Introduction to Lean and Six Sigma Module Three

Introduction to Lean and Six Sigma

Module Three

5 S Program • 5 S is a key tool used in eliminating wasted motion, waiting and excess inventory • Just remember…. “Everything has a place, and everything in its place”

Elements of a 5 S Program Sort — Perform “Sort Through and Sort Out, ” by placing a red tag on all unneeded items and moving them to a temporary holding area. Within a predetermined time the red tag items are disposed, sold, moved or given away. “When in doubt, throw it out!” Set in Order — Identify the best location for remaining items, relocate out of place items, set inventory limits, and install temporary location indicators. Shine — Clean everything, inside and out. Continue to inspect items by cleaning them and to prevent dirt, grime, and contamination from occurring. Standardize — Create the rules for maintaining and controlling the first three S’s and use visual controls. Sustain — Ensure adherence to the 5 S standards through communication, training, and self-discipline.

Plant Layout Plant layout is critical in eliminating wasted motion, transportation and potential defects When parts have to travel large distances inside a production facility, time is being wasted and the potential for damage is introduced

Good Plant Layout Team Center Mill #1 Mill #2 Mill #3 Raw Material Inspection Storage Lathe In Process Inspection Shipping Finish Machining Ship 6

Bad Plant Layout Team Center Mill #1 Mill #2 Lathe Raw Material Inspection In Process Inspection Finish Machining Mill #3 Shipping Ship Storage 7

Visual Workplace - Visual Controls • Simple signals that provide an immediate understanding of a situation or condition. They are efficient, self-regulating, and worker-managed.

Everyday Examples:

Manufacturing Examples:

End Of Module 3