A STRATEGY FOR PERFORMANCE EXCELLENCE

1. 1 A STRATEGY FOR PERFORMANCE EXCELLENCE 5S is the foundation, the building blocks, for a �Kaizen� approach to incremental improvement. 5S focuses on the elimination of wastes( Muda) in the work environment: to include the office environment as well as the manufacturing environment. In simplest terms , it is the cleaning up of all the wastes so that the work environment produces �what� it wants, at the �time� it is needed in the �correct quantities�.5S is the foundation, the building blocks, for a �Kaizen� approach to incremental improvement. 5S focuses on the elimination of wastes( Muda) in the work environment: to include the office environment as well as the manufacturing environment. In simplest terms , it is the cleaning up of all the wastes so that the work environment produces �what� it wants, at the �time� it is needed in the �correct quantities�.

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4. 4 What is 5S ? An essential step required for Waste Elimination An integral step in Kaizen A required element to achieve Lean-site Manufacturing. 5S was created in the Japanese manufacturing environment and literally stands for 5 Japanese words which begin with S: Seiri, Seiton, Seison, Seiketsu, Shitsuke When translated together mean a cleaning activity at a workplace. Aforementioned, 5S is an integral step towards Kaizen and Lean-site Manufacturing with the primary goal of being able to supply the customer ( internal,external) with the �right product� at the �right time� in the correct quantities.5S was created in the Japanese manufacturing environment and literally stands for 5 Japanese words which begin with S: Seiri, Seiton, Seison, Seiketsu, Shitsuke When translated together mean a cleaning activity at a workplace. Aforementioned, 5S is an integral step towards Kaizen and Lean-site Manufacturing with the primary goal of being able to supply the customer ( internal,external) with the �right product� at the �right time� in the correct quantities.

5. 5 5S Performance Excellence Model This model shows the inter-relationship of the 5S steps with the customer�s expectations of improved quality,improved safety, reduced nonconformance costs, improved product service options;thus, leading to a satisfied customer. Please note that the base of the pyramid is self-discipline-control. This step is key in maintaining the progress already achieved by the previous 4 S�s. Also please note, that the deliverables are closely related to the deliverables of a Kaizen process.This model shows the inter-relationship of the 5S steps with the customer�s expectations of improved quality,improved safety, reduced nonconformance costs, improved product service options;thus, leading to a satisfied customer. Please note that the base of the pyramid is self-discipline-control. This step is key in maintaining the progress already achieved by the previous 4 S�s. Also please note, that the deliverables are closely related to the deliverables of a Kaizen process.

6. 6 The Five Elements of 5S Each of the translated 5S�s are defined here.Each of the translated 5S�s are defined here.

7. 7 Tool Kit Comparison This matrix is extremely important in understanding the relationship of Kaizen, Six Sigma, and Lean- site manufacturing. Notice that many of the continual improvement tools are common amongst the three programs. In essence it is important to note that Lean-site Manufacturing is really a deliverable of Kaizen ( when employed completely and correctly). It is also important here to recognize where 5S fits into the equation. 5S focuses on the elimination of wastes, so it is common and required for successful completion of Kaizen and Lean-site initiatives.This matrix is extremely important in understanding the relationship of Kaizen, Six Sigma, and Lean- site manufacturing. Notice that many of the continual improvement tools are common amongst the three programs. In essence it is important to note that Lean-site Manufacturing is really a deliverable of Kaizen ( when employed completely and correctly). It is also important here to recognize where 5S fits into the equation. 5S focuses on the elimination of wastes, so it is common and required for successful completion of Kaizen and Lean-site initiatives.

8. 8 Expanding the Strategy A further breakdown of the continual improvement tools for Six Sigma and Kaizen, indicating the importance of waste elimination & 5S in Kaizen efforts.A further breakdown of the continual improvement tools for Six Sigma and Kaizen, indicating the importance of waste elimination & 5S in Kaizen efforts.

