Quantifying the benefits of 5S Implementation

[dasamit123]

Dear Forum Users,

I need your suggestion on How to quantify the benefits of implemeting 5S. Normally, when we propose to some manufactring unit to implement 5S, they want to know the benefits in numbers, costs etc. I know qualitative outcomes of 5S but not quantitative. Please suggest some ways to bring some factual results out of effective 5S execution at shop floor.

Thanks for your time.

Regards
Amit

 

[Polly Pure Bread]

Re: Quantification of 5S Benefits

Make Rules/Quality Workplace Standards
e.g. lights, computers, etc shall be turned off when not in use. you can quantify the cost savings.

 

[dasamit123]

Re: Quantification of 5S Benefits

Thanks for your answer.

When someone is to be conviced on 5S effectiveness, what results and factual outcomes we can promise to him?

Thanks for your time.

Regds
Amit

 

[Polly Pure Bread]

Re: Quantification of 5S Benefits

When someone is to be conviced on 5S effectiveness, what results and factual outcomes we can promise to him?

Improve the quality of work life through a clean and organized workplace using a team-based approach.

 

[DanteCaspian]

It really is that simple.
Further gains are that it allows a company to shape a cultural mindset in preparation for other continuous improvement efforts.
I would not have been able to teach and help a process just today for the sake of one-piece-flow and high quality yield without the basic principles of 5S in place.
If you need to provide further information in a quantitative way, you may need to show them. That is how I gained traction in a few places... just do it in a selected area and then show and tell.

 

[AndyN]

Re: Quantification of 5S Benefits

Thanks for your answer.

When someone is to be conviced on 5S effectiveness, what results and factual outcomes we can promise to him?

Thanks for your time.

Regds
Amit

Amit - implementing a 5S approach in the workplace is (in part) a method to reduce the '7 Wastes' which are also part of TPS/Lean. It shouldn't be too difficult to see (literally) what affects a production line (if that's what you're considering) and has an impact on one or more of the 7 Wastes. Once you know that, you can put a cost to it - wasted movement, wasted time (like waiting) until a tool is found etc. etc.

 

[dasamit123]

Thanks Andy, for your reply.

Actually, I am facing problem in convincing some of european plants of my company, that 5S can be effective in cost reduction or improving productivity. While selling any idea, we need to provide some facts and/or cash benefits. Some units say that its is just improvised cleaning and nothing more. They already have a system of housekeeping and I know, 5S will obviously add further value to it. But, unless I show, some case studies in terms of impact on profictability or give them some attraction in terms of cost reduction possibilities, it is becoming difficult. Qualitative benefits are convincing ones but, it is suitable to only those who have already seen it implemented somewhere in his career history, but to convince someone, who is new to this concept is challenging.

Please suggest something, which I can use as an example.

Regards
Amit Kumar

 

[AndyN]

Amit;

Good deal! Why not make a video of the typical workplace/workcell where the 5S would bring most benefit? As you know, if you were implementing an entire "lean' program, you'd probably diagram (spaghetti style) the walk the operator/s make. Since you are unlikely to get that help, you could video or make many still photos to demonstrate how much wasted traveling is involved in an 'un-5S' ed space.

I have some poor photos which actually show the operator in the 'future' state standing drinking tea because he has so much time on his hands!! Not before 5S though!!

 

[John Nabors - 2009]

Amit-

Or, you might try pointing out to your superiors that 5S is one of the foundations of the Toyota Production System and ask them: do you want to imitate the success of Toyota, or do you just want to keep making Yugos?

Kind Regards -John

 

[sixsigmais]

Thanks Andy, for your reply.

Actually, I am facing problem in convincing some of european plants of my company, that 5S can be effective in cost reduction or improving productivity. While selling any idea, we need to provide some facts and/or cash benefits. Some units say that its is just improvised cleaning and nothing more. They already have a system of housekeeping and I know, 5S will obviously add further value to it. But, unless I show, some case studies in terms of impact on profictability or give them some attraction in terms of cost reduction possibilities, it is becoming difficult. Qualitative benefits are convincing ones but, it is suitable to only those who have already seen it implemented somewhere in his career history, but to convince someone, who is new to this concept is challenging.

Please suggest something, which I can use as an example.

Regards
Amit Kumar

Use the idea on cost saving. 5s save space, save time and easy to get tools.

Use some example and calculate the cost compare on before and after 5S