Standardised work & 5S Improving safety & efficiency

Transcription

1 Specify VALUE from the customer viewpoint Standardised work & 5S Improving safety & efficiency Pursue PERFECTION in quality & quantity by continuous Improvement Introduce Standard Working Remove Waste Identify the VALUE STREAM & remove waste Set up Visual Control Eliminate Batching Identify Root Cause Get it RIGHT first time every time Make Value FLOW Best quality, Lowest cost, Shortest time, Best safety, Highest morale J I T People J & Teamwork I D Continuous Improvement O Waste K reduction A Levelled workload Stable and standardized processes Visual management Philosophy 1

2 3 key elements to standardised work: Takt time Work sequence Work in process 3 key aspects to standardised work: It is not static When a better way is found, the procedure is updated It supports stability and reduces variation Variations, defects and deviations are easily recognised It is essential for continuous improvement Moving from one standard to a better one without slipping back 2

3 Why standardised work? Process stability Repeatability Clear stop/start points Organisational learning Are we in control? Don t lose the expertise Audit Assessing the current service Problem solving Error proofing Allows us to identify them To rectify and prevent them! Continuous improvement A yardstick Training Provides a basis for employee development Standards provide the means of creating consistent performance & so is the basis for process stability least waste takt time according to specification correct sequence documented and implemented repeatable 5S Translation Focus on using the English words - much easier to remember! Step Japanese Literal Translation English Step 1: Seiri Clearing Up Sort Step 2: Seiton Organizing Set In Order Step 3: Seiso Cleaning Shine Step 4: Seketsu Standardizing Standardise Step 5: Shitsuke Training & Discipline Sustain 3

4 Why 5S? 5S is a structured program to implement: Workplace organisation Standardisation Improved safety Improved work efficiency Improved productivity Improved flow Reduced variation Reduced waste Before 5S If only we had more space! How safe is this? 4

5 How easy is it to find what you are looking for? Is this a safe working environment? Is this SAFE? How clean is your working environment? Heater! Open top bin 5

6 1. Sort 2. Set 3. Shine 4. Standardise 5. Sustain 5S in practice SORT - Decide what is needed Define target area Remove everything Only put back necessary items Unnecessary items - Red Tag it! Holding area A method for sorting Item Where should we put this? Useful Keep & Store Unknown Red Tag / Holding area Useless Frequency of Use A B Frequency of Utilization Distance Class C Use this graph as a general guide for deciding where to store items along with the table below. Keep within arms reach Keep in local location Keep in remote location Daily or several times Useful Sorting Useless a day A YES MAYBE NO Weekly B MAYBE YES NO ABC Storage Dispose Monthly or quarterly C NO NO YES 6

7 Designated area (definitely not a corridor) Defined timescale for clearing Responsible 5S manager Top Tips Not an office already in use Large area initially Not too remote from service area/department Red Tag Holding Area Date Name of item Area/location removed from Reason for tagging Defunct Surplus Obsolete Quantity Next steps/what to do with it Move Dispose Other Store Date SET IN ORDER arranging necessary items A place for everything and everything in its place Clearly defined areas for equipment portable or stationary Think about how work flows Put the items in the best location Use visual management - labels, tape, signs and shadow outlines, coloured areas Mark off common areas with coloured tape and label them 7

8 What you need, where you use it SHINE Cleaning the Workplace Clean everything and find ways to keep it clean Cleanliness should be part of the daily work - not an occasional activity initiated when things get too messy Everything in its place frees up time for cleaning Create a plan to clean the area How often? By whom? Standards: A simple visual cue! STANDARDISE Creating consistency How you are going to ensure the first 3S are being maintained and incorporated into everyday activities? Standardised workstation layout helps sustain Create a set of standards that everyone has to adhere to Use Visual Management to facilitate easy understanding of these standards Standardising includes measuring, recording and training Ensure everyone is working the same way to improve safety work efficiency productivity 8

9 SUSTAIN maintaining 5S Train, communicate with and empower all staff Develop a system that enables everyone in the workplace to see problems when they occur. Develop schedules and check lists - 5S area audits Looks just like the picture! Why sustain? Cleaner Safer Improved quality Improved Job Satisfaction Improved Productivity Score S Audit - Treatment Room Date Tools available to sustain 5S Audit Sheet & Graph Paper 9

10 Before Sorted and Organised! After Before Mark off areas and label! After Marking off areas & footprints in General Practice Where is it? Good visual management gives the right info in one glance! Which trolley is being used? 10

11 Good inventory management & stock control Clear orderly working Before Missing manuals become obvious After Everything in it s place! Before Reception area After Consultation Room Consumables Cupboard Before After 11

12 Before you get started. Take lots of photos of the area before you start Designate a holding area and red tags Effective communication is paramount Give all staff plenty of notice to remove all personal items from the work area without standards, change would amount to little more than trial and error Spear and Bowen Everyone in the area should be involved You will need electrical tape to temporarily mark off areas and a labeller Stability Objective Create a basis for consistency Remove random activities Reduce variability of demand Level Remove impediments to flow a stable process will also have a higher degree of flexibility and capacity of meeting varied customer demand The benefits Process stability = repeatability Clear stop/start points for each process Organisational learning Audit & problem solving Employee involvement & error proofing Continuous improvement Training 12