

Specific Location

Frequency of Activity

Activities to Perform

In Material

Improvement Areas Areas Identified Identified Improvement

Morale

Reduction Reduction

Misc Misc Mat Mat

Visuals Visuals

Inventory Reduction Reduction

Quality Quality

Reduction Reduction

Cost Cost Reduction Reduction

©©

Delivery Delivery

SSaaffeettyy

Moorraallee M

Reduction Reduction

Visuals

Inventory Reduction Reduction

Reduction

©©

Photos

Photos

5S Radar Chart

5S Radar Chart

Comments: Everyone enjoyed the event and looks forward to improving on the area in another 3 months, when the team re-visits the area.

Sort

Sort

5.5

5.5

5

5

4.5

4.5

4

3.5 3

2.5

2.5

2

2

1.5

1.5

Straighten

1

Sustain

Notes, Slide 48:

50

Sweep

Straighten

1

Sustain

0.5

Standardize

Overall Results Summarized:

4

3.5 3

Standardize

0.5

Sweep

5S Map: 30% less space used 5S Office Evaluation Review: 1.5 Original Score, now 2.4 30 Day 5S Action Log: 20 items to change for 5S Red Tag Register: 56 items were moved out of area 5S Sustainment Schedule: Defined and taking action 10 items identified as unsafe and removed

5S Assessment Facilitator:

Name:

Workshop: Date: Circle or write the answer that best fits the question or completes the statement. 5S originally had a) 4 b) 1 c) 2

2.

What company started what is now known as 5S? a) Volvo b) Toyota c) Ford

3.

4.

5.

6.

S’s.

What is the first S of the 5S’s? a) Straighten b) Sort c) Sweep of the 7 Wastes of Operations which one is the worst? a) Overproduction b) Inventory c) Defects If a company implements 5S successfully, the need for self-discipline is . a) Eliminated b) Reduced c) Increased 5S is one of the building blocks of ? a) Operations b) Cleanliness c) Lean

7.

Why do we clean during 5S? a) To inspect b) Because it is the right thing to do c) To prevent bad parts

8.

What does inventory exist in the company as? a) Raw, WIP, FG b) GF, WIP, RAW c) PIW, WAR, FG

9.

The S in Straighten allows for a person to have minimal . a) Work b) Waiting c) Motion

10.

What is the 5S Sustainment Schedule used for? a) Recording workshop activity b) Recording the cleaning that is needed c) Scheduling the next workshop

11.

For 5S to be successful we need the involvement of . a) Top management b) Entire department c) Everyone

12.

The 5S Map provides a simple point of view of the work area. a) Bird’s eye b) Planning c) Outline

13.

Processing is the hardest waste to find because . a) There are so many processes b) It may initially seem to be a value-added step c) It is totally necessary

14.

The 30-Day Action Log allows the company to . a) Document a list of unsolvable problems b) List workshop problems to be solved on one document c) Demonstrate its commitment to 5S

1:c, 2:b, 3:b, 4:a, 5:b, 6:c, 7:a, 8:a, 9:c, 10:b, 11:c, 12:a, 13:b, 14:b

1.

Appendix

Participant Workbook In this Section You will find copies of the forms used in the workshop filled out for your reference.

53

54

©

Reduction

Cost Reduction

Receive Order

Into PDF Flow

Delivery

Safety

Morale

Improvement Areas Identified

Enter Data

Info System

Quality

Print Proof

Reduction

Inventory Reduction

In Box

Connect

Visuals

3/12/09 Date _____________________________

Name________________________________________

Convert to CD

To _______________________________ Production Planning

From what process to what process

Inbound From ____________________________

Department______________________ Order Entry

5S Map

55

Are the areas walls and dividers free of items not used in operations?

Are the aisles and walkways open and clear? Is the work zone free of any spills of fluids? Is the work zone free of unnecessary articles and items? Is the work zone free of excess consumables/materials? Is the information board active?

Evaluation Criteria

Date Sorted

4/2/08 4/3/08 4/4/08 4/4/08

Item Description

Spare File Folders Assorted Items Extra Printer Print Drums

Log Number

B001 B002 B003 B004

Score (1-5)

Need product development approval.

Need approval of management.

No need for approval.

Classification (i.e. need approval, other dept. needs to assess, throw out, etc.)

Work Area:_______________________ Order Entry

Ideas / Suggestions / Comments

Not needed in area - should be stored elsewhere. Back to stores, not Red Tag Area.

Not needed at desk. Too much stuff in area. In work area but not used.

Reason for Tag

Red Tag Register

Sort Score: Subtotal divided by 6

Category Subtotal

All items that are not necessary or unsafe have been removed from the area where people travel and work. Consider whether there are any chemicals, lubricants, water, oils or other materials that may be hazardous in the area and on the floor. Are items that are not needed been removed from the work zone, i.e. tools, jigs, stationary, extra items. Evaluate against how many items are in the production work zone. Assess if the materials, parts, and supplies are currently needed for operations. All announcements are displayed currently and in good presentable shape. Arrangement is straight and placed under appropriate headings. Extra items are not on the walls, dividers, or hanging of signs that are not necessary.

Rank these items from 1 through 5: 5 being well done

Project Date: _______________________ April 7-11, 2008

VI

V

IV

III

II

I

5S Element Number

Evaluation Area:____________________________

5S Office Evaluation Review

Date: ______________________

SORT

56

Item Number

©

2/16/10 A001 2/17/10 A002

Date Logged

Gary Fitzman Sarah Ellis

Implement Kanban for paper replenishment.

Too many unnecessary boxes of paper in storage.

Who is Responsible

Need to call Xerox to address this.

Suggestion to Solve Problem

Office Copy Room Work Area:_______________________

Main Xerox 95 will not shutdown when running color jobs.

5S Problem

Start Date:______________________ 2/16/2010

30 Day 5S Action Log

57

©

Sarah Janzen

Person Responsible

Order Entry - Desk 3

Specific Location

Start Date: ______________________ April 08, 2008

weekly

Frequency of Activity

Organize & clean area, turn off HVAC before leaving.

Activities to Perform

Work Area:_______________________ Order Entry

5S Sustainment Schedule

58