I am looking for some good references about how Safety is incorporated into a 5S initiative. Books, articles, etc. I did a search here but did not turn up anything about Safety included in a Lean implementation.

If by chance, anyone has some photos of 6S in action, please private mail to me.

Thank you kindly!!

--QG

I am looking for some good references about how Safety is incorporated into a 5S initiative. Books, articles, etc. I did a search here but did not turn up anything about Safety included in a Lean implementation.

If by chance, anyone has some photos of 6S in action, please private mail to me.

Thank you kindly!!

--QG

I would argue that safety should always be present in any 5S activities, it isn't a stand-alone piece that I have seen some people throw around. First and foremost, safety is always a concern.

Wayne

Hey, QG....books on safety?!?! They have those?!?! ;)

During our "revamp" of our 5S programme last year, safety and environment were considered. We realized fairly quickly that safety was already considered.

We look for oil spills and puddles and hoses lying around....slipping and tripping hazards. We look for everyone (including contractors, temporary employees and visitors) wearing the proper Personal Protective Equipment. We look for designated walkways clear of obstacles and lighting and dust and dirt.

Even the environment was already considered, but we expanded on it more. Garbage cans and recycle bins properly used. Power turned off (lights, monitors, etc.) when item/area not in use.

Hope this helps a bit.

Thanks for the feedback, and very pleased to know that safety continues to be a primary concern!

I'm posting again to see if I get any new takers. In particular, I would love to get some photos of how companies include safety with their visual workplace. For example, on work team/cell communication displays, do you show days without accidents? Any special signage about the 6S's? Has anyone done any 5S training that included inputs about safety?

Thanks much for all the continued support and ideas!

--QG:)

Amazon.com:

Looks like this guy has a bad seller rating though but here is ONE.
5S for Safety Implementation Toolkit (CD-ROM)
by Tel-A-Train and the Productivity Development Team, Productivity Development Team
Availability: Available from these sellers.
Seller: stevesfinebooks (Safe buying guarantee)
1 used & new available from $943.03

http://www.amazon.com/gp/product/1563271230/sr=8-2/qid=1139853210/ref=sr_1_2/002-3522220-8948069?%5Fencoding=UTF8

Here is TWO:
http://www.amazon.com/gp/product/1563270471/sr=8-5/qid=1139853210/ref=sr_1_5/002-3522220-8948069?%5Fencoding=UTF8

Here is THREE:
Lean Six Sigma for Service : How to Use Lean Speed and Six Sigma Quality to Improve Services and Transactions


I found the first one to be most helpful while working at a very large company implementing 5S and Safety. We had one of the 5 top rated 5S programs in the world at the time (about 6yrs ago). Many colleges visting me to review our program.
If you have specific questions, I can help out as well.

there is an example here http://www.vitalentusa.com/learn/6s_article.php

i came accross it during a search for 6S so i am not associated with the site in any way :)

i would recommend some research into SMS or Safety Management Systems, which will give lots of examples on how to incorporate safety into daily activities :tg:

I saw this at a company I was benchmarking with a couple weeks ago. In each work cell they had a communication board with their KPIs listed. Safety was one of those indicators. It was the responsiblity of a leader from the cell to update the cross on a daily basis. Cells with all green on the cross recieve some kind award or recognition at the end of the month.

Our company has incorporated safety checks into our layered audit initiative. This was at the request of the plant manager who was looking for compliance with the governmental (CDN) workwell audits. The layered audit process (in my opinion) was a great place to implement the maintainance of safety initiatives within the corporation. In addition to the safety checks, the layered audits also incorporate 5S (which has given us the most findings) into the maintainance of 5S objectives. Layered audits (so far) have been a great maintainance tool in all area including safety, 5S and process control.
:eek: :o :tg:

I am currently working on setting up 5s+1 in our warehouse. Since Safety is #1, I decided to name it 5s+1 instead of 6s to ensure safety is always at the forefront of our audits. I am just getting this going and working on putting the team together to begin training and implementation. To gear up the staff to know what is coming, I send out 5s+1 Tips of the week out to all the staff via e-mail. It seems to be producing results already even though the staff really does not know the program fully. I'll let you know how this progresses. I found a great audit sheet on this forum that I have adapted to the 5s+1. I'll attach it. I'll send pictures when we get this rolling.

djhopkix,

I get a message "this file is not in a recognizable format" when opening it.

Welcome to the cove with a great contribution
I opened it OK.

Thanks

No too sure why that is, do you have MS Excel?

Couldnt do that from my work computer too.."The serevr returned an invalid or unrecognizable response" :(

I have opened it and saved again for those having problems. It could be an Excel version issue. I have saved as Excel 95
Please give feedback

Our company has incorporated Safety into 6S years ago. Posters are used companywide to communicate the initiative. Also, on each shopfloor, information on recent accidents are detailed with photo to show to employees what has caused the incident and how s/he may has avoid it. No. of accidents are reported to top management regularly and procedure was setup showing employees how to react to accident. We have safety and 5S committee conducting audit from time to time. Nevertheless, there is nothing new. But by bringing out Safety as the 6th 'S', the company puts it to the same level of concerns as for 5S.

