Mini 5S - Implementing TQM - Seeking Suggestions

[Trolle]

Mini 5S

If I’m not mistaken, 5S can be good tool, fundamental for implementing any form of TPM. However it seems to be somewhat of an overkill to implement it in a manufacturing site with just two employees, (well motivated).

Nevertheless, in order get some sort of sallying point for TPM concept I still would like to kick start with a local mini variant of 5S. My problem is this; how much mini can you go and still qualify as a 5S thingy?

Cheers!

 

[Marc]

This was lost in the haze. Any takers?

 

[ralphsulser]

5S Audit form

I will post a simple 5S Audit Form that may help you get started even though you have only 2 employees, this may make you take a look at what is going on and needs improvement. Hope this helps

 

[RoxaneB]

If I’m not mistaken, 5S can be good tool, fundamental for implementing any form of TPM. However it seems to be somewhat of an overkill to implement it in a manufacturing site with just two employees, (well motivated).

I don't see how this can qualify as an opportunity for overkill. When I perform a 5S audit, I pretend I'm a Customer walking around a potential Vendor. Are ceiling tiles free from water stains? Is the floor clean? Are desk predominently uncluttered? It's good business practice to have a clean and orderly work environment....it's not only more effective, but safer, too!

When we first implemented 5S, there were a few people groaning at the concept of cleaning up and always putting things back in the same place. I countered with questions like, "Do you put your kitchen utensils back the same place every night?", "Do you return the butter or margarine to the fridge?"...we '5S' in our homes without calling it that. Why should our work environment be any different?

Nevertheless, in order get some sort of sallying point for TPM concept I still would like to kick start with a local mini variant of 5S. My problem is this; how much mini can you go and still qualify as a 5S thingy?

It's your system, make it work for you. There is no Standard with detailed requirements to "meet" 5S...to my knowledge. And obviously a 5S programme in an office environment will have different criteria than that of a manufacturing location. You can go as "mini" or as "large" as you would like...just make it work for you...get the benefits from it. If you don't believe it, you can't sell it to others.

I've attached a copy of our 5S checklist that we use when doing an audit. My organization is big on Visual Managment....lots of colour to show "at a glance" how we're doing. The checklist, once completed, is coloured for each 'S' and then an overall colour at the bottom (along with the score).

To help get 'buy in', for the first year, a green score must be >= 70%. Next year, we'll audit a bit tougher and a score of >=75% must be attained; the year after that 80%...eventually, we'll probably require a score of >=95% in order to be green.

 

[Wes Bucey]

I don't see how this can qualify as an opportunity for overkill. When I perform a 5S audit, I pretend I'm a Customer walking around a potential Vendor. Are ceiling tiles free from water stains? Is the floor clean? Are desk predominently uncluttered? It's good business practice to have a clean and orderly work environment....it's not only more effective, but safer, too!

When we first implemented 5S, there were a few people groaning at the concept of cleaning up and always putting things back in the same place. I countered with questions like, "Do you put your kitchen utensils back the same place every night?", "Do you return the butter or margarine to the fridge?"...we '5S' in our homes without calling it that. Why should our work environment be any different?

My brother, who is a professional automobile mechanic, has often said,

Before you leave your car with a mechanic, check his work area. Is it clean and neat? If the guy doesn't take care of his own tools and work area, why do you expect him to take care of your car?

Pretty much what any customer might wonder if he makes a site visit to a messy, dirty shop: "Why on earth would I expect this place to take good care of my product?"

 

[Bill Pflanz]

I happened to have come across a small reference guide on 5S that I forgot I had. It is called The 5S Pocket Guide and is a concise summary of the theory and methodologies. This guide and other reference material on 5S can be purchased on www.qualitycoach.net.

Someone gave me the guide and I just kept if for future reference. The guide includes some examples of appraisal sheets, goal line/time line templates, and action item log sheets. It also includes some ideas on how to visually inspect the area and collect the information for the worksheets. Considering the low cost of $4.95, it does provide an inexpensive introduction to 5S.

