5S培训(英文版)

5STHESECRETTOJAPANESESUCCESSWHATPROBLEMSDOUCOMMONLYENCOUNTERATYOURWORKPLACEHIGHABSENTEEISMHIGHTURNOVERDEMOTIVATEDEMPLOYEESDISORDERED/CLUTTEREDENVIRONMENTMISTAKES/ERRORSTHESOLUTIONTOALLTHESEPROBLEMSIS5S5SHOUSEKEEPINGTECHNIQUEPRODUCTIVITYANDSAFETYENHANCEMENTTECHNIQUEIDEABEHIND5SINORDERTOACHIEVEHIGHLEVELSOFQUALITY,SAFETY,ANDPRODUCTIVITY,WORKERSMUSTHAVEACONDUCIVEWORKINGENVIRONMENTWHATIS5S?DevelopedbytheJapaneseHousekeepingSystemHelpsCreateaBetterWorkingEnvironmentandaConsistentlyHighQualityProcessTHE5SPRINCIPLESSEIRI–Organisation/SortoutSEITON–Orderliness/SystemizeSEISO–TheCleaning/ShiningSEIKETSU–STANDARDIZESHITSUKE-Sustain/DisciplineDISCOVERYOF5SThirtyyearsagoresearchersstartedstudyingthesecretofsuccessofJapanesemanufacturingcompanies5SturnedouttobethemostimpressivesecretThefactoriesweresowellorganizedthatabnormalsituationswerereadilyapparentDISCOVERYOF5SEquipmentsweresocleanandwellmaintainedthatanyproblemsuchasalooseboltorleakingoilcouldbeeasilyseenThispassionofcleanlinessandorderlinessbecameahallmarkofJapaneseorganizationsADVANTAGESOF5SIftoolsandmaterialsareconvenientlylocatedinunclutteredworkareasOperatorsspendlesstimelookingforitemsThisleadstohigherworkstationefficiency,afundamentalgoalinmassproductionADVANTAGESOF5SAcleanandtidyworkplaceleadstogreaterwellbeingandincreasedmotivationCompanyimageimprovesADVANTAGESOF5SHealthandSafetyisensuredMachinemaintenanceQualityProductivityLeanManufacturingADVANTAGESOF5SRESULTSINAPLACEEASIERTOMANAGESMOOTHWORKINGNOOBSTRUCTIONNODEVIATION,NOPROBLEMSB/CEVERYONEKNOWSWHERETHETHINGSARESPPOSEDFTOBEADVANTAGESOF5STIMESAVINGQUICKRETRIEVALACCIDENTS&MISTAKESMINIMIZEDINCREASESSPACECREATESWORKPLACEOWNERSHIPADVANTAGESOF5SFOUNDATIONOFALLQCTOOLSCONTINUOUSQUALITYIMPROVEMENTLEANMANUFACTURINGKINDERGARTENOFQUALITYTOOLS&TECHNIQUESADVANTAGESOF5SVISUALMANAGEMENTSYSTEMVISUALCONTROLTOSEETHEABNORMALITIESSIMPLESIGNALSTHATPROVIDEANUNDERSTANDINGOFTHECONDITION(NORMAL/ABNORMAL)ALOOKATTHEPROCESSREVEALSITSDIRECTION(RIGHT/WRONG)LeanProductionThelatestincarnationofJITBasedonToyotaProductionSystem.WasteeliminationWidelyusedinautomotivemanufacturing&otherrepetitivemfg.It’samindset&commitmenttoachieveatotallywaste-freeoperationthat’sfocusedonyourcustomer’ssuccess…achievedbysimplifyingandcontinuouslyimprovingallprocessesIt’stheeliminationofwasteEverywhere–whileaddingcustomervalue…Leanproductioncutscosts&inventoriesrapidlytofreecash,whichiscriticalItalsosupportsgrowthbyimprovingproductivity&quality,reducingleadtimes,andfreeinghugeamountsofresources.FromtheoperationsperspectiveFromtheoperationsperspectiveForexample,leanproductionfreesofficeandplantspaceandincreasescapacitysocompaniescan1.Addproductlines2.In-sourcecomponentproduction3.Increaseoutputofexistingproductswithoutacquiringnewfacilities.KINERGARTENOFALLTHEQCTOOLS5SISTHESTARTINGPOINTOFALLTHEQCTOOLSCOULDBESAIDASTHEPRE-REQUISITEOFALLQCTOOLSMETHODOLOGYOF5S1.ORGANISATION(SEIRI)DecidewhatyouneedRemoveunnecessaryclutterAlltools,gauges,materials,classifiedandthenstoredRemoveitemswhicharebroken,unusableoronlyoccasionallyusedREDTAGTECHNIQUEGIVESTAFFREDLABELSASKSTAFFTOGOTHROUGHEVERYITEMINTHEWORKPLACEASKIFNEEDED&THOSETHATARENEEDED,INWHATQUANTITYNOTNEEDEDREDTAGITSTOREINTHEREDTAGAREAREDTAGForwaveringitemsPLACETHESUSPECTEDITEMSINTHEREDTAGAREAFORONEWEEKALLOWTHESTAFFTOREEVALUATETHENEEDEDITEMSATTHEENDOFWEEKTHOSEWHONEEDITEMSSHOULDBERETURNEDREDTAGORGANISATIONPRIORITYFREQUENCYOFUSEHOWTOUSELowLessthanonceperyearOnceperyearThrowawayStoreawayfromtheworkplaceAvg.OncepermonthOnceperweekStoretogetherbutofflineHighOncePerDayLocateattheworkplace2.ORDERLINESS(SEITON)ONCEYOUHAVEELIMINATEDALLTHEUNNEEDEDITEMSNOWTURNTOTHELEFTOVERITEMSORDERLINESS(SEITON)Organiselayoutoftoolsandequipment–Designatedlocations–Usetapesandlabels–Ensureeverythingisavailableasitisneededandatthe“pointofuse”ORDERLINESS(SEITON)WorkplaceCheckpoints:-Positionsofaislesandstorageplacesclearlymarked?Toolsclassifiedandstoredbyfrequencyofuse?Palletsstackedcorrectly?Safetyequipmenteasilyaccessible?Floorsingoodcondition?3.SEISO(CLEAN/SHINE)CreateaspotlessworkplaceIdentifyandeliminatecausesofdirtandgrime–removetheneedtocleanSweep,dust,polishandpaintSEISO(CLEAN/SHINE)DivideareasintozonesDefineresponsibilitiesforcleaningToolsandequipmentmustbeownedbyanindividualFocusonremovingtheneedtoclean4.SEIKETSU(STANDARDISE)GenerateamaintenancesystemforthefirstthreeDevelopprocedures,schedules,practicesContinuetoassesstheuseanddisposalofitemsRegularlyauditusingchecklistsandmeasuresofhousekeepingRealchallengeistokeepitclean5.SHITSUKE(SUSTAIN/DISCIPLINE)Meansinoculatecourtesy&goodhabitsDrivingforcebehindall5SDeming’spointnumber1:ConstancyofpurposeMakeitawayoflifePartofhealthandsafetyInvolvethewholeworkforce*DevelopandkeepgoodhabitsLITMUSTESTFOR5S30SECONDRULEONEMUSTLOCATETHEITEMWITHIN30SECONDIF5SISPROPERLYIMPLEMENTEDALSOAPPLIESTOTHEELECTRONICRECORDSRETRIEVALWHATUHAVECOMEACROSSATTHEENDOFDAYFollowingscanbeharnessedformthe5S1.NEAT&CLEANWORKPLACE2.SMOOTH