the five ss. 2 resistance to 5s implementation whats so great about sort and set in order? – the...

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The Five Ss

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Page 1: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

The Five Ss

Page 2: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Resistance to5S Implementation

• What’s so great about Sort and Set in Order?– The fact remains that 5S implementation is needed when

the factory is not neat and organized.• Why clean when it just gets dirty again?

– Sometimes people accept dirtiness as an inevitable condition in their workplace.

– They say that cleaning it up would do little good since it would soon get dirty again.

– This logic doesn’t hold, however, when we look at the negative impact of a dirty work place on the quality and efficiency of the work

Page 3: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Resistance to5S Implementation

• Sorting and Setting in Order will not boost output.– Production workers assume their job is to make things, not

organize or clean things.– This is an attitude that needs to change as workers learn

how important the Sort, Set in Order, and Shine activities are to actually maximizing output.

• We already implemented Sort and Set in Order– People some times think that rearranging things a little

and putting them into neat rows one time is all there is to it.

– However, such “orderliness” only scratches the surface.

Page 4: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Resistance to5S Implementation

• We did 5S years ago– This is heard most often from people who think the 5Ss is a

fad rather than a continuous activity.– 5Ss is actually a basis for making all other improvements.

• We’re too busy for 5S activities– 5Ss is one of the first things passed over when work gets

busy or production priorities become critical.– Since 5S is fundamental to factory operations, putting it off

for too long a period can have negative consequences.

Page 5: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Resistance to5S Implementation

• Why do we need to implement the 5Ss when we are so successful today?– It can be difficult to implement the 5Ss or any

improvement program at companies that are currently profitable.

– If you tell workers that it is more efficient to keep only one box of parts on hand at each operation, they may respond by saying”Yes, but we’re doing all right, and this is the way we’ve always done it.

Page 6: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Resistance to5S Implementation

• These types of resistances are common in the early stages of 5S implementation.– If we ignore such resistance and plow ahead with

implementation, the result is likely to be nothing more than superficial improvements.

– Instead, we need to address these concerns directly.• In order for the 5Ss to work, everyone needs to

truly understand just how necessary they are.

Page 7: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefits of5S Implementation

• 5S should have many benefits for you. It will– give you an opportunity to provide creative input

regarding how your workplace should be organized and laid out and how your work should be done.

– make your workplace more pleasant to work in.– make your job more satisfying.– remove obstacles and frustrations in your work.– help you know what you are expected to do, and when

and where you are expected to do it.– make it easier to communicate with people you work

with.

Page 8: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefits toYour Company

1. Zero changeovers2. Zero defects3. Zero wastes4. Zero delays5. Zero injuries6. Zero breakdowns7. Zero complaints8. Zero red ink

Page 9: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefit toYour Company

• Zero changeovers bring product diversification.– To remain competitive, companies must reduce

changeover times to zero, increase changeover frequency, and become more adaptive to product diversification.

– The 5Ss help lower changeover time by reducing material and tooling searching times and raising overall operator efficiency.

Page 10: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefit toYour Company

• Zero defects bring higher quality– Defects result from many causes including

attaching the wrong part and using the wrong jig.– Sort and Set in Order prevent these kinds of

errors.– Further, keeping production equipment clean

reduces equipment-operation errors and enables faster retooling.

– These and other effects of 5S implementation all add up to fewer defects.

Page 11: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefit toYour Company

• Zero waste brings lower costs– In-process and warehouse inventories– The use of excess amounts of space for storage– Stand-by waste while waiting for equipment to

transport items– Searching waste, when items are hard to find.– Motion waste, in side-stepping poorly located

equipment and supplies

Page 12: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefits to Your Company

• Zero delays bring reliable deliveries– Factories that lack thorough 5S implementation tend to

produce defects no matter what they try to do to prevent them.

– Deadlines are missed due to wasted motion and too many errors and defects while products are being reworked

• Zero injuries promotes safety– Injuries can be expected when items are left in walkway,

when stock is piled high in storage areas, or when equipment is covered with grime, cutting shavings, or oil.

Page 13: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefit toYour Company

• Zero breakdowns bring better equipment availability– When daily maintenance tasks are integrated with

daily cleaning tasks, operators notice problems before they cause a breakdown.

• In this way, equipment is more consistently ready for use.

– Clean, well-maintained equipment breaks down less frequently and is also easier to diagnose and repair when breakdowns do occur.

Page 14: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

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Benefits toYour Company

• Zero complaints bring greater confidence and trust– Factories that are virtually free of defects and delays are

also free of customer complaints about product quality. – Products from a neat and clean workshop

• Are defect-free• Cost less to make• Arrive on time• Are safe to use

• Zero red ink brings corporate growth– Companies cannot grow without the trust of customers.– The 5Ss provides a strong base upon which to build

customer trust and loyalty.

Page 15: The Five Ss. 2 Resistance to 5S Implementation Whats so great about Sort and Set in Order? – The fact remains that 5S implementation is needed when the

To Be Competitive, BoldlyGo Where No One Has Gone Before!