Bill Pflanz

 

[Greg B]

When I perform a 5S audit, I pretend I'm a Customer walking around a potential Vendor. Are ceiling tiles free from water stains? Is the floor clean? Are desk predominently uncluttered? It's good business practice to have a clean and orderly work environment....it's not only more effective, but safer, too!
When we first implemented 5S, there were a few people groaning at the concept of cleaning up and always putting things back in the same place. I countered with questions like, "Do you put your kitchen utensils back the same place every night?", "Do you return the butter or margarine to the fridge?"...we '5S' in our homes without calling it that. Why should our work environment be any different?.

Roxane, As usual you have nailed it. Excellent explanation.

I've attached a copy of our 5S checklist that we use when doing an audit. My organization is big on Visual Managment....lots of colour to show "at a glance" how we're doing. The checklist, once completed, is coloured for each 'S' and then an overall colour at the bottom (along with the score).

To help get 'buy in', for the first year, a green score must be >= 70%. Next year, we'll audit a bit tougher and a score of >=75% must be attained; the year after that 80%...eventually, we'll probably require a score of >=95% in order to be green.

Roxane, How do you score the system on your sheet. I see you have two sets of numbers 5, 3-4,2,1,0 and below them 1,2,3,4,5 - How do these work? How do you add up the total score and then get a percentage? The form layout is excellent but this is the only area I do not understand. Your help wil be appreciated as we are just starting out on the 5S trail. We have been a licensed GMP (Good Manufacturing Practises) producer for a number of years and this allows us to make feed products for animals and the agricultural industries. Part of this is good cleaning etc and 5S is our next step.

Greg B

 

[RoxaneB]

Roxane, How do you score the system on your sheet. I see you have two sets of numbers 5, 3-4,2,1,0 and below them 1,2,3,4,5 - How do these work? How do you add up the total score and then get a percentage? The form layout is excellent but this is the only area I do not understand.

At first glance, Greg, the audit sheet may seem confusing but with practice it becomes easier to use. One of our major concerns on the steering committee for the 5S initiative was consistency. We have strong auditors, weak auditors, and auditors with different focuses. To remain as objective and consistent as possible, we implemented a scoring system based on a tally of problem areas.

In other words...

• # of problems = 0 then Score = 5
• # of problems = 1 then Score = 4
• # of problems = 2 then Score = 3
• # of problems = 3-4 then Score = 2
• # of problems = 5+ then Score = 1
• Category = N/A then Score = N/A

Using "Sort" as an example, there are 3 categories to review. If all 3 categories are relevent/applicable to the area, then their score is out of 15 (i.e., with a max possible score of 15/15 and a min score of 3/15)

If they do not have a red tag area (as they have already dealt with their red tag items and no more currently exist), their score is out of 10 (for a max score of 10/10 and a min score of 2/10). If an item scores an N/A, it does not contribute to the overall score in anyway.

Each 'S' attains it's own individual score so that an area can see which 'S' needs to be worked upon.

The final score is attained by (total points allotted [excluding N/A's])/(sum of the denominators from each 'S'). Clear as mud?

Your help wil be appreciated as we are just starting out on the 5S trail. We have been a licensed GMP (Good Manufacturing Practises) producer for a number of years and this allows us to make feed products for animals and the agricultural industries. Part of this is good cleaning etc and 5S is our next step.

Best of luck on the 5S trail! Make it fun for everyone! Set aside group clean-up time or a Cleaning Day for each area (not always feasible to shut the whole plant down for a cleanup). Keep us updated!

 

[veedub565]

I've attached a copy of our 5S checklist that we use when doing an audit. My organization is big on Visual Managment....lots of colour to show "at a glance" how we're doing. The checklist, once completed, is coloured for each 'S' and then an overall colour at the bottom (along with the score).

I am currently in the process of creating a presentation on 5s to present to my employers, I would dearly love a copy of your checklist to use as a handout to give them some food for thought

 

[RoxaneB]

I am currently in the process of creating a presentation on 5s to present to my employers, I would dearly love a copy of your checklist to use as a handout to give them some food for thought

Welcome to the Cove, veedub565!

Feel free to use the checklist that I attached in my 13-Apr-04 post! As you can see from Greg's post, it may be a little confusing at first, but we did our best to remove some of the subjectivity out of auditing.

Good luck with your 5S initiative and keep us updated!