9. 9 Comparative Analysis Another comparative analysis showing the major steps in each of a Six Sigma and a Kaizen Program and that the primary focus of 5S is process related i.e. not only to the processes of cleaning,organizing etc. associated wtih5S, but also the work processes of documentation,selling,purchasing,manufacturing,distribution and integration of these with5S processes.Another comparative analysis showing the major steps in each of a Six Sigma and a Kaizen Program and that the primary focus of 5S is process related i.e. not only to the processes of cleaning,organizing etc. associated wtih5S, but also the work processes of documentation,selling,purchasing,manufacturing,distribution and integration of these with5S processes.

10. 10 Why 5S The primary focus of 5S is the elimination of wastes in the work environment that result from unorganized, unclean material, tools, machines, desks, inventories, aisles,walkways, storage locations. 5S provides a structured methodical approach towards this goal.The primary focus of 5S is the elimination of wastes in the work environment that result from unorganized, unclean material, tools, machines, desks, inventories, aisles,walkways, storage locations. 5S provides a structured methodical approach towards this goal.

11. 11 Overproduction Delays (waiting time) Transportation Process Inventories Motions Defective products Untapped Resources Mis-used Resources The 7 types of wastes are identified. It is important that the group understand these 7 wastes. The primary focus of Kaizen and Lean-site Manufacturing are focused on the elimination of these wastes. 5S in turn focuses on the elimination of many of these wastes ( Delays, Transportation, Inventories, Motions, Defective products).The 7 types of wastes are identified. It is important that the group understand these 7 wastes. The primary focus of Kaizen and Lean-site Manufacturing are focused on the elimination of these wastes. 5S in turn focuses on the elimination of many of these wastes ( Delays, Transportation, Inventories, Motions, Defective products).

12. 12 Overproduction ______________________________ Delays (waiting time)__________________________ Transportation _______________________________ Process_____________________________________ Inventories__________________________________ Motions ____________________________________ Defective products ____________________________ Untapped Resources __________________________ Mis-used Resources ___________________________ Have each member work by themselves and identify an example of each type of the seven wastes. ( 10 minutes)Have each member work by themselves and identify an example of each type of the seven wastes. ( 10 minutes)

13. 13 This matrix identifies the first 4 steps in the 5S program and their related wastes and deliverables. This justifies the previous emphasis that 5S eliminates non-value added activities and creates opportunity to increase profits !This matrix identifies the first 4 steps in the 5S program and their related wastes and deliverables. This justifies the previous emphasis that 5S eliminates non-value added activities and creates opportunity to increase profits !

14. 14 Listed above is the implementation plan for a 5S program. Each step is explained on the upcoming slides. Listed above is the implementation plan for a 5S program. Each step is explained on the upcoming slides.

15. 15 Removing �Red Tagged� stuff What Stuff would you �Red Tag� in these pictures ? Have the group get in teams of three or more and identify the items in each picture that they would red tag. For each item they identified to be red tagged, have them identify why, and under what conditions they would red tag an item.Have the group get in teams of three or more and identify the items in each picture that they would red tag. For each item they identified to be red tagged, have them identify why, and under what conditions they would red tag an item.

16. 16 In the following pictures, identify some of the �finding wastes � ( assume you work in a distribution center and you have to fill an order with product located in the following pictures). ___________________ ___________________ _________________ ___________________ ___________________ _________________ ___________________ ___________________ _________________ ___________________ ___________________ _________________ Have the group form teams of two. Identify the wastes in each picture. Define why they are wastes. Give them about 15 minutes do this.Have the group form teams of two. Identify the wastes in each picture. Define why they are wastes. Give them about 15 minutes do this.

17. 17 A standardized work area is a result of applying the first 3 S�s. the result will be a clean, organized work area with evidence of visual color and sign strategies.A standardized work area is a result of applying the first 3 S�s. the result will be a clean, organized work area with evidence of visual color and sign strategies.

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19. 19 Cleaning should involve everyone;including people in the office environment. Make it as fun as possible. Have competitions, awards, recognition programs. Make it simple, use cleaning tools you have available.( rags,mops,soap).Cleaning should involve everyone;including people in the office environment. Make it as fun as possible. Have competitions, awards, recognition programs. Make it simple, use cleaning tools you have available.( rags,mops,soap).

20. 20 The Resource Allocation Matrix identifies the required 5S task that needs to be completed in each 5S step job with the required frequency of action.The Resource Allocation Matrix identifies the required 5S task that needs to be completed in each 5S step job with the required frequency of action.

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