SAN FERNANDO VALLEY PALLET COMPANY

'5S' PROJECT

MSE 507Lean Manufacturing Systems

Spring – 2016

Project Guide: Professor S. Jimmy Gandhi

Team 04Renan GamaViralkumar JayswalPerparim RushitiPooja ChintakuntaRanmini Menikdiwela

Content• 5S Methodology• Company Introduction• About Pallet Production Process• How to Implement 5S?

- Sort- Set- Shine- Standardize- Sustain

5S Methodology

Main idea about 5S implementation in organization is to make, clean, tidy and well organized workplace.

S1 - Sort S2 - Shine

S3 - Standardize

S5 - Sustain

S3 - Set in order

Start

We implement 5S,• Company : San Fernando Valley Pallet• Area : Production Division

Company Introduction

• San Fernando Valley Pallet Co. is a Family owned business which is being operated since 1996.

• It provides all types of pallets, from standard pallets and crates to custom sizes, per customer specifications.

• Their pallets are designed with innovation for maximum capacity.

• They have two multi acreage facilities to serve better in Southern California. They have more than 20,000 pallets in stock and keep inventories of custom and standard sizes to meet customers’ requirements.

• They are Certified Pallet Maker for Export Pallets.

Pallet Production Process

No New Pallet Construction Process Old Pallet Construction Process1 Cut cants into specific sizes (required

length, height and width)Sort old pallets

2 Butt joins short length wooden pieces Dismantle the wooden pallets

3 Place the pallet elements on the line Refurbishment - Join pallet components (runners) using nailing machine

4 Join pallet components (runners) using nailing machine x 2

Finished pallets temporally stored in the production line

5 Finished pallets temporally stored in the production line

Finally transfer to the main storage area

6 Finally transfer to the main storage area

How to Implement 5S in Pallet Production Process?

SORT

Sort is a practice of removing all the unnecessary materials from the current production process and keeping only the essential items.

Problem:• Production floor become messy and crowded • Unnecessary time for searching tools and other materials• Unwanted inventory and machineries are costly to maintain and required significant amount of work space• Excess stocks hide the production problems hence unneeded items and equipments make harder to advance the process flow

How we can sort?

Eliminate nonessential items from the work place such as wood pieces, tools, machinesand other materials.

• Specify separate location as Red Tagged area.• Red Tagged items, which are nonessential.• Create a “Local Red Tagged” and stored nonessential items in the local red tag area

for 5 days.• We proposed to have one local red tagged area in production floor.• If the production team not reclaimed any red tagged items within 5 days, items are then

moved to “Central red tagged” area. • One central red rag area to be introduced to the entire manufacturing floor.

SORT

• Those items are located in the central red tag area for another 5 days. • Everyone can sift through the items to check whether they have anything need.• Thereafter, company can disposes of them through recycling, resale or trash.

SORT How we can sort?

SET• SFV Pallet Current Layout

Arranged required items in a way that easy to use.

How to Set in order?

• Three major production Areas: “Assembly Custom Sized Pallets”, “Assembly regular Sized Pallets” and “Repair Regular Pallets”.

SET

1. Proposal of New Layout

• Thereafter we analyzed the production process in order to find the additional improvement opportunities such as ways to reduce waste and errors and make palette production area more visually instructive.

2. Visually instructive• Label items: Palette nailing machines, tables and other tools to be labeled

(Labeling items will help everyone to find items easily and put them back at the right place. This helps to reduce unnecessary motion, searching waste, human energy waste and unsafe conditions)

• Display safety alert: Alerting people will improve safety• Display procedures: Display standard SOPs/operation steps

SET How to Set in order?

1. Proposal of New Layout

Pallet assembly table design 1 : Table slope can be adjustable

Pallet assembly table design 2 : Pallet can be rotate or spin easily

3. Reduce waste/errors: Pallet assembly table designs

SET How to Set in order?

Pallet assembly table design 3Suspend the pneumatic nailing tool

SET How to Set in order?

3. Reduce waste/errors: Pallet assembly table designs

• Quality standards need to be presented in graphically or physically• Find out critical to quality operations • Visually display those operation’s, acceptable and unacceptable outputs in a common

area

4. Quality Inspection

SET How to Set in order?

