ELECTRONETICS. Scope: Prep Area

Transcription

1 ELECTRONETICS 5S TRAINING Scope: Prep Area February 19, 2010

2 Sponsor Michael Quinn, VP Manufacturing Production & Assembly, Northwest Center Scott Patterson, Plant Manager, Electronetics

3 What is 5S? It is considered a first step in becoming Lean (getting rid of waste) It is one of the methodologies in Lean: used to achieve stability in the workplace accomplished primarily thru Visual Control It is not just a task or project, but it is a cultural change

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5 Visual Control Components of Visual Control: 5S.... Workplace Organization, including Visual displays Signboards Demarcations Standard Work Instructions Boundary Samples Visual controls Metric/Status Boards Error Prevention Boards Andons

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8 Another way to look at it 3S = Sort Store (simplify, straighten, set in order) Shine (showcase) 2S = Standardize (establish standard work) Sustain (making improvements last) 3S + 2S = 5S = Stability = foundation for disciplined approach to workplace

9 Seattle Ronald McDonald House " Lean" Project December, 2009 February, 2010 Before 5S After 5S Before 5S After 5S

10 Before 5S

11 After 5S

12 Before 5S

13 After 5S

14 Workplace Scan To identify workers, processes, and functions of the area. To plan the Workplace Scan. Directions: Target Area Name: Define the boundaries of the target area and tape it off. State the primary purpose of the target area. Record the functions of the target area. Scan Step Who When Draw an area layout Draw a material spaghetti chart Complete 5-S & Safety audits Take photos Create a workplace scan display View on web at etcwa.com

15 Prep Area Current to Future State Note: Future state is a projection based on the assumption that shelf space needed will be reduced due to benefits of 5S, specifically: Elimination of unused items Relocation of seldom used items Optimization of space available

16 Prep Area Current State Physical Process Map Electronetics, Everett WA Observed 12/2/09, 10-11:30am Prep Area Cu foil, sleeves, shrink tube, wire Terminated leads Nomex wires Wire strip Shunt build Nomex cutter Shunt cutter Wire spool pallet Wire prep Shunt build operator and path Wire termination operator and path Shelf, desk, box, equip. or obstacle Roller conveyor

17 Prep Area Future State Prep Area Physical Process Map - Future Electronetics, Everett WA ROLLER WORK BENCH RACK RACK RACK RACK WORK BENCH WORK BENCH NOMEX DESK SHUNT BUILD SHUNT TRIM WIRE TRIM & PREP FILE Shunt build operator and path Wire termination operator and path

18 Workplace Audit Checklist Sort Straighten Shine Standardize Sustain BEFORE AFTER Distinguish between what is needed and not needed Unneeded equipment, tools, furniture, etc. are present Unneeded items are on walls, bulletin boards, etc. Items are in aisles, stairways, corners, etc. Unneeded inventory, supplies, parts, or materials are present Safety hazards (water, oil, chemical, machines) exist A place for everything and everything in its place Correct places for items are not obvious Items are not in their correct places Aisles, workstations, equipment locations are not identified Items are not put away immediately after use Height and quantity limits are not obvious Cleaning, and looking for ways to keep it clean and organized Floors, walls, stairs, and surfaces are not free of dirt, oil, and grease Equipment is not kept clean and free of dirt, oil, and grease Cleaning materials are not easily accessible Lines, labels, signs, etc. are not clean and unbroken Other cleaning problems of any kind exist Maintain and monitor the first three S s Necessary information is not visible All standards are not known and visible Standard Work doesn t exists for all cleaning and maintenance jobs All quantities and limits are not easily recognizable Items cannot be located in 5 seconds Stick to the rules Area workers have not had 5-S training 5-S is not performed routinely Personal belongings are not stored neatly Standard Work is not available or up to date Daily 5-S audits are not performed View on web etcwa.com Note: Check all that apply, plan countermeasures.

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24 Directions 1S - Sort Red Tag Checklist Red tag every item that may not be needed Enter a when a category is inspected Examine all items in each category Floors Aisles Operation areas Work Stations Corners, behind/under equipment Stairs Small rooms Offices Loading docks Inside cabinets and drawers Machines Small tools Dies Jigs Bits Conveyance equipment Plumbing, pipes, etc. Electrical equipment Wire, fixtures, junction boxes Cabinets Benches and tables Chairs Carts Other View on web etcwa.com Search these storage places Shelves Racks Closets Sheds Other storage areas Search the walls, boards, etc. Items hung on walls Bulletin boards Signboards Other Look for unneeded material / supplies Raw materials Supplies Parts Work in process Finished products Shipping materials Look for other unneeded items Work clothes Helmets Work shoes Trash cans Other

25 Unneeded Items Log Unneeded Item # Date Reason for Tagging Notes / Disposition View on web etcwa.com

26 Item Disposition Guidance Directions Determine the category each tagged item belongs Determine required action, record on tag and Unneeded Items Log Take action Category Action Obsolete Sell Hold for depreciation Give away Throw away Defective Scrap Trash / garbage Unneeded in this area Used at least once per day Used about once per week Used less than once per month Seldom used Use unknown Return to supplier Throw away Repair Remove to proper location Throw away Recycle Remove to proper location Carry with you Keep at place of use Store in area Store where accessible in plant Store in distance place Sell Give away Throw away Find out use Remove to proper location View on web etcwa.com

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31 Make visual! Include only what is needed Use shadow boards Use only space needed Example of STORE: Everything has its place and Everything is in its place

