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Housekeeping An essential manufacturing basic Contributes to machine and plant safety Enhances the ability to produce the quality of products desired by our customers Reduces machine downtime Extends the life of the equipment Promotes positive team morale Organization improves performance < If these (3) Three things are not in place, turn the lights off and go home.
Fundamentals of Good Housekeeping Organization There is a place for everything and everything is in it’s place Cleanliness Everything and every place is clean all the time – it’s an ongoing process! Requires a behavioral change and an elevation of expectations
Organization Organization – the Plant The expectation must be a CLEAN & SAFE ENVIRONMENT The plant team must promote behaviors that support a CLEAN & SAFE ENVIRONMENT The plant team should implement the Reliable Methods available to achieve the expectations
Organization2 Organization – the Concept A place for everything and everything in it’s place A Process Reliability expectation and the foundation of a good system Provides a means of creating a CLEAN & SAFE ENVIRONMENT
Reliable Methods SORT – identify what items, tools and materials are needed within the work area SET – establish the “place” for everything SHINE – clean everything as “clean as possible” STANDARDIZE – document the cleaning processes and expectations for cleanliness SUSTAIN – regular audits, recognition and holding people accountable to the expectations
TAKE PICTURESBEFORE YOU BEGIN IMPROVEMENT EFFORTS
SORTIdentify what is needed at the machine Based on “current production” needs For our machines would that be a shift? Or Day? What Tools, Supplies and Materials are needed? Only tools needed to set up and run the machine Supplies & materials to get through the shift (day) Red Tag and Remove what is not needed YOU WILL HAVE CLUTTER IF YOU HAVE TOO MANY TOOLS, SUPPLIES OR MATERIALS!
SET Identify a “Place” for everything - Organization Where possible, place tools and materials near where they are used Label locations – so everyone knows where items should be placed and will know when they are not in place (“Shadow” Tools)Standardized Work Stations, Chart Boards, and Tool Shadow Boards can make this easier to manage
SHINEClean Everything This means as clean as physically possible Includes the inside and outside of the machine Includes the entire work area Take pictures when clean Machine inside and out Work area Work tables
STANDARDIZEDocument the cleaning processes and expectations for cleanlinessUse these RELIABLE METHODS: Establish Housekeeping Areas Create Housekeeping Checklists Pictures of the “Clean Machine” become the expectation/criteria Establish Housekeeping Audit Process Visitor Feedback on Housekeeping
SUSTAINRegular audits, recognition and holding people accountable to the expectations Must have total employee involvement Management must support the elevated expectations Provide recognition for exceeding expectations Provide consequences for failing to meet expectations Make organization and cleanliness a part of the daily routine
Reliable Method: PR Housekeeping Audit ProcessThe housekeeping audit process is intended to provide a means of: Evaluating the effectiveness of housekeeping practices Identifying areas requiring corrective action to meet expectations Aligning housekeeping expectations throughout the plant
Audit Checklist Create a checklist of cleanup issues to be audited in each area. Each checklist item should be evaluated using Excellent/Acceptable/Unacceptable Points Awarded - 3 points for Excellent; 2 points for Acceptable; 0 points for Unacceptable A minimum acceptable point total should be established for each area through the sum total of acceptable responses. The Housekeeping Champion should establish the frequency of housekeeping audits.
Conducting the Audit Led by the Supervisor/team leader assigned to the area Conducted by at least three individuals Each person uses the audit checklist for the area and grades the area independently Must provide descriptions of why any item receives a less than excellent rating Also comment on “Well Dones”
Scoring the Audit The audit team reviews and discusses the results of the audit The Audit Team establishes an audit team grade for each audit item. The audit team grade for each item will be the lowest grade (point value) identified for the item from the three auditor’s score sheets. Compare score to minimum acceptable
Communicating Results Audit results should be posted at the machine The comment section should be used as a list of corrective actions required Teams should be recognized by the Housekeeping Champion for “Well Dones” observed
Summary Housekeeping is an essential manufacturing basic – One leg of the 3 Legged Stool Plant Team Expectation must be a CLEAN & SAFE Environment Implementing Housekeeping Reliable Methods will lead to meeting the expectation:A SAFE & CLEAN WORK ENVIRONMENT