Acceptable Unacceptable

SHINE Keep clean the workplace every day by eliminating dirt and dust.

Problem:

Wood dust and other dust particles cause injuries/health issues.

Machines that do not receive sufficient maintenance, tend to breakdown or cause defects.

Untidy appearance at workplace.

How to shine the workplace?

• Establish a regular schedule for cleaning every day – - Routing cleaning everyday end of the shift (15 min before)- Deep cleaning every Friday, 30 min before the shift end(Clean things such as tools, equipments, pallet making tables/jiggers and work floor)

• Each team member need to be equipped with adequate cleaning supplies • Cover storage & production area well to protect by weather condition

SHINE

Kärcher Industrial vacuum cleaners IVC-Series for wood industry

https://www.youtube.com/watch?v=0q6A63ZYEm4 Cost = $450 - $500 each

STANDARDIZE

How to standardize the workplace processes?

Instructions and Training –• Instructions for operations (Standard Operating Procedures - SOPs) must be provided,

in order to standardize the methods and practices for each operation. • Training may be necessary in order to reinforce the procedures and practices for each

operation.

Visual Aids - • Visual aids, such as signs, arrows, lines must be implemented in the operation area. • Different colors of labels, signs, and lines can be used for the different kinds of pallets • New/Old palettes, Finished/Unfinished palettes, Rejected palettes• Different lengths of cut wood, different colors of labels can be used (so that the worker

will easily identify the material needed)

All the best practices and new procedures recommended in the previous 3 steps must be standardized

• For the different operations, different colors of lines can be used to surround the operation area, each color meaning a different level of risk. So, operations which can offer more danger, can be surrounded with a vivid color line in the ground, which will make easier to workers identify risky areas and will increase safety.

STANDARDIZE How to standardize the workplace processes?

• In order to mark the floor with the safety lines, it is better to buy a floor marking, to paint it manually, or buy the tape and mark it manually.

Breaks• After every break, (lunch break, shift) workers must put all the tools and equipments back to

the place where it belongs before leave the workplace. • For the lunch break, a specific place should be dedicated. In this place the workers should

have the microwave, tables, chairs, water, and so on. Doing that it is easier to keep the workplace clean, avoid potential contaminations/intoxications, and the safety is increased.

Prices

• Vinyl Safety Marking Tape $8 ~$12 at Amazon.

• 3M Lane Marking Applicator $150 at Amazon.

STANDARDIZE How to standardize the workplace processes?

SUSTAIN

How to sustain in correct procedures?

• Conduct a regular auditing procedure in order to ensure that employees understand the importance of proper work place organization.

• Create a “Housekeeping Scorecard” to analyze the team performance in monthly basis.

• Further the audit provides a good opportunity to get employees feedback for future improvements.

• Culture change - this is not something to be done just one time, it is something to be introduced to the company culture in order to maintain the practices.

Making a habit of properly maintain the correct procedures

5S Housekeeping Scorecard 5S Housekeeping Scorecard

Date : 0 – No Problems1 – One to Two Problems2- More than Two Problems

Auditor : Location :

N/A 0 1 2 DescriptionSort

1 No unnecessary materials in area.2 Unused wooden pieces are out of the work area.3 No unnecessary equipments, machines and personal items.

Set In Order4 Tools and equipments are properly identified and stored in designated area.5 Pallet assembly tables are cleaned and organized.6 Finished pallets temporally storing area cleaned and organized.7 Machines are properly identified and properly located.

Shine8 Pallet assembly table surface, tops of machines free of dust.9 Floors are cleaned around the work area.

10 Work stations clean and organized. Standard

11 Damaged/non functional equipments are removed from the work area.12 Machines are properly maintained.13 Properly maintained red tag procedures.14 Properly follow the pallet construction process15 Properly follow the safety instructions

Total

SAFETY

• 5S + Safety = 6S• Although safety is already included in the traditional 5 steps;

–Clean workplace -> Safer workplace;–Well maintained equipment -> Safer equipment.

• Concentrate on safety aspects of your initiative, reviewing every action and each area to ensure that you have not overlooked any potential hazards.

–In the sort phase, besides red tags, use yellow tags to Environmental Health & Safety hazards (evaluated separately);

–Display safety alert: Alerting people will improve safety;

Eliminate Hazards

Questions?

Thank you…