32 2S - Straighten Inspection Sheet Equipment Directions Machines Small tools Dies Jigs Bits Conveyance equipment Cleaning equipment Electrical equipment Fixtures, junction boxes, etc. Computer equipment Inspect all items in entire area Move items to proper place Enter a when a category is inspected Materials / supplies / inventory Other items Raw material Supplies Parts Work in process Finished product Shipping materials Cleaning supplies Furniture Cabinets Benches and tables Chairs Carts Shelves Racks Charts, graphs, etc. Books, checklists, etc. Bulletin boards Signboards Pens, pencils, rulers, etc. Work clothes Helmets Work shoes Trash cans Personal items View on web etcwa.com

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36 3S Shine Inspection Sheet Directions Search all items in the area for cleaning needs Use this with the Initial Cleaning Plan Enter a when a category is completed Large Surfaces Ceilings Aisles Work Stations Corners, behind/under equipment Stairs Loading docks Walls Doors Pillars and posts Floors Other Carts Shelves Racks Inside equipment / furniture Machines Conveyance equipment Closets Drawers Cabinets Sheds Tool boxes Storage bins Surfaces of equipment and furniture Machines Conveyance equipment Plumbing, pipes, sinks Electrical equipment Fixtures, junction boxes Chairs Other items Materials and supplies Trash cans Bulletin boards Labels and signs Small tools Hoses, cords, tubing, etc. Other View on web etcwa.com

37 Directions Initial Cleaning Plan List tasks and complete the columns below Target Area Task Location Who When Materials and Tools Needed View on web etcwa.com

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50 Make visual! Clean floor Taped-off areas Use labels (bilingual) Appropriate work surface for job function Good lighting Example of Sustaining Tools in Place

51 5S Evaluation and Sustainment For each "S", circle the block that best describes the station being assessed. Category 5 Points 4 Points World Class Best-in-Class Sort Every item in the area is needed. No needed items missing. Minimal clutter, small amount of unneeded items. 3 Points 2 Points Minimum Acceptable Marginal Some clutter. Clutter and unnecessary Some items stored on top of cabinets. items on desks, shelves, and/ Some needed items are not present. or cabinets. Week of: Reviewer: 1 Point Poor 0 Points Unacceptable Generally cluttered. Many Station is cluttered/unsafe. unnecessary items on desks, Abundance of unnecessary shelves, cabinets, and/or items, including furniture and floor. equipment. Store Shine Standardize Sustain Area very well organized. Excellent visual controls are in place. Designated locations for items. Aisles straight, clear and well marked. Everything in the area is in great condition and operates perfectly. No dust or dirt, clean floor. Area well organized. Most items in designated location. Visual controls in place. Aisles neat and clear. Everything in area is clean & functional. Floors clean. Recycle bins used and emptied daily. Area well organized with the exception of a few problems. Most items have designated location, and most are stored properly. All aisles are marked, but some equipment is not. Many visual controls are in place. Area moderately organized. Many key items have no designated location, some items properly stored. Equip and aisles are not clearly Inadequate organization. Many key items have no designated location. Shelves & drawers poorly labeled. Aisle or equip markings are not clear Poor organization. Little indication of designated locations. Items improperly stored on floor. Safety hazards. No visual controls, marked. Some visual controls or straight. Few visual controls signs, or labels. in place, many more could be added. or instruction are present. Safety equipment not designated. Most items in area are clean & functional. There is some clutter. Some Area needs to be picked up. Area is dirty. Possible health Some shared equipment doesn't work. items are not clean (floors, Many items need to be and safety hazards exist. Floors are moderately clean. waste containers). cleaned (floors, waste containers). 5S checklists for all personal / 5S checklists for most 5S checklists for most personal/shared areas No 5S checklists for personal/ Very few 5S checklists exist No 5S checklists exist. 5S shared areas are available and personal/shared areas are are available and followed. Opportunities shared areas, or not followed. for the area. 5S assessment assessment not done within followed. Opportunities for available and followed. Opport- unities for improvement noted- some Assessment done weekly, but not done week prior. Unclear if previous week. No evidence improvement noted- all resolved. unities for improvement resolved. Metrics & charts in the area no opportunities for actions taken to resolve prob- of follow-up actions to Metrics & charts in area are are noted- most resolved. are current. improvement noted. lems. Metrics/charts not problems. Metrics/charts are current. Metrics & charts are current. Metrics/charts not current. current. not current. Clearly documented and System in place and System in area and moderate interest in System in area, little interest No system in area, little No system or commitment followed system to maintain strong interest in maintaining maintaining 5S. Minimum performance maintaining 5S. Minimum interest maintaining 5S. within organization to 5S. World class performance 5S. Good performance sustained for at least 1 month. performance sustained for Very little stability in new 5S sustain 5S. sustained for at least 6 months. sustained for at least 3 mo. less than 1 month. performance. Sort Store Shining Standarize Sustain Score Opportunities for Improvement Who When

52 Current State 5S Category Score Sort 0.5 Store 1 Radar Chart Prep Area Shine 0.5 Standardize 0 Sustain 0 Date 2/10/10 Electronetics Sort 5 4 Prep Area 3 Sustain 2 1 Store 0 Standardize Shine

53 5S Category Score Sort 4 Store 4 Radar Chart Prep Area Shine 4 Standardize 4 Sustain 1 Date Following Implementation Electronetics Sort 5 4 Prep Area 3 Sustain 2 1 Store 0 Standardize Shine

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57 Summary 3S + 2S = 5S = Stability = foundation for disciplined approach to workplace Success of 5S depends heavily on leadership to ensure that a culture valuing standardization and sustainment is established.