5s培训教材 英文版 ppt课件

LocalPlantSafetyProtocol WHYAREWEHERE 1 Tolearnhowtoidentifyandeliminatewaste2 Toimproveourworkenvironment Safety Quality Efficiency WORKSHOPNORMS Mandatoryattendancefor3days Beontime Beanactiveparticipant Turnoffradiosandpagers Havefun GM NAOPlantoWin Why5S Whatis5S OPERATIONALDEFINITIONNo 21WorkplaceOrganizationOPERATIONALDEFINITIONNo 22VisualandAudioControls WorkplaceOrganizationandVisualControls How 6 THELEANORGANIZATIONINCLUDES PLANT and OFFICE 5SWORKSHOPPurpose Toteachpeoplehowtoidentifyandeliminatewaste Process 3full daysessions 3hoursclassroom Remainderoftimechangingyourworkenvironment Day16 30 6 40OpeningComments Safety6 40 8 15Orientation8 15 8 30Break8 30 9 40Orientation Cont d 9 40 10 00ProceedtoAssignedAreas 3 10 00 11 00Sort RedTaggingProcess 11 00 11 45Lunch12 00 3 00Sort RedTaggingProcess Cont d 3 15 4 00PlantLeadershipReviewProcessDay26 30 11 00Straighten Sweep11 00 11 45Lunch12 00 3 00Standardize SustainActivity3 15 4 00PlantLeadershipReviewProcessDay36 30 11 00Standardize SustainActivity11 00 11 45Lunch12 00 1 00PlantLeadershipReviewProcess1 00 1 30OpenItemsReview1 30 2 30ContinuousImprovementWall2 30 4 00Wrap up EntireGroup 5 SAGENDA 5S PASTEXPERIENCE TLOOffice 1992WhyOffice 1 ImprovesourUnderstanding2 avings FloorSpace 35 Reduction Efficiency 50 Improvement Supplies 44 ReductionIdentifiedbyToyotaasCompetitiveAdvantageTeachingExperience EXECUTIVEFEEDBACK Outstanding WewillimplementleanofficeatNUMMI G Convis VicePresident Manufacturing Engineering Outstanding WouldyouteachourJapanesecoordinatorsfromNUMMI I Itoh CEOandPres NUMMI Excellent NUMMIcanlearnmuchfromtheTLO IhavebeeninplantsallovertheU S ThisisthebestapplicationoftheTPSIhaveseen IwilltakewhatIhavelearnedandteachToyotawhenIreturntoJapan O Kimura CEOandPresident NUMMI utstanding The5SprocessisthefoundationoftheToyotaProductionSystem A Toyoda V P ProductionControlandQualityAssurance NUMMI 5STEACHINGS 1995 97 NUMMI21NAO Warren6MetalFabDivision MFD 5TruckGroup3Delphi3SmallCarGroup2ServicePartsOrg SPO 2Other4TOTAL46 5STEACHINGS 1998 throughDecember23 1998 NUMMI46NAO WarrenMI5MetalFabDivision MFD 3Powertrain3Delphi2FlintComponents1SmallCarGroup1TOTAL61 NUMMICOILYARDIMPROVEMENTSDUETO5S 60 FloorspaceReduction80 InventoryReduction 227 70Coils 2 25MillionInventorySavings 500 000CraneAvoidanceImprovedVisualControls DOMOREWITHLESS ReducingSalariedStaffingdoesNOTresultinincreasedproductivity ReducingWASTEleadstoincreasedproductivity OBJECTIVE EliminateWaste Costs Profits WASTE Difficulttorecognizewaste Needtomakeobvioustoeverybodywhatwasteis Wastemustalwaysappeardistinctlyandclearly Thisisthefirststeptowardsattainingimprovementinefficiency Mustre examinethewaywethinkaboutwaste ObservationsmadebyOhno SHIFTMINDSET CURRENTTHINKING REQUIREDTHINKING WASTENOTDEFINEDREACTTOLARGEEXAMPLESREACTIVEIMPROVEMENT WASTEIS TANGIBLE IDENTIFYMANYSMALLOPPORTUNITIES LEADSTOLARGEOVERALLCHANGE CONTINUOUSIMPROVEMENT COMMWIP WASTE TYPESOFWASTE C O M M W I P SHIFTMINDSET CURRENTTHINKING REQUIREDTHINKING WASTENOTDEFINEDREACTTOLARGEEXAMPLESREACTIVEIMPROVEMENT WASTEIS TANGIBLE IDENTIFYMANYSMALLOPPORTUNITIES LEADSTOLARGEOVERALLCHANGE CONTINUOUSIMPROVEMENT COMMWIP WASTE TYPESOFWASTE Over Production Processing MaterialMovement Waiting Inventory Correction Motion EFFECTSOFWASTEONPEOPLE