Course Code: 5ssystem
Duration: 7 hours
Overview:

You will learn:

  • Knowledge about 5S method steps and practical contingencies.

  • The knowledge to lead the implementation of a 5S program.

  • Insights on the main obstacles to a successful 5S implementation.

  • The knowledge to identify and eliminate waste from the operations.

  • The knowledge to simplify the tasks, using visual management.

Requirements:

  • There are no requirements for this course. 5S is understandable without any physical or software support.

Course Outline:

Introduction:

Eliminate waste by implementing 5S is a course intended to explain, in a simple way, how to use this tool to keep workplaces clean, organized, safe and continuously improving.

It goes through all the 5S steps, with the unique know-how of ALC, a team of Lean 6 Sigma experts with decades of experience on the subject.

The course is streamlined in each stage of 5S but starts with an overview of the starting condition and problem statement. This gives insights on the importance of the tool and makes it possible for the student to compare with his/her own experience and background. It also a basis to make the important before & after comparisons. Each step of 5S is explained, first with simple animations and after with a real implementation case in a manufacturing company.

In a single course, we give you the chance to minimize the implementation risks, to avoid typical failure modes and to radically improve the processes of your company!

Who this course is for:

  • Continuous Improvement managers
  • Production and Operations managers
  • Quality and Maintenance managers Team Leaders
  • Anyone envolved in improvement journeys

Course Content:

  • The need for 5S:
  • When and why appeared 5S:
  • You will discover the origins and the real context of 5S. After the Second World War, eliminating waste was more crucial than ever. Since then, preventing and eliminating waste in processes is critical for the success of the operations.
  • Implementing 5S in real situations:

  • Examples of waste we can typically found on real workplaces. Establish the initial state of a door lock assembly line, which willl go through the process of implementing 5S

    It starts with a general view of the line’s workstations in order to identify the improvement opportunities. There are some examples, such as objects without a clear location and marking and the use of degradated or inadequate tools and the lack of standard maintenance procedures.

  • Presenting 5S:

  • Explaination about 5S - a methodology named after five words started by “S” in Japanese. We are talking about Seiri, Seiton, Seiso, Seiketsu and Shitsuke. Each word represents a different stage of this waste eliminating cycle that you need to understand.

  • First 5S Audit:

  • Continuing with our example of the door lock assembly line, the continuous improvement manager and the production manager decide to implement 5S.

    The first 5S audit is performed in order to assess the current state. It is made on the shop floor, supported by a check-list with several items, the final score generating a 5S audit result in percentage.

  • Sort: ( Scenarios)

  • Sort is the first step of 5S, we will focusing on choosing only the right objects and removing the unnecessary ones is a simple technique we can implement at work, but it definitely requires discipline.

  • Now that the the current state is known, the first step of 5S implementation takes place – Sort.

    The main goal of this stage is to remove unnecessary objects and to identify anomalies, by moving every object and equipment on the line. All objects must be cleaned, and eventually painted, to improve visual management and to help detecting anomalies.

  • Set in order (Scenarios)

  • Set in order goes further and applies criteria such as distance and frequency of use to place objects, and makes use of visual management to make clear and evident where every object should be.

  • 5S in the the door lock assembly line team moves on to the next step, Set in Order.

    Every object gets its location defined, considering criteria like frequency and sequence of use.

    There are 3 keys to Set in order: defining and identifying the objects, defining and marking their location and defining and visually representing their maximum quantity.

  • Shine (Scenarios)

  • Shine - the third step of 5S. Its purpose seems obvious, but unfortunately it is frequently misunderstood. There can be many sources of dirt, so the focus is on eliminating the source, or, if this is not possible, to contain it.

  • The purpose of Shine in 5S is not just to clean, but to define strategies to minimize the effort of keeping a clean workplace. The dirt sources should be eliminated or, if not possible, contained. Cleaning kits and cleaning standards are essential.

    We start by inspecting in detail the work stations, cleaning, and identifying sources of dirt. In the example given, an excess of oil in the belts was found.

  • Standardizing (Scenarios)

  • Standardizing means creating the rules to guarantee a safe, clean and eficient workplace. It helps to smooth the work, because operations are performed like expected. “No surprises” is good to avoid waste.

  • Our team is ready to start to standardize. They will have to define a set of standards to keep the line in order, clean, safe and without useless objects.

    The standards must be simple, objective and visual. The standards must be visible to anyone in the line.

  • Sustain (Scenarios)

  • Consistency is needed to sustain 5S, so it is important to get everyone involved. A useful tool is to create an audit routine, in order to check the development of 5S. On this video, we explain this process.

  • All the work and improvement done during the previous 5S steps must be sustained. It is necessary to respect the rules to be able to identify improvement opportunities, correct anomalies and improve standards.

    Sustain uses a set of measures to promote respect for the rules, such as audits and 5S deployment communication.

  • Conclusions:

  • The differences on a workstation before and after 5S are astonishing. The impact of 5S is visible and its results undeniable.

    Starting with a pilot will help the team to learn by doing and from the errors made, without disturbing the other areas.

    Once this initial stage of the lean transformation is complete and the sources of waste are now clear, take advantage of the motivation of the team and get everyone to the next level of improvement.