But by bringing out Safety as the 6th 'S', the company puts it to the same level of concerns as for 5S.

How do you isolate Safety as the 6th S?

I guess the way I look at it is that no matter what the topic or process is, 5S applies. Safety is not an "S" unto itself...it should be integrated into the concept of 5S.

If we find hoses are lying on the floor this is not a failure to put things back in their place (i.e., Simplify) but can result in a safety issue (e.g., tripping)...but the safety issue has risen from the inability to Simplify.

Or am I missing something here? (totally possible)

Well, Here is an update.... "The Man" decided that the audit I posted here was too complex, so they nixed the idea of using it. I had my first Continuous improvement meeting with about 12 employees last week and it went very well. We decided to Keep 5s and Safety seperate to emphasize Safety over all. I am using the Enna 5s Training package. Not to promote Enna, but so far it is very useful in training the staff.

What we call "6S" derives from "5S" the method of workplace organization and visual controls popularized by Hiroyuki Hirano (1990). The five "Ss" refer to five Japanese words—seiri, seiton, seiso, seiketsu, and shitsuke. Seiri means to separate needed and unneeded materials and to remove the latter. Seiton means to neatly arrange and identify needed materials for ease of use. Seiso means to conduct a cleanup campaign. Seiketsu means to do seiri, seiton, and seiso at frequent intervals and to standardize your 5S procedures. Shitsuke means to form the habit of always following the first four Ss.

The origin of 5S seems rooted in the works of two American pioneers who were scrupulously studied by Japanese managers. These were Frederick W. Taylor's Scientific Management (1911) and Henry Ford (1922). Indeed, Ford's CANDO program (Cleaning up, Arranging, Neatness, Discipline, Ongoing Improvement), which builds on Taylor's work, appears as the obvious origin for 5S.

(FYI) The above insert was taken from the link that "Kei ko" sent it.

My understanding of 6S is a Japanese program that was "Americanized" by adding another S. This became popular from my experience about 8 yrs years ago. I am suprised we haven't added a 7th S yet. (Ya'll can make up some clever ones I'm sure, I betting the book will net atleast $150k).

Anyhow, back to the point. I would recommend a "Near miss" program that would fall into this safety category. (Near miss - proactive aproach to address potential safety problems before an incident occurs. Ex. Cleaning and fixing an oil spill from a leak before someone has a chance to step in it, or grind the sharp edges of a new constructed rack that just came to the line.

Anyhow, back to the point. I would recommend a "Near miss" program that would fall into this safety category. (Near miss - proactive aproach to address potential safety problems before an incident occurs. Ex. Cleaning and fixing an oil spill from a leak before someone has a chance to step in it, or grind the sharp edges of a new constructed rack that just came to the line.

Aren't all safety programs based on preventing accidents? Isn't that the whole idea? In the 6S scheme of things, spilled oil would be part of cleaning, and preventing the oil from leaking in the first place would be safety.

Okay, let me preface this post by saying that I'm tired and cranky and extremely irritable. So, I apologize up front if these questions of mine ruffle any feathers. :)

I just don't get it. How does Safety become the 6th S? I mean, logically, Safety should be an incorporated aspect within the existing 5Ss. As the 6th S, what are you looking for that differs from the concepts of the first 5Ss?

I'm sorry, but, yeah, I do see this becoming extremely complicated, top-heavy, user-unfriendly and just difficult to maintain...6Ss...then 7...

Please tell me what items you specifically check for during a 5S (or rather 6S) check/audit that are soley Safety related?

Aren't all safety programs based on preventing accidents? Isn't that the whole idea? In the 6S scheme of things, spilled oil would be part of cleaning, and preventing the oil from leaking in the first place would be safety.

To take this one step further, anything we do, not just in a safety program, should be considered for caution when a potential hazard may occur. As for preventing the leak from occuring, I would tend to think that this would fall under TPM.

As for RC's comments . . . . I have to agree with him.

Leave 5's alone.

Unless of course there's money in it.

We already have a Good Catch/Near Miss program and a Safety Management by Walking Around SMBWA program where safety audits are performed in a specific area and the results posted. This system works fairly well by itself. The GC/NM program works well also, employees receive a "safety buck" that can be used onsite at the cafe or vending machines when they report a Good Catch. SMBWA AR's are tracked and followed up on by management.

Corporate wants to eventually see that the SMBWA goes away and is incorporated into 5s. Not sure that this can happen even though when you are looking for 5s items during an audit. Everything should be captured that is safety related considering if it is not "right" it should be caught.

Update on the Continuous Improvement Team- This week we start taking pictures, Sorting and Red Tagging. Should be fun!