Toyota 5S System
SCM 494 Dr. Ron Tibben-Lembke
The 5S
Seiri
sort (housekeeping) Seiton set in order (workplace organization) Seiso shine (Cleanup) Seiketsu standardize (Cleanliness) Shitsuke sustain (Discipline)
Visual workplace
Benefits of 5S
Reduce
waste hidden in the plant Improve quality and safety Reduce lead time and cost Increase profit
Seiri sort
Ensuring
each item in a workplace is in its proper place or identified as unnecessary and removed. Sort items by frequency of use Get rid of unnecessary stuff
Bare essentials for the job Red Tag system Can tasks be simplified? Do we label items, and dispose of waste frequently?
Seiton set in order
Time
spent looking for things, putting away Arrange materials and equipment so that they are easy to find and use
Prepare and label storage areas Use paint, outlines, color-coded Consider ergonomics of reaching items Frequent, infrequent users
Seiso shine
Repair,
clean & shine work area (Everyone is a janitor) Important for safety Maintenance problems such as oil leaks can identified before they cause problems. Schedule for cleaning, sweeping, wiping off Cleaning inspection checklists Workspace always ready to work See workspace through customers eyes
Seiketsu standardize
Formalize
procedures and practices to create consistency and ensure all steps are performed correctly. Prevention steps for clutter Otherwise improvements from first 3 lost Everyone knows what they are responsible for doing, when and how Visual 5S see status at a glance Safe apparel, no wasted resources
Shitsuke sustain
Keep
the processes going through training, communication, and organization structures Allocate time for maintaining Create awareness of improvements Management support for maintaining Training, rewards
Visual Controls - Andon
Inidcators
activities Placed in plain sight of all workers so everyone can understand status of system at a glance If a machine goes down, or a part is defective or delayed, immediate action can be taken
for tools, parts, and production
Texas Die Casting
Set-up
Cage
www.tocforme.com
Texas Die Casting
Set-up
Cage
Texas Die Casting
Office Entryway
Texas Die Casting
Misc. Table
Texas Die Casting
Supply
Cabinet
Implementation
Gradually
too fast unsustainable During slow time Importance of training, Management commitment Before & After photos Change of mentality, not campaigns and slogans. Old way no longer OK MBWA, Patrols
