Workplace Organization and Standardization (5S)
Kaizen Blitz
A
Kaizen Blitz is a very intensive and focused approach to Process
Improvement. A specific area is selected
to be addressed by a multi-functional team of people. The team applies the basic 5-S concepts to
the area of: Sort, Set-in-Order, Shine, Standardize,
and Sustain. Throughout, the team
looks to apply visual techniques to maintain order and control. These concepts can be applied to any area
within the operation, both production and non-production areas.
First
the team will Sort - take an inventory of all items that are presently
in the area. Items will be sorted into
three categories: items that are frequently used; items that are no longer
used; items that are periodically used.
Plans are made to discard all items no longer needed. All remaining items are Set-in-Order. A place is designated for each item that is
required in the area - a place for everything and everything in its place. Then everything in the area is Shined
up and made to shine - work benches, equipment, tools, etc. Next, the team works to Standardize
the improvements. Methods and procedures
are implemented to keep the area organized at all times. Finally, the team looks to Sustain
workplace organization throughout the area to make it a way of life. Roles and responsibilities are often defined
at this stage.
Visual
Controls will help maintain the gains made.
"Shadow boards" to organize tools and other items required in
the area will be designed and implemented.
Labeling of bins, shelves, racks, etc. help to maintain visual
order. Visual procedures assist
personnel to standardize work practices. Visual measures help personnel to
track performance.
Not always can everything be implemented during the three
day Kaizen event. Therefore, the team
will develop an action plan with assigned responsibilities and expected
completion dates to insure that the necessary follow-up takes place.
The results of such an effort can be significant,
particularly if the concepts are applied in conjunction with other concepts
such as Cellular Manufacturing or Set-up Reduction/Quick Changeover. People throughout the organization can
visibly see the improvements, which creates much needed energy and
enthusiasm. After all, no one likes to
work in a disorganized, unsafe work environment.
Typical 3-Day Agenda
Pre-event: Scoping: identify
target area for the event
Day 1: Education in basic concepts
Conduct a Workplace Scan
Sort – red tag items in target area
Day 2: Set-in-Order – labels, home addresses, signs
Shine
– clean area, provide cleaning tools and supplies, initiate countermeasures
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Typical 3-Day Agenda (continued)
Day 3: Standardize – develop checklists, implement basic pull systems where
appropriate
Develop Sustain Model
Rescan area
Develop follow-up plan
The actual number of days required
will depend on the current condition of the target area. For example, the amount of items that will be
red tagged and will need to be removed from the area can greatly impact the
time required.
Typical Deliverables
·
An area that has
been effectively organized. Measurable
improvement is typically possible by the end of the event.
·
A cross
functional team of people who will be able to apply 5-S and Visual techniques
to other areas of the operation.
·
Actions List to
assist in follow-up, if all changes were not possible during the Kaizen event.
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Workplace Organization & Standardization (5S)
One Day Workshop
Participants
will learn, in depth, the 5-S concepts of: Sort, Set in Order, Shine,
Standardize, and Sustain.
These concepts can be applied to any area within the operation, both
production and non-production areas.
First,
a review is provided of Lean Enterprise and how Workplace Organization and
Standardization forms a foundation upon which other lean concepts can be
applied. Then, participants will learn
the importance of performing a Workplace Scan prior to any 5S effort. The Workplace Scan provides a baseline
against which progress will be compared.
Next Sort will be reviewed.
Items will be sorted into three categories: items that are frequently
used; items that are no longer used; items that are periodically used. Plans are made to discard all items no longer
needed. Elements of a Red Tag system is
covered in depth at this time.
All
remaining items are Set-in-Order.
A place is designated for each item that is required in the area - a
place for everything and everything in its place. Then everything in the area is made to Shine
- work benches, equipment, tools, etc.
Inspect through Cleaning, countermeasures and other Shine
concepts are reviewed. Next, the team
works to Standardize the improvements.
Methods and procedures are implemented to keep the area organized at all
times. Different levels of control are
reviewed to ensure work standardization over time. Finally, the team looks to Sustain
workplace organization throughout the area to make it a way of life. Roles and responsibilities are often defined
at this stage. Elements of a typical
Sustain model are covered.
Visual
techniques will help maintain the gains made.
Videotapes and photographs of specific techniques are provided
throughout the workshop. "Shadow
boards" to organize tools and other items required in an area, labeling of
bins, shelves, racks, etc. help to maintain visual order. Visual procedures assist personnel in the
area to conduct processes to be performed. Visual measures help personnel to
track performance.
The workshop typically runs a full day, including a
simulation to reinforce the participants' understanding of the concepts. Another version runs 1/2 a day, without the
simulation, and is often used to kick-off a 5S Kaizen event.
Duration: One day
Who should attend:
anyone who works in a manufacturing or service organization, including
managers. Office personnel can also
benefit by attending this workshop.
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Management Associates Tele: 856-235-8051 • Website:
cma4results.com |
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