CausesphysicalfatigueCausesemotionalfatigueIncreasesfrustrationsIncreasesstressCausesyoutoblameothersStealsyourtime EXERCISETOIDENTIFYWASTE 1 Breakintoteams 2 Chooseateamrecorderandpresenter 3 Forthenext15minutes reviewthedefinitionofthetypeofwaste Listwhatthistypeofwastewouldlooklikeifyousawitinyourplant workarea 4 Whatcausesthistypeofwaste 5 Shareyourfindingswiththewholegroupusingtheoverheadprovided 3minutes WASTEOFPROCESSING Whatdoesitlooklike Whatcausesthistypeofwaste Definition Doingsomethingthecustomerdoesnotperceiveasaddinganyvalue Forexample aguidepininajigdoesnotfunctionproperlyandtheoperatorhastodosomething xtra byholdingthejigwithhislefthand EngineeringchangeswithoutprocesschangesLackofcustomerinputconcerningrequirementsDecisionmakingatinappropriatelevelsIneffectivepoliciesandproceduresPoorjobatgettingbuildinfotooperators LackofpostedboundarysamplesUnclearcustomerspecificationsExcessiveprocessingofinformationbyoperatorsComplexprocessingofproductExtracopies excessiveinformationRedundantapprovalsOperatordoingunnecessaryoperationorrepair WASTEOFCORRECTION Doingsomethingoveriswaste Itwillrequireadditionalmotion additionalprocessingandwaiting Itusesmoreinventoryanddrivesupcost Whatdoesitlooklike Whatcausesthistypeofwaste Definition WASTEOFOVERPRODUCTION Whatdoesitlooklike Whatcausesthistypeofwaste Definition Generatingexcessparts information etc toosoonortoofastinaprocessiswaste Wasteofoverproductioncausesotherformsofwaste Forexample excesspartsrequirestacking storing etc WASTEOFMOTION Whatdoesitlooklike Whatcausesthistypeofwaste Definition Unnecessaryworkmovementsareaformofwaste Searchingformisplaceditemsiswasteofmotion Intheidealstate allmotionormovementshouldaddvaluetowhatyouareproducingforyourcustomer WASTEOFMATERIALMOVEMENT Transporting storingorrearrangingitems parts equipment people etc unnecessarilyiswaste Toeliminatewasteofmaterialmovement 1 makethedistanceasshortaspossible and 2 eliminatethetemporarylocationofitems Whatdoesitlooklike Whatcausesthistypeofwaste Definition WASTEOFWAITING Whatdoesitlooklike Whatcausesthistypeofwaste Definition Waitingwhileequipmentisautomaticallyprocessing orwatchingamachinewhileitoperatesiswaste Waitingforpeople informationorormeetingstostartontimeiswaste WASTEOFINVENTORY Whatdoesitlooklike Whatcausesthistypeofwaste Definition Toomuchofanythingiswaste Ittakesupspace canleadtoobsolescence impactssafety causeswasteofmotionandwasteofmaterialmovement Itmaycomefrompurchasingexcessivequantityofmaterials equipmentortools Break THE5 S PROCESS DISCIPLINEINPROCESS Processrequiresongoinginspectionandenforcementtoensure StandardizedWork isbeingfollowed Processdoesnotimproveautomatically Followingstandardswillonlymaintain notimprove process Improvementfocusesonentireprocess Stabilize Identify Waste Improve ProblemSolve Standards Enforce Inspect Standardize BENCHMARKING TLOOFFICE SEENOTESPAGE TLOLOCATORBOARD SEENOTESPAGE TLOSUPPLYCABINET SEENOTESPAGE TLOPULLCARDINSTRUCTIONSANDTPMCARD SEENOTESPAGE TLODESK SEENOTESPAGE TLOPRINTER SEENOTESPAGE TLOTOOLTABLE SEENOTESPAGE LORDSTOWNSTAMPINGBEFORE Seenotespage LORDSTOWNSTAMPINGAFTER SeeNotesPage PARMASTAMPINGBEFORE SeeNotesPage PARMASTAMPINGAFTER SeeNotesPage LANSINGPOWERTRAIN SeeNotesPage LANSINGPOWERTRAIN SeeNotesPage NUMMITRUCKFRAME SeeNotesPage TIMETOGOTOWORK