LEAN

5S

(a.k.a. Visual Workplace, Visual Factory) A workplace organization tool/process that maximizes the cleanliness, organization, and safety of all elements in a working environment.

5S so named for its 5 primary undertakings:

Sort: Remove all unneeded items from the workplace.

Set In Order: Make a place for everything and put everything in its’ place.

Shine: Thoroughly clean and inspect everything in the work area (preventative cleaning also applies).

Standardize: Maintain the improvements through discipline and structure.

Sustain: Continue to support 5S efforts through auditing, job descriptions that include maintenance of the system, management support and expectations, etc.

Note: 5S efforts almost always improve workplace safety, operator morale, quality, and throughput. It can also be very impressive to visiting customers and prospective clients.

Click HERE to see some photos that show great examples of 5S organization principles at their best.

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5 Why’s

(a.k.a. “5 Why’s & 1 How”) A pen and paper tool for discovering the root cause of a problem or issue.

Example:

(1st Why) Why is there oil on the floor?

(Answer after investigation) It is leaking from a hose.

(2nd Why) Why is oil leaking from this hose?

(Answer after investigation) The hose is rubbing on a fan belt.

(3rd Why) Why is it rubbing on the fan belt?

(Answer after investigation) The fan belt housing is very loose.

(4th Why) Why is the fan belt housing so loose?

(Answer after investigation) Some of the bolts that hold it in place are missing or broken off.

(1 How) How do we fix the problem?

(Answer) Replace the hose and fan belt, remove broken bolts on fan belt housing and replace with new ones, torque all bolts to proper specifications, check bolt torque with regular preventative maintenance.

Note: You probably noticed our example only includes 4 whys. The number of whys is much less important than finding and fixing the root cause of the problem you are having.

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6 Sigma

A scientific/data-driven approach for achieving 6 standard deviations between the mean and nearest specifications limit. Six Sigma methods can be applied to all aspects of manufacturing, transactional processes, and virtually any form of work or processing.

Comments: In application we have found a Lean Manufacturing approach to correcting serious problems and realizing significant gains followed by using 6 Sigma methods to “fine tune” and realize further gains to be a very effective strategy.

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