Lecture 6: 5S the foundation of Visual management

Question 1

5S steps and meaning

Answer 1

Sort (clearout)
Set (configure & classify)
Shine (clean & check)
Standardise (Conformity)
Sustain (Custom & Practice

removes waste & improves workplace safety and quality

Question 2

Step 1: Sort

Answer 2

Distinguish between what is, and is not needed, remove all items that are not required or obsolete.

Audit an area via 5W & 1H

Benefit: reduce waste

Question 3

5W & 1H

Answer 3

Why is this quantity required?
Where si this item used?
When is this item used? (frequency)
What is the purpose of this item?
How is this controlled?
Why is this stored here?

Question 4

Step 2: Set

Answer 4

• A place for everything and everything in its place
• Arrange all items where they are needed
• Place items according to the frequency of use.
• Identify min/max levels
• Identify the ‘home’ for all items.
  -Classify, label & make easily visible, what should & should not be there.

Benefit:
- Clear visual standards and abnormalities become clear.
- Workspace optimised to eliminate time searching items.

Question 5

Step 3: Shine

Answer 5

• Routine cleaning
• Total Productive Maintenance (TPM)
• Focus on area safety & quality
• Define the frequency & method to ensure the standard is maintained (e.g. cleaning schedule)
• end of shift check

Benefit:
- A safe working environment that is maintained to a standard.

Question 6

Step 4: Standardise

Answer 6

• adherence to the known standards
• ongoing conformance
• Use visual controls to make deviations from the standard obvious
• Develop counter-measures to prevent going backwards
• Continually review to enhance the standard

Benefit:
- Ongoing consistency within the workplace area

Question 7

Step 5: Sustain

Answer 7

• Maintain the standard through the organisation culture
• Continually challenge standards to improve
• Go - Look - See: conduct ‘waste talks’ at all levels of the organization
• Managers must lead by example
• Take responsibility
• Conduct 5S audits to monitor ongoing performance

Benefit:
- An organisation culture of continuous improvement

Question 8

5S implementation guidelines

Answer 8

1. Identify a project area
2. train your people
3. take photos of the project area (before & afters)
4. Identify the teams
5. Make time available

Question 9

Visual display meaning

Answer 9

communicate important information, but do not control the process

Question 10

Visual Controls

Answer 10

Build visual control into the process to ensure that activities are performed according to standard