DevelopRedTagStandards AssignMaintenance InspectionResponsibility Summary Wrap up RedTaggingProcess Buy in ImprovementReview Straighten Sweep WasteElimination Buy in ImprovementReview Standardize MakeVisual Buy in ImprovementReview AssignRemainingOpenItems CreateContinuousImprovementWall 5SPROCESSFLOW CLEARING Standardized Sustain Sweep Straighten Sort SORTING THERED TAGGINGPROCESS Gotoassignedarea assignkeeperofMasterLists Photographareacompletely Markphotos efore anddatethem Discusseachitemanddecidewhethertheitemshouldbe ed tagged Use50 rule beredtagdemons Beforeanyitemisdisassembled managermustapprove Takered taggeditemstomarshallingarea Managerhasfinalapprovalonallactions Documentchangesonformprovided SORTING CLEARINGUP WhatWillBe edTagged Stock Rawmaterials parts assemblies etc Machinery Trucks presses drills hoists etc Tools Equipment Motors wrenches pumps phones etc Facilities Worktables chairs desks etc Documents Files notices awards memos folders etc Stationary Pencils staplers erasers paper whiteout etc Fittings Nuts bolts wire hooks etc Locations Rooms bays floors shelves etc Others Catalogs radios magazines books etc edTagAnythingButPeople MASTERLISTFORSORTING ItemReasonDatetoAct SORTING RED TAGGING BUY INANDIMPROVEMENT Day1LeadershipReviewItemstoDiscuss IntroduceallteammembersIdentify5SboundariesReviewpurposeoftheareaReviewred taggeditems DAY2 Namethe7typesofwasteGiveexamplesof7typesofwasteWhatis5S REVIEW DevelopRedTagStandards AssignMaintenance InspectionResponsibility Summary Wrap up RedTaggingProcess Buy in ImprovementReview Straighten Sweep WasteElimination Buy in ImprovementReview Standardize MakeVisual Buy in ImprovementReview AssignRemainingOpenItems CreateContinuousImprovementWall 5SPROCESSFLOW ORGANIZING Standardized Sustain Sweep Straighten Sort Whydowestraighten Whydowesweep Boostsmoralebyimprovingtheworkenvironment STRAIGHTENANDSWEEP Easytosee easytoget easytoreturn Enablessharingoftoolsandsupplies Identifiesexcessinventory Improvessafety Cleaningisinspecting STRAIGHTENANDSWEEP Visuallyinspectentirearea andask Whyareitemslocatedwheretheyare Whereshouldeachitembe Aretoolsandequipmenteasytosee easytoget easytoreplace Isthereclosedstoragewhereopenwouldbeappropriate Organize cleanasyougo Frequently useditemsshouldbeeasiertoget Arrangeitemsfororderlyappearance PartsStorage A 1 2 3 ToolStorage hyisitallmessedup ACCIDENTSTENDTOHAPPENLESSWHENTHEWORKPLACEISCLEANANDWELLORGANIZED SAFETY ToolBox OFFICEGUIDELINES ConferenceRooms 1 Furnitureandmaterialssufficientformeetingneed Supply 1 Findsomethingin30seconds 2 3 daysupplyofconsumableitems Wallarea 1 Mustproviderecognitionofpeople sideas 2 Continuousimprovementswillbeshowninorganizedfashion identifyingwasteand17initiatives 3 Visualdisplayoncontinuousimprovementandlearning Locator MailArea 1 Mustbevisual seewithin2secondsifthereismail Library 1 Usercanfindinformationwithoutaskingfordirections NUMMISTAMPINGGUIDELINES Supplies 1 Finditemwithin30seconds2 Centralsupplyforcommonuseitems3 Centralsupplyforcommonuseinformationandannouncements4 OpenstorageforcommonusetoolsanditemsDeskTops 1 Standardizeddesktopmanagement stapler rolodex calendar G Lbumpcapandin trayWalls1 Recognitionofteammembers2 SectionGoalsandObjectives3 Feedback MonthlyProgress4 Clearviewoutofwindows