5S管理培训.ppt

1、管理培训王德良,5S Is A Process for creating and maintaininga clean, organized, safe,high-performanceworkplace 5S就是 创造并维护一个 干净、有秩序、安 全并且 高效的工作环境 的过程 Why Do It?为什么要进行5S管理？To drive improvement in GSQDC ） (Growth, Safety, Quality, Delivery, Cost)就是为了在GSQDC （即增长、安全、质量、交货和成本）等方面努力做出提高,Sort整理,Set InOrder整顿,Shine清

2、洁,Standardize标准化,Sustain维持,What is 5S And Why Do It?什么是5S和为什么要采用它？,Safety安全Reduce the number of lost time accidents, workmans compensation claims and OSHA recordable injuries减少浪费时间的工作，减少工人索赔事件和工伤记录 Quality质量 Eliminate the possibility of using previously rejected parts or the wrong tools. 消除使用不合格零件和不

3、正确工具的可能性 Eliminate contamination and assure compliance to standard procedures 消除污染并确保达标 Delivery交付Eliminate wasted time throughout the process to promote on-time delivery improvements通过推动按期交货的提高来消除时间浪费 Productivity生产效率Eliminate wasted time looking for tools. 避免浪费时间去寻找工具 Reduce cycle time, reduce equ

4、ipment downtime through regular cleaning and inspection减少循环时间，通过定期清洁和检查来减少设备停机时间。,5SMeasurable Benefits可预期的收益,Where Does 5S Apply?5S适用的场所,Any process involved in delivering value to the customer任何一道工序都要向客户传达我们的价值观 Factory工厂 Office办公室 Everywhere任何地方,It starts in YOUR workplace! 始于你工作的地方,5SThe Goal5S的

5、目标,5S is a Foundation for Improvement 5S是做出提高的基础 Visual Management is the Ultimate Goal透明化管理是最终目标 It is up to Each and Every One of us to Make 5S a Personal Goal我们每一个人都要把实现5S当成自己的目标,5S is a series of techniques that provide the foundation for a visual management system. 5S是为建立透明化管理体系打基础的一系列技能。,5STec

6、hniques5S技能,Sort 整理 Identify and eliminate what is not needed确定并消除不需要的东西 Set in order 整顿 A place for everything and everything in its place 所有的条件都应具备，所有事情都要各得其所 Shine 清洁 An effective, organized, professional environment 一个高效、秩序井然并且专业的工作环境 Standardize 标准化 Develop standards and stick to them/发展为标准并遵循该

7、标准 Sustain维持 5S is a way of life /5S 是一种生活方式,Sort整理,Separate the necessary from the unnecessary把必要的事情和不必要的事情分开 Unnecessary tools, equipment, and procedures need to be removed from the workplace不必要的工具、设备和程序需要从工作区清除掉,Remove the clutter so you can see what is happening.拨开杂乱无章的事务，你才会发现正在发生的事情,Sort整理Leve

8、ls of Achievement成功的步骤,Shine清洁,Look for problems disrepair, unmarked gages, worn, loose找出问题待维修之处，未标记的量具，破损和松动等 Eliminate the source of contamination消除污染源 Bring back to as new condition恢复原有的良好状态 Make the normal visible regular cleaning, visual data使正常状况显而易见定期清理，数据公开 Visual controls on delivery of val

9、ue signal and response在传达价值观方面进行透明化控制提示信号和反馈 Data driven, continuous monitoring数据驱动，持续监控,An effective, organized environment.一个高效的、井然有序的工作环境,Shine清洁 Levels of Achievement成功的步骤,Standardize标准化,Define and document the current process定义并存档当前的过程 Make it the standard for everyone是每一个人都接受这个标准 Define and wo

10、rk to the future state定义并朝着目标努力,Develop standards and stick to them.发展标准并遵循这些标准,Standard Color Code标准颜色标记,A standard color code identifies critical items, parts and areas within our companies to allow any employee or visitor to easily understand production in different business units 用一个标准的颜色标记来标明关键

11、物品，如零件和公司的各个区域，以使每个员工或来访者都能很容易地明白各个环节的生产,Daily 5S Checklists日常5S检查列表Example例子,Standardize标准化 Levels of Achievement成功的步骤,Sustain维持,Set a good personal example树立一个好的个人榜样 Regular evaluation of 5S program对5S项目进行定期评估 Constantly look for ways to improve the program 不断地寻求提高该项目的方法 5S becomes part of the cul

