6S presentation GIỚI THIỆU 6S (5S + SAFETY

6S had been improved from 5S (5S + safety) The 6 pillars: Sort Set in Order Shine Standardize Sustain Safety Why 6S? The 6S system sounds so simple that people often dismiss its importance. However, the facts remain

Why 6S

Why 6S?

The 6S system sounds so simple that people often dismiss

its importance However, the facts remain:

“The First Pillar”- Sort

Sorting eliminates unnecessary items from the work place using a 3-step process – red tagging, holding and dispositioning.

What does Sorting accomplish?

 When unneeded items are removed from the workplace

 Annoyance and clutter are eliminated

 The factory or workplace remains uncrowded

 Time is not wasted searching for parts and tools

 Money is saved – unnecessary inventory and machinery is removed and no longer requires maintenance.

 Hidden problems resulting from excess stock on hand disappear

Making it happen – Red tag

Making it happen – Holding

 Why?

Holding is an “emotional

buffer”–when item is set aside and

watched for an agreed upon period

of time people tend to be more

ready to let it go when that time is

over.

 Auction each red-tagged item in

the holding area by asking 3

questions:

 Is item needed?

Is item needed in this

Making it happen – Disposition

Based on answers, sort all red-tagged items according to this

chart:

Never Place in holding area

Seldom (once a year) Store in a remote location

Infrequently (less than once a

month) Store at facility

Once a week Store in work area

Once a day or more Store at work place

“The Second Pillar”- Set in order

Setting in Order involves arranging and labelling needed items in

a work area using visual controls so they are easy to find, use and put away.

What does Setting in Order accomplish?

 When obvious items stored in obvious places,

excessive searching is eliminated and anyone

entering the work area can easily adapt.

 Unnecessary motion is reduced

 No more frustration from not finding things

(saved human energy)

 Defects resulting from using the wrong part

are eliminated.

 Inventory is kept from becoming excessive

 The work place is safer – no bumping into

things, tripping over things, injuries from

searching or lifting improperly.

Making it happen - Arrange

Decide on the best placement of item necessary to the work flow – consider traffic area, natural reach, keeping heavy items at

waist level

The best arrangements show work flow and status (WIP,

finished goods, etc.) at a glance

Making it happen - Identify

Mark location for each item

Some techniques for visual identification include:

“The Third Pillar”- Shine

Shining takes these items that have been identified as necessary for the work place and thoroughly cleans them inside and outside for a clean and bright atmosphere.

What does Shining accomplish?

In a clean environment, accidents such as slip or getting shavings in eyes – can be prevented Machine problems such as oil or coolant

leaks become obvious and can be quickly addressed

Employee morale improves – it’s more pleasant to work in a neat,

clean environment

Customers are impressed with the atmosphere of excellence

Contamination reduced – which can affect people, parts, machines

Maintenance become easier, so machines suffer fewer breakdowns

Making it happen

Determine cleaning/inspection target use a 6S map that shows

all target areas and who is responsible for cleaning them

Determine cleaning/inspection method and frequency

Assign cleaning/inspection job:

Clean/inspect

Correct equipment problems (instantly or schedule as necessary)

Task Location Who When Materials/

items needed

5-Minute Shine Examples

“The Fourth Pillar”- Standardize

After Sort, Straighten and Shine activities have been performed, Standardize looks for ways to turn these standards into habit.

What does Standardize accomplish?

It prevents setback or backsliding in

the efforts from the first 3 pillars

It reduces 6S time by making it

more automatic communicating

step-by-step guidelines in a way that

reduces interpretation

It clearly identifies best practices in

one area and help to cross them to

other areas

Making it happen

Write, illustrate, photograph standards for each of the first 3

pillars

Sort:

 How much inventory of an item should be kept in the area.

 List or show which tools belong at a work station

 Post a schedule for removing scrap.

Straighten:

 Tape off aside way

 Build a shadow board for needed tools

Shine:

 Create a checklist for cleaning tasks and their owners

Making it happen

Assign who is responsible for which activities

Perform periodic checks

Use photo of a properly 6S work area as a work standard

Establish prevention strategies:

 Look at tool usage for effective location even redesign process to

eliminate certain tools if possible.

 Implement JIT inventory system

 Eliminate sources of contamination.

“The Fifth Pillar”- Sustain

Sustain a clean, well organized work area takes time and effort, it

is the most difficult of the 6S to accomplish You will know

you’ve sustained what you’ve accomplished when the staff’s

hearts and minds have been won and they want to apply best

practices in their areas.

What does Sustain accomplish?

It keeps the momentum going

It is more efficient (you don’t

have to go back to pillar 1 and

start over)

It paves the way for even greater

gains beyond those identified in

the first – sorting, setting in order,

shining, standardizing steps

Making it happen – Sustain is a habit

Determine what method you will use to sustain the standards:

 Concept training

 Communication board

 Before and after photos

 One-point lessons

 Visual standard procedures

 Daily 5-minute activities

 Weekly 6S application

Making it happen – Sustain is a habit

Management helps 6S to become a habit by:

 Educating, coaching, supporting, encouraging, promoting

 Allowing time in the workday for implementation

 Providing resources

 Creating teams

All staff members sustain by:

 Leaning

 Helping to educate involve co-workers

 Being enthusiastic and positive

 Participating fully

“The Sixth Pillar”- Safety

No job is so important or so urgent that we cannot take the time

to do it safety.

What does Safety accomplish?

Safety is priority number 1

Create a safe place to work

Enhance safety consciousness

Prevent accidents and injuries

Safety and quality go hand-in-hand

Safety improve as the other standards are established

Making it happen

Tools and techniques to increase safety consciousness:

 Basic safety awareness training

 Hazard identification

 Understanding of policies and procedures

 Incident tracking, investigation and elimination of root causes.

 Visual aids for safety equipment and protocols.

 Machine guarding

 Safety audits/evaluations.

Making it happen

Typical safety concerns to consider:

 Lift and carry weight

 Push/pull weight

 Pinch points

 Trip and stumble opportunities

 Competition for space

 Improper use of equipment, tools and fixtures

 Repetitive motions

 Access to and availability of safety/emergency equipment

 Use of personal protective equipment (PPE)

SAFETY in the factory

Finger protector Wearing steel gloves

SAFETY in the factory

Stacker cover Wearing safety shoes

when using forklift

SAFETY – Before and After

Trip hazards in front

of an emergency eye Clean, neat area – station easily accessible

SAFETY – Before and After

Improper lifting position – never reach over head

Keep heavy item at waist level wherever possible

SAFETY – Before and After

Constant reaching causes

repetitive stress and carpal Elbow at side for both typing and mouse holding

HOUSEKEEPING – Before and After

Clutter workplace Clean workplace

HOUSEKEEPING – Before and After

Clutter workplace Clean workplace

HOUSEKEEPING – Before and After

Clutter workplace Clean workplace

Thank you for

your kind attention!