NoObstructions Teamsreviewareaswithotherteams Istheareaorganizedtoeliminatewaste Canimprovementsbeidentified STRAIGHTENANDSWEEPBUY INANDIMPROVEMENT Day2LeadershipReviewItemstoDiscuss AnyadditionalitemsaddedtotheredtagareaKeyitemsstraightened organized Keyitems areasswept cleaned DevelopRedTagStandards AssignMaintenance InspectionResponsibility Summary Wrap up RedTaggingProcess Buy in ImprovementReview Straighten Sweep WasteElimination Buy in ImprovementReview Standardize MakeVisual Buy in ImprovementReview AssignRemainingOpenItems CreateContinuousImprovementWall 5SPROCESSFLOW Standardized Sustain Sweep Straighten Sort AssignMaintenance InspectionResponsibility STANDARDIZEANDMAKEVISUAL Whydowemakevisual Promotesadherencetostandards Abnormalitiesbecomeobvious Everybodycanbeinspectors Whydowestandardize Definesaplaceforeverything Establishesabaseline Essentialforcontinuousimprovement STANDARDIZEANDMAKEVISUAL STANDARDSFORSIGNSANDLABELSGMTECHNICALLIAISONOFFICE ColorScheme Description BlackonBrightGreenBlackonWhiteRedonWhiteBlackonYellow GoldRedonBlueBlackonFluorescentPink Locations rooms directions areaidentification etc TemporaryPersonnel nametags locatorboard STAcenter etc WallPostings TPM StandardizedWorkandothermiscellaneouspostedinformation Informational Storagelocations othermiscellaneousinformation etc TLOPersonnel nametags locatorboard etc SafetyItems firstaidkit etc Instructional 5 S checklist recyclingreminder etc OFFICESTANDARDSGMTECHNICALLIAISONOFFICE IndividualWorkAreas Supplies indesk OneuseperweekEquipment Outline n box messagepad telephoneandanyotheritemswhichmaybeusedweeklybyothersAllOffice SuppliesTarget 3 daySupplyAbletofindwithin30secondsLineage Size Floorlines 75in widthDesk TableTop 25in widthColor Floorlines YellowDesk TableTop GreensolidUsage Locationsshouldbeidentifiedwithlineswhentheitems 1 Arefrequentlymovedfromhomepositionforuseorserviceoraccidentallymoved2 havecriticallocationsforsafety visualorganizationortimesavingspurposesSignsandLabels SeeseparatesheetTime Abletofindanareaoritemwithin30seconds PLANTSTANDARDS 1 FloorLocation 3 4 Yellow2 WallOutlines 1 4 Blue3 Desk TableTopOutline 1 4 Green ManufacturingFloor 1 Safety CautionBlackwith3 YellowHash2 Walkway Pedestrian 3 Green3 ExitStripe6 OrangewithWhite4 OutlineLocation4 YellowwithBlackLabel5 ProductiveAreaClearGlossConcrete6 ProductiveSlipHazardNon SkidGray7 BreakAreasHighGlossLightGray8 Aisleways4 Yellow DashCorners 9 DirectionalArrowsBlack10 CheckpointLocationsYellowFootprint WallandFloorOutlines DAY3 REVIEW Whatarethe7typesofwaste Giveanexampleofthewasteofprocessing Whydowesustain Promotesasafeworkenvironment Maintainstheplanttothestandard Promotesgoodhabitsanddiscipline earewhatwerepeatedlydo Excellence then isnotanactbutahabit ARISTOTLE SUSTAIN StandardizedWorkSheetdeveloped documentedandposted TotalProductiveMaintenance TPM isassignedandposted VerificationisperformedbyManagement SUSTAIN MAINTENANCEANDINSPECTION TOTALPRODUCTIVEMAINTENANCECARD Area Performedby Ext Verifiedby Ext Date Performed Verified Date Performed Verified Date Performed Verified STANDARDIZEANDSUSTAINBUY INANDIMPROVEMENT Teamsreviewallworkperformedwithotherteams Isareavisual AreSWSappropriate Buy inforTPMassignment Pullsysteminplace Take fter pictures date andpostonwallwith efore pictures