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download 5s for operators 5 pillars of the visual workplace pdf

5S / Visual Workplace
Handbook
Building the foundation for continuous
improvement
SORT
SHINE
SET IN ORDER
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www.BradyID.com/visualworkplace
SUSTAIN
5S WORKPLACE ORGANIZATION
5S is one of the most widely adopted techniques from the lean manufacturing toolbox. Along with Standard Work
and Total Productive Maintenance, 5S is considered a “foundational” lean concept, as it establishes the operational
stability required for making and sustaining continuous improvements.
The primary objective of 5S is to create a clean, orderly environment- an environment where there is a place for
everything and everything is in its place. Beyond this, many companies begin their lean transformation with 5S
because it exposes some of the most visible examples of waste it also helps establish the framework and discipline
required to successfully pursue other continuous improvement initiatives.
Target Outcomes and Benefits










Reduce non-value adding activity
Reduce mistakes from employees and suppliers
Reduce time for employee orientation and training
Reduce search time in navigating the facility and locating tools, parts and supplies
Reduce parts stored in inventory, and associated inventory carrying costs
Reduce unnecessary human motion and transportation of goods
Improve floor space utilization
Improve employee safety and morale
Improve product quality
Extend equipment life through more frequent cleaning and inspection
5S produces measurable benefits. One of the surest ways to identify these benefits is to establish and track specific
metrics. For example, measure the time required to locate items in the workplace before 5S and then measure the
time required after the workspace has been improved. Longer term benefits can also be measured by monitoring the
amount of workplace injuries reported after 5S has been implemented. Not only may workplace injuries decrease, but
training costs may, too. It is easier and faster to train employees in a work area that is orderly and well marked.
Another way to measure 5S benefits in the workplace is to take pictures. Pictures are very effective at visually
highlighting the improved appearance and order in the workplace. Concrete measurements are a complement to the
pictures, fueling the momentum needed to sustain 5S.
WHAT IS VISUAL WORKPLACE?
Visual Workplace - also known as Visual Factory or Visual Management – is a lean concept that emphasizes putting
critical information at the point of use. Visual systems and devices play a critical role in many of the most popular lean
tools, including 5S, Standard Work, Total Productive Maintenance, Quick Changeover, and Kanban (Pull Production).
In fact, Visual Workplace serves as the key sustaining force for these initiatives, because it ensures that lean and six
sigma improvements remain clearly visible, readily understood, and consistently adhered to long after the Kaizen or
rapid improvement event is over.
A visual workplace is a work environment that is self-ordering, self-explaining,
self-regulating and self-improving – where what is supposed to happen does happen,
on time, every time, because of visual solutions.
From “Visual Workplace, Visual Thinking” by Dr. Gwendolyn Galsworth, www.visualworkplace.com
Companies are often surprised to learn that only a fraction of their
activities actually add value for their customers. It’s not uncommon that
50% or more of a facility’s activities are considered waste!
A primary cause of waste is information deficits – employees simply
lack the knowledge they need to do their jobs efficiently and effectively.
This leads employees to waste valuable time and motion searching,
waiting, retrieving, reworking or just plain giving up! A visual workplace
eliminates questions, generating significant improvements in
productivity, quality, customer satisfaction, safety, and more.
Visuals Critical To Lean Success
Successful lean initiatives start by establishing a base of operational stability. After all, you can’t make lasting improvements
on a base of chaos. By reinforcing standards and highlighting abnormalities at a glance, visuals support the foundational
concepts of 5S, Standard Work, and Total Productive Maintenance, which are used to stabilize the work environment, work
methods, and equipment performance.
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Once a stable operating base has been
Improvement
Visual Workplace
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established, the next step is to implement a
Sustains lean
Plan
kaizen-style improvement program that continues
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to raise the bar in operational excellence. At this
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stage, creating a visual workplace becomes even
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more critical, since a continuously improving work
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environment is also a constantly changing one.
Experienced lean practitioners know that keeping
employees informed of evolving best practices
Time
and preventing the natural tendency to revert
back to old habits is a major hurdle. The use of
visuals helps to ensure that the new standards remain clearly visible, readily understood, and consistently
adhered to by all employees long after the lean blitz or rapid improvement event is over.
Improvement