LEAN MANUFACTURING - MAINPowerpoint file - 5S Basic Training 5S examples and LEAN terms (large file 1.3M - right click to download)
Powerpoint file - web powerpoint LEAN MANUFACTURING: Why It's Not Easy and How to Make It Work
Wow! With each improvement made, the GEMBA becomes a little brighter as waste (muda) and disorder are reduced. Recent 5S tours have been encouraging. Of course improvement opportunities were spotted and action taken; but for the most apart, we are holding on to improvements you’ve already made during 5S events, etc. In order to keep improving (TOC step #5), it makes sense to continue follow-ups. This is the “Sustain” step of 5S. . . .and since the people who work with a process know it best, who better to review progress? Therefore, each area has been asked to implement a “5S Tour” at least weekly. Take a good look around...imagine zero waste/zero confusion!
Ten Kaizen Principles- Get rid of all old assumptions.
- Don't look for excuses, look for ways to make things happen.
- Say "NO" to the status quo.
- Don't worry about being perfect - even if you only get it half right " start NOW!
- It does not cost money to do KAIZEN.
- If something is wrong "Fix it NOW.
- Good ideas flow when the going gets tough.
- Ask "WHY" five times - get to the root cause.
- Look for wisdom from Ten people rather than one.
- Never stop doing KAIZEN.
5S -Sort, Set in Order, Shine, Standardize and Sustain- Sort - All unneeded tools, parts and supplies are removed for the area
- Set in Order - A place for everything and everything is in its place
- Shine - The area is cleaned as the work is performed
- Standardize - Cleaning and identification methods are consistently applied
- Sustain - 5S is a habit and is continually improved
Also - Work areas are safe and free of hazardous or dangerous conditions
5S EXAMPLES- Maintenance-April 2002
 - Maintenance Event Above (before and during pictures)
- Machining-July 2002
- Machining Event Above (during and after pictures)
- Quality Assurance-July 2002
- Quality Assurance (before and after pictures)
- Tool Room-August 2002
- Tool Room (before and after pictures)
- Finishing-September 2002
- Finishing (before and after pictures)
- Stock Room-October 2002
- Plant-Wide 5S Event-December 2002
- Web slide show of the Plant-Wide 5S event on December 2002
- TOC and 5S at work at the Tap and Plug Operation
- Die and Storage Areas-March 2003
- Areas Behind the Building-May 2003
- Mini 5S event of office storage areas-May 2003
- Die Setup Area-June 2003
- Office and Office Storage Areas-March & April 2006
- ANNUAL 5S Event Schedule-Finishing, Tool Racks, Stockroom, Maintenance, Outside, Millwater, Restrooms, Vibratory, Machining, Tool Room, Quality, Die Casting, Furnace, Shipping and Office
Examples provided by: Texas Die Casting Note on printing the pages above. To get the complete picture on the right side of the screen set the right margin to .25 (Internet Explorer-File, Page Setup - adjust the right margin to .25)
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Main Lean