12、ture of the entire organization 使5S成为整个组织的文化理念的一部分,5S is a way of life! 5S任何时候都适用,Management Evaluation管理评估5S Patrol Report 5S巡检报告,Used by management to highlight 5S violations管理层用来突出与5S不相符的地方 Post report at the point of violation在不符区域张贴报告 5S Patrol Report stays at the location until violation is co

13、rrected 5S巡检报告将一直保留到不符点被纠正为止 Look for root cause solutions and sustainability 寻找根源的解决办法并解决并保持。 Challenge your people as to how the violation occurred in the first place质询你的人员这些不符合要求地方最开始是怎么发生的。 Track the # of violations, look for continuous improvement跟踪这些不符合要求的地方，并寻求不断的改进提高,Sustain维持 Levels of Achi

14、evement成功的步骤,5S is a Foundation for Improvement 5S是提高的基础 Visual Management is the Ultimate Goal 透明化管理是最终目标 It is up to Each and Every One of us to Make 5S a Personal Goal 实现5S的目标需要我们每一个人的共同努力,Sort Sort everything in the work area 整理在工作区对所有的物品进行分类,Set In Order - Organize the Entire Work Area 整顿对整个工作区

15、进行组织,Shine - Clean the Workplace Thoroughly 清洁彻底清理工作区,Standardize - Make Changes to Maintain the First Three Ss 标准化作出改进以保持前三个步骤,Sustain - Make 5S a Part of Our Daily Life 维持使5S成为我们日常生活的一部分,Summary总结,5SA Leaders Guide领导的引导,Key Takeaways A 5 step process Not housekeeping or cleaning up 一个5步的过程没有家政或清洁工

16、作 Sort Throw away 整理清除工作 Set in Order Everything in its place.Everything 整顿物品各得其所 Shine Clean with an eye towards problems 清洁清理的同时要看到问题的所在 Standardize maintain what has been done 标准化保持所作出的改进 Sustain Becomes part of the culture 维持使成为企业文化的一部分。 Why do? Drive G,S,Q,D,C improvements 为什么这么做？-推动增长、安全、质量、交货

17、和成本等的提高。 RED only for scrap or rejects 红色只用于废品和不合格品。 Foundation for Standard Operations 标准化操作的基础。,5SA Leaders Guide领导者的引导,What You Should Do/Demand你需要做的/指挥的 Do not walk past it anymore! Demand that it be addressed. It is not normal to have disorganization不要迈它而过！要求它应被放在该放的位置。没有秩序是不正常的。 Drive the expe

18、ctation everyday!每一天都要努力实现你的期望。 Hold people accountable使人们都有责任感。 Demand it be an office requirement把这作为办公室的要求。 Get rid of toolboxes, personnel inconsistencies such as chairs, refrigerators。拿走工具箱，和不必要的用品如椅子、冰箱等。 Eliminate the source of contamination and not just the clean up 不仅仅是要清理干净，而且要消除污染源。 Speak

19、 in terms of which “S” has been completed 通过完成5S中的要求来说话。,Sort整理Red Tag Process红标签程序,Red tag all unnecessary items用红标签标记所有不必要的物品 Create a temporary red tag holding area划分一块临时堆放带红色标签的物品的保管区域 Move red tagged items to the holding area for one week用一周的时间将带红色标签的物品都移到该保管区域 After one week, disposition items

20、:一周后，对这些物品进行处置： Salvage修补 Long term storage长期存放 School donations捐赠 Scrap作废 Disposal扔掉 Continue red tagging regularly继续定期进行红色标记,Sort整理Red Tag Helpful Hints,Dont compromise; IF IN DOUBT, THROW IT OUT! 不要让步：如果有疑问，就舍弃！ Do not be defensive. Be fair all areas get tagged! 不要有所保留。要公平所有的区域都要进行分类标记 Necessary

21、items can be tagged if improvements are known or suggested. 如果某些物品有必要做出提高，也要对他们进行标记。 Do not put multiple tags on any one object. 不要在一种物品上进行多次标记 Make reasonable allowances for decorative items such as family pictures, plants.允许一些适量的装饰品的存在，如家庭照片、盆景植物等。 Disposition all red tags.对所有作红色标记的物品进行处理 Track Re

