The 5S playbook: a step-by-step guideline for the lean practitioner

78 Pages·2016·33.859 MB·English

by  Ortiz, Chris A

Productivity Improvement / 5S and Visual Controls O
R The LEAN Playbook Series
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The LEAN Playbook Series
The 5S Playbook
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A Step-by-Step Guideline for the Lean Practitioner E
5 The 5S Playbook
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A powerful and effective Lean tool, 5S can help prevent company failure A
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and launch an organization into world-class operational excellence. Until now, B
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however, there has been a need for a book with detailed step-by-step guide- O
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lines on how to properly implement 5S (Sort, Set in Order, Scrub, Standardize,
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Sustain) and the visual workplace. Complete with color images, A

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The 5S Playbook: A Step-by-Step Guideline for the Lean Practitioner T A S t e p - b y - S t e p G u i d e l i n e f o r
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fills this need. P
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Y t h e L e a n P r a c t i t i o n e r
This new book in The LEAN Playbook Series is your guide to proper 5S and -
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visual workplace implementation. It is ideal for Lean practitioners and facilita- T
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tors looking for a training tool and a guideline that can be used in the work area

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while improvements are being made. U
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Like a football coach, you can use this playbook for quick reference to convey L
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what’s needed to facilitate effective 5S kaizen events. If for some reason you E

forget a “play” during the 5S implementation, you can easily reference the F
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playbook. You can follow page by page and use the playbook to facilitate a 5S R

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implementation, or you can go directly to certain topics and use it to help you
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implement that particular “play.”

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The playbook includes color images from actual 5S implementations. In addi- N

tion to the images, a combination of short paragraphs and bulleted descrip- P
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tions walk you through each step of an effective 5S implementation. A
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Looking for supplemental information or Lean coaching from Chris Ortiz? Go I
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to www.leanplaybooks.com to receive ongoing support and advice on how to N
E
use The LEAN Playbook Series for training and implementation. R
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ISBN: 978-1-4987-3035-8
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9 781498 730358

The 5S Playbook
A S t e p - b y - S t e p G u i d e l i n e f o r
t h e L e a n P r a c t i t i o n e r
The LEAN Playbook Series
PUBLISHED
The 5S Playbook: A Step-by-Step Guideline for the Lean Practitioner
Chris A. Ortiz
FORTHCOMING
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Chris A. Ortiz
The Kanban Playbook: A Step-by-Step Guideline for the Lean Practitioner
Chris A. Ortiz
The LEAN Playbook Series
The 5S Playbook
A S t e p - b y - S t e p G u i d e l i n e f o r
t h e L e a n P r a c t i t i o n e r
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A PRODUCTIV ITY PRESS BOOK
CRC Press
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© 2016 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20150520
International Standard Book Number-13: 978-1-4987-3037-2 (eBook - PDF)
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Contents
How to Use This Playbook ............................................................................vii
Introduction .....................................................................................................ix
8 Wastes ............................................................................................................xi
Lean Metrics ...................................................................................................xiii
5S Supply List ................................................................................................xvii
5S Supply Cart ................................................................................................xix
1 Sort ....................................................................................................1
Step 1 ..................................................................................................................1
Red Tagging .......................................................................................................2
Why Sort? ...........................................................................................................3
Red-Tag Areas .....................................................................................................4
Production ......................................................................................................4
Boxes ..............................................................................................................4
Rented Container ............................................................................................5
Office ..............................................................................................................5
Sorting Hardware ...........................................................................................6
Body Shop ......................................................................................................6
Removal Procedure ............................................................................................7
Removal Ideas ................................................................................................7
2 Set in Order .......................................................................................9
Stage 2 ................................................................................................................9
Painted Work Areas and Aisleways .................................................................10
Floor Tape Work Areas and Aisleways ............................................................11
Machine Shop ...................................................................................................12
Tools .................................................................................................................18
Tool Check Cards .............................................................................................21
Examples ..........................................................................................................24
Tool Placement .................................................................................................24
3 Scrub ................................................................................................27
Stage 3 ..............................................................................................................27
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vi ◾ Contents
4 Standardize ......................................................................................29
5 Sustain ............................................................................................. 31
End-of-Day Cleanup Procedure ........................................................................31
Daily Walkthrough ...........................................................................................32
5S Audit Form/Criteria .....................................................................................32
Sample 5S Audit Form: Form 5-1 .....................................................................33
Assigning Auditors and Rotation .....................................................................34
Sample Auditor Rotation ..................................................................................34
5S Tracking Sheet .............................................................................................34
Sample 5S Tracking Sheet ............................................................................35
Incentive Program ............................................................................................35
6 5S Shadow Board: How-to Reference Guide .................................... 37
Introduction ......................................................................................................38
Why Use a 5S Shadow Board? .........................................................................39
How to Build a 5S Shadow Board ..................................................................39
Steps 1 and 2 ....................................................................................................40
Step 1: Paint Peg Board ...............................................................................40
Step 2: Begin to Place the Boards on a Flat Surface
to Verify Space Requirements ......................................................................40
Steps 3 and 4 ....................................................................................................41
Step 3: Hang Board in Desired Location ....................................................41
Step 4: Place Tools on Board .......................................................................41
Steps 5, 6, and 7 ...............................................................................................42
Step 5: Leave Enough Room for the Shadow or Outline............................42
Step 6: Finalize All Tool Locations ..............................................................42
Step 7: Use a Paint Pen to Outline Tool ......................................................42
Steps 8 and 9 ....................................................................................................43
Step 8: Make and Place Labels Near Tool ...................................................43
Step 9: Place Color Tape Around Tool for Designation ..............................43
Steps 10 and 11 ................................................................................................44
Step 10: Designate the Board with a Location ............................................44
Step 11: Place a Designation Label on Tool ................................................44
Completion .......................................................................................................45
Examples ..........................................................................................................46
Conclusion ..............................................................................................49
Definition of Terms ................................................................................ 51
About the Author ....................................................................................59
How to Use This Playbook
In most cases, a playbook is a spiral-bound notebook that outlines a strategy for
a sport or a game. Whether for a football game, a video game, or even a board
game, playbooks are all around us and when written properly provide immediate
and easily understood direction. Playbooks can also provide general information;
then, it is up to the user of the playbook to tailor it to their individual needs.
Playbooks contain pictures, diagrams, quick references, definitions, and often
step-by-step illustrations to explain certain parts. You can use playbooks to help
you understand the entire game or you can pick and choose to focus on one
element. The bottom line is that any playbook should be easy to read and to the
point and contain little to no filler information.
The 5S Playbook is written for the Lean practitioner and facilitator. Like a
football coach, a facilitator can use this playbook for quick reference and be able
to convey what is needed easily. If for some reason the person leading the actual
5S implementation forgets a “play,” the playbook can be referenced.
You can follow page by page and use the playbook to facilitate a 5S implemen-
tation or you can go directly to certain topics and use it to help you implement
that particular “play.”
Looking for more supplemental information or Lean coaching from Chris Ortiz?
Go to www.leanplaybooks.com and be able to receive ongoing support and
advice on how to use the playbook series for training and implementation.
vii