The Technical Assistance Program's Manufacturing Extension Partnership (MEP)
Center provides continuous improvement education, training and implementation services.
Learn how applying lean tools can eliminate waste in your business….
The "Lean" tool kit has several elements that are used to help manufacturers achieve
continuous improvement. In addition to 5S, there is Pull/Kanban, Cellular/Flow Manufacturing,
Total Productive Maintenance (TPM), Quality at the Source, Point of Use Storage
(POUS), Quick Changeover, Standardized Work, Batch Reduction, Teamwork, Visual Management,
Plant Layout, and Value Stream Mapping.
Lean Manufacturing is a systematic approach to identifying and eliminating waste
(non-value added activities) through continuous improvement by flowing the product
at the pull of the customer in pursuit of perfection.
The eight major sources of waste are:
- Overproduction
- Waiting
- Transportation
- Non-Value Added Processing
- Excess Inventory
- Defects
- Excess Motion
- Underutilized People
5S program is a great place to start. A 5S program strives for a safe, clean, and
neat arrangement of the workplace providing a specific location for everything,
and eliminates anything not required.
The 5S‘s stand for Sort, Set in Order, Shine, Standardize, and Sustain
Sort — "Sort Through and Sort Out", by identifying all unneeded
items and moving them to a temporary holding area. Within a predetermined time these
items are disposed, sold, moved, or given away. “When in doubt, throw it out!”
Set in Order — Identify the best location for remaining items,
relocate out-of-place items, set inventory limits, and install temporary location
indicators.
Shine — Clean everything, inside and out. Continue to inspect items
by cleaning them and to prevent dirt, grime, and contamination from occurring.
Standardize — Create the rules for maintaining and controlling
the first 3 S's and use visual controls.
Sustain —Ensure adherence to the 5S standards through communication,
training, and self-discipline.
When implementing 5S, an organization is striving for a workplace that is clean,
organized, orderly, safe, efficient, and pleasant. This will build a foundation
for all other improvement activities. The results are fewer accidents, improved
efficiency and quality, and better workplace control. Therefore, the organization
will realize reduced waste and reduced cost.