22、d Tag dispositions in a log.跟踪这些处理。,Dont red tag people 不要对人进行红色标记,Sort整理Red Tag红色标记,Should be full size 标签的尺寸：(8.5” x11”) Bright red to promote visibility要明亮的红色，以更加显眼。 Should have pre-printed sequential tag numbers应该标记标签的序列号。 Perforated lower section to record location of tag 在标签下方打孔以利于固定标签。,3. Bra

23、instorm and Plan Countermeasures头脑风暴和计划执行对策,Focus on 5S things that can be done within the event关注事件中与5S有关的事情。 Bias for action versus planning and analysis 对行动与计划的不一致的地方进行分析。 Low cost solutions creativity before capital低成本解决方案 Right sized resources 适当数量的资源 Maximum waste elimination 最大限度地消除浪费 Visual

24、Controls 外观控制,Attack items that impact:从有影响的地方开始抓起： Process Flow过程流 Material Flow原材料流 Information Flow信息流,If I could start from scratch如果我能从杂乱无章开始,Set In Order整顿,Put everything in its place准备好所需要的所有物品 Frequency of use使用频率 Economy of Motion尽量减少移动 Use visual aids从外观来协助整顿 Shadow boards遮光板 Standard work

25、标准工作 Labels (return addresses)标签 Clearly marked places for items that are movable清楚地对需要移走的物品进行登记。 Colors, shapes颜色，形状 Keep it that way保持这么做,A place for everything and everything in its place.万事均须具备，事事各得其所,Set In Order整顿Organize组织,Place All Necessary Items in the Best Location and Visually Organize t

26、he Area 对所有所需物品放置于最佳位置，并对工作区从外观上进行有序化组织。 First decide where all items should be so that the organization is easy to use and understand首先要确定所有物品应该放置的位置，然后就很容易理解并照办。 Choose proper storage methods that minimize inventory and promote visual management选择最优的存储方法，减少库存，促进透明化管理。 Visually indicate locations s

27、o items in use can be returned and missing items are easily identified明确指定物品的位置，以至于需使用的物品及时取用，用完的容易确认。 Make sign boards that clearly explain inventory, equipment, and other items so anyone can understand the workplace制作信息板，清楚地说明库存、设备和其他物品的情况，已达到所有的人都能了解工作区的情况。,Organize the Necessary Items So That Th

28、ey Can be Used and Returned Easily,4. Make Changes做出改变,Implement countermeasures.对策实施 Bias for action, try something! 不要不屑于行动，试着做点什么。 Do Not dictate how things will be done.不要只是一味地说事情应如何去做，而要主动去做 Ask team members, build coalition.咨询团队成员，建立协作意识,Sort, Set In Order, Shine activities should be conducted

29、 immediately分类、整顿和清洁工作应该立即去做,5. Verify Changes对所作的改变进行合理化确认,Redo 5S Audit 再次作5S审核 Results achieved?得到什么结果呢？ If waste elimination is successful, there should be a noticeable change in the way the area looks and works 如果在消除浪费方面成功的话，那么工作区的面貌和工作应该得到了显著地提高。 If not, go back and make additional changes 如果没

30、有，回头继续作出改进。 Re-verify with additional observations 然后进一步观察并确认所作的有益改进。,Items that that are still in question should be “Red Tagged”仍然存在问题的地方应该再进行红色标记。,6. Quantify Results量化结果,Document the results against the event objectives using summary sheets 用总结表的形式来备份所有事情的目标完成情况。 Take digital photographs of comp

31、leted area 对达标区域进行拍照 Did you make progress in waste elimination?你在消除浪费方面做出改进了吗？ Conduct final 5S audit and verify that all red tagged items are dispositioned 进行最后一次5S审核，并确保所有进行红色标记的地方都进行了处理。 Will the improvements contribute to:所作的提高能否： Meeting customer expectations满足客户期望 Increase productivity增加生产效率

32、Reduce quality defects减少质量缺陷 Increase employee participation增加员工的参与性,7. Document the New Standard备份新的标准,Standardize the processes对过程进行标准化确认 Create visual documentation of 5S processes and schedules Sustain with Leadership This will be the process used by everyone所有的人都要遵循该进程 All personnel on all shif

33、ts should be instructed所有员工都应得到指导 Create a visual board to keep track of 5S scores in the area设立一个看板来随时跟踪该工作区的5S进程。,Standardize标准化,Maintain and improve the clean, organized workplace保持工作区的干净、有序并继续改进。 Eliminate excess storage areas and flat surfaces避免多余的存储空间。 Make changes to equipment that make it easy and quick to clean and eliminate dirt an