The 5s system, workplace organization and standardization -- Facilitators Guide

[John B]

Hi, my name is John, and I am co-opping for an automobile parts supplier this summer (as I did last summer, although all i worked with was work instructions and control plans and a bit on FMEA's.) I will be entering my final year of college next fall (mechanical engineering)

anyway, this summer my supervisor, plant foreman and production manager, has asked me to facilitate a 5S system in one of our work areas. he gave me a binder intended to teach someone the suggested method on how to facilitate this process. ("The 5s system, workplace organization and standardization -- Facilitators Guide.", Productivity Press)
it is divided up into 7 modules that are to be presented/taught to a core implentation group, then acted on by performing excercises in the work area.

i have read and reread the guide and read half of "The Visual Factory" by Michel Greif, and found several interesting and informative sites on 5s, TPM, Lean Manufacturing, and Kaizen, and most recently this message board.

my question is, do any of you have any tips for me in trying to facilitate this process?
my supervisor has given me quite a bit of freedom in this project, and i am just trying to learn as much about the subject as i can (so i don't look silly/stupid/ignorant when i try to present this stuff)

our plant has tried to implement 5s in the past, but with no success. there are several areas which have almost got it, but nothing lasts. also, i am working with several others here who have gone through formal training and have worked a bit on the implementation at our plant, but its always nice to hear suggestions from outside sources as well.

anyway, i am just trying to figure out the best way for me to go about handling this task, and any suggestions/tips/advice/warnings anyone out there could give would be appreciated.

thanks,

John

 

[Jim Evans]

John,

I am charged with the same challenge at my company. We had people from the Ford Lean Team do our initial training and now I will be working with implementation teams throughout the plant doing 5S activities. We are using the same materials that you are using.

If you are a supplier to Ford I would suggest you contact the Lean Resource Center Library in Dearborn. They will have the videos that go along with your Productivity Press printed materials. As long as you are a Ford supplier the materials at the center are FREE to borrow. Try their website on the Ford Supplier Network: https://web.lean.ford.com

For my part in the first session that I conducted I insisted that our company president, controller, HR director, other "office types" be a part of that training. Unless you have complete commitment (especially for resource allocation) from upper management on this program it will be doomed to failure. It was important for the folks out in the shop to see my class in their bluejeans out pushing brooms, scrubbing down machines etc.
They don't get off with just a session or two out in the plant either. All are assigned to be mentors on implementation teams throughout the shop. We will allso implementent 5S in our offices and the hourly personnel from the shop will be auditors in this area (for some reason they are taking great glee in this).

I used something called the numbers game that the people from Ford gave me when they were here. It illustrated the point of clutter, missing tools and organization very well. I would finally suggest you use lots of overhead projector images: Before and after pictures, forms, etc. to supplement your presentation.

Good luck with your project.

Jim Evans