The Quick Changeover Playbook: A Step-by-Step Guideline for the Lean Practitioner by Chris A. Ortiz

Author:Chris A. Ortiz
Language: eng
Format: epub
Publisher: CRC Press/Taylor & Francis Group, LLC
Published: 2015-05-17T00:00:00+00:00

Chapter 3

5S and Layout Improvements

Introduction

5S is a concept of aggressive visual transformation of a work area. It is the organizational side of Lean that can help improve productivity and output and reduce lead times through extreme organization. The key philosophy of 5S is “everything has a home.” The 5Ss are as follows:

Sort: The act of removing and discarding all unnecessary items from the work area.

Set in Order: The act of organizing what is needed so it is easily identifiable through the use of floor markings, labeling, and designations in a designated place.

Scrub/Shine: Clean the work area, including the floor, work surfaces, tools, equipment, racks, bins, and so on.

Standardize: Consistency is used in the implementation so colors and designations have similar meanings (i.e., red floor tape means caution and green floor tape means garbage can locations).

Sustain: The act of maintaining the organization through daily checks.

5S is the first improvement tool in your setup reduction projects. Ensuring machine operators spend minimal time searching for items for a setup will reduce the overall cycle time.

Sorted items from a machine work area

Red tags: visual representing unneeded item

Staging material racks to assigned equipment ahead of time

Outgoing painted parts

Green: ready for assembly

Red: parts needing paint

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