5s(英文版培训)PPT课件.ppt

1 ASTRATEGYFORPERFORMANCEEXCELLENCE 5s 2 ExecutiveOverview Participantmanual ToolsWorkbook KnowledgeBreakthrough Lecturenotes Lecturenotes PerformanceExcellenceSeriesTrainingModuleElements 3 Session1 0Introduction 3Session2 0WasteManagement 14Session3 05SImplementation 20Element3 1SystematicOrganization 31Element3 1 1RedTagSystem 47Element3 2SortingVisualPlacement 33Element3 2 1VisualSignSystem 66Element3 2 2VisualColorSystem 76Element3 3ScrubbingClean 40Element3 4StandardizingControl 45Element3 5SelfDisciplineControl 48 5s TableofContentsKnowledgeBreakthrough 4 Whatis5S AnessentialsteprequiredforWasteEliminationAnintegralstepinKaizenArequiredelementtoachieveLean siteManufacturing SystematicOrganization Seiri Orderliness Seiton Cleanliness Seiso Cleanup Seiketsu Cleanup Seiketsu Standardization Perseverance Shitsuke 5s 5 5SPerformanceExcellenceModel Systematic SystematicOrganization Scrubbingclean Self Discipline Control CustomerExpectations SortingVisualPlacement StandardizingControl ImprovedQualityImprovedSafetyReducedcostsConsistentDeliveriesImprovedProduct ServiceOptions 5s 6 TheFiveElementsof5S SystematicSystematicOrganization Identifyingwhatitemsarerequiredandwhicharenot SortingVisualPlacement Itemsshouldbeeasilyretrievable easytoget andvisual easytosee Self Discipline Control EnsuringthatSystematicOrganization VisualPlacement Cleanlinessaremaintained ScrubbingClean Keeptheareafreefromdebris dirt oil itemsnotneeded StandardizingControl Maintainandcontinuallyimprovethepreviousimprovements 5s 7 MajorCPITools 6s KaizenLeanDescriptionCp Cpk4ProcesscapabilityassessmentDOE4DesignofexperimentsSPC4ProcesscontrolbasedonstatisticsanddataanalysisFMEA4RiskassessmenttoolRegression4CorrelateeffectonevariablehasonanotherProcessMap444Mapprocessstepstocommunicateandidentifyopportunities5whys 2hows444DeterminationmethodsforrootcausediscoveryPareto444ColumnchartrankingitemshighesttolowestFishbone444Cause EffectDiagram5S44EliminationwasteVisualMgmt444EmphasisonvisualtechniquestomanageprocessPoka Yoke44ErrorproofingtechniquesSpagettiChart44Kanban44MaterialstoragetechniqueusedtocontrolprocessTaktTime44DeterminepaceorbeatofaprocessStdWork44EvaluatetasksdoneduringaprocessSMED44Singleminuteexchangeofdies QuickmachinesetupTPM4IntegratemaintenancestrategywithprocessCellularFlow4Reduceinventory cycletimethruprocesslayoutandpullproductiontechniques ExpandProcessImprovementProgramtoUtilizeKaizenToolKit ToolKitComparison 5s 8 6SigmaDisciplinedMethodologyTechnicalApproach Quantitative DataDriven StatisticalCustomerFocusReduceVariationFocusonLargeImpactLarger LongerProjects KaizenPhilosophicalApproachCommonSenseApproach Qualitative DataDriven ObservationOperationalFocusWasteElimination5SIncrementalChangeSmaller ShorterProjects ComplimentaryToolsDrivingContinuousImprovement ExpandingtheStrategy PerformanceExcellence 5s 9 ComparativeAnalysis ImprovementMethodologiesSimilarinStructureImprovementsmeasuredagainstestablishedprocessTeamorientedSimilarimprovementtoolsMeasureeffectivenessofimprovementsMaintainnewperformancelevelStandardize ProceduralizeResultsMoreEfficientProcessesComparisonBothareEffectiveImprovementMechanismsCPI 6sbestappliedtolargecomplexproblemsKaizen Leanbestappliedtoachieveincrementalchangesandeliminatewastes Measure DataCollection DetermineProcessPotential GoalsEvaluate RootCause VitalFew StatisticalAnalysisImprove Verify ImplementImprovement ValidateImprovementStandardize Standardize Leverage SPC UpdateProcedures Evaluate BaselineProcessPerformance EstablishTargetDecide Comparesolutions ChooseAct Communicate Implementimprovement ControlMeasure Validateimprovement Standardize UpdateProcedures Focus ReduceProcessVariation IdentifyCriticalCauseandFocusResourcesforMaximumImpact Focus EliminateWaste5S SeekIncrementalProcessChanges Kaizen Lean 6s Summary TechnicalApproachbasedonStatisticalAnalysis RequiresSignificantDataCollection BestappliedtoManufacturingProcesses TypicalProjects1 3Months Summary CommonSenseApproachbasedonObservation Applicabletoalltypesofprocesses Definedimprovementstrategy TypicalProjects1week 5s 10 Why5S Toeliminatethewastesthatresultfrom uncontrolled processes Togaincontrolonequipment material inventoryplacementandposition ApplyControlTechniquestoEliminateErosionofImprovements StandardizeImprovementsforMaintenanceofCriticalProcessParameters LookFamiliar 5s 11 OverproductionDelays waitingtime TransportationProcessInventoriesMotionsDefectiveproductsUntappedResourcesMis usedResources 9Wastes TheNinetypesofwastes 12 Overproduction Delays waitingtime Transportation Process Inventories Motions Defectiveproducts UntappedResources Mis usedResources 9Wastes Giveanexampleofeachtypeofwaste TheNinetypesofwastes ThinkBreak 13 EliminationofWaste 14 SystematicOrganization Cleanliness VisualPlacement Standardization 5SImplementationPlan ProgressiveEnhancements Step1Establish5SImplementationTeam Step2DevelopSpecificImplementationPlan Step3DevelopCommunicationPlan Step4Develop5STrainingPlan Step5Implement5S Step6VerificationofEffectiveness 15 Removing RedTagged stuffWhatStuffwouldyou RedTag inthesepictures PictureA PictureB ThinkBreak 16 Inthefollowingpictures identifysomeofthe findingwastes assumeyouworkinadistributioncenterandyouhavetofillanorderwithproductlocatedinthefollowingpictures Everythinghasauseableplace ThinkBreak FindingWastes 17 Someevidenceofstandardizedworkareas Clear shinyaislewaysColorcodedareasSlogans banners Nowork in process WIP One PieceFlowStandardizedWorkSheets 18 VisualColorSystemImplementation Developamapidentifyingthe accessways aisles entrances walkwaysetc andthe action areas Performanynecessaryrealignmentofwalkways isles entrances Assignanaddresstoeachofthemajoractionareas MarkofftheWalkways Aisles entrancesfromtheactionareasTable1 0Applyflow directionarrowstoaisles walkw