Introduction to the concept of Visual Control using 6S techniques

1. 5-S / 6-S Guideline for the Lean Practitioner
Mohammed Raja, PhD, CPIM, CSCP
York College of Pennsylvania
April 14th, 2016
Before After

2. AGENDA
 What is 5-S / 6-S Visual Control
 Role of the Leader
 6-S Number’s Game
 Benefits of 6S
Mohammed Raja, PhD, CPIM, CSCP
York College of Pennsylvania

3. What is 5-S 6-S Visual Control
Henry Ford’s CANDO program: Cleaning up, Arranging, Neatness, Discipline, Ongoing Improvement
Step
#
Japanese
5-S
1 Seiri
2 Seiton
3 Seiso
4 Seiketsu
5 Shitsuke
Sort
Set in Order
Sweep/Shine
Standardize
Sustain
Description
Identify what’s needed and what’s not needed
Organize what is needed
Clean everything inside and out
Establish policies and procedures
Ingrain 5S culture through Training
Safety Create a safe working environment
A series of steps and procedures used to arrange work areas in the best
manner to enhance Safety, Performance, and Cleanliness.
6-S Word

4. 6S Supply List
 Pegboard
 Peg Anchors
 Paint
 Paint Pens
 Label Maker/Cartridges
 Digital Camera
 Scissors
 Floor Tape
 Clipboards
 Box Cutters
 Tape Measure (100 feet)
 Velcro Tape
 Glue Gun
 Stencils (A-Z and 1-10)
 Red Tags
 Cleaning Supplies
 Cleaning Gloves
 Large Dry Erase Board

5. Purpose of 6-S Visual Control
Drive cultural change within the organization through …….
 Behavioral modifications
 Structured process improvements
 Empowered Employees
Sustain
Sustain
Sustain
Sustain
Safety
Safety
Safety
Safety
Foundation for a Lean Transformation
 To solve problems in their work area
 Build knowledge and capability
 Minimize/eliminate wasteful activities

6. 8 Deadly Wasteful Activities
TIMWOOD(S)
Poor Layout
Widely Spaced Equipment Large Safety Stock
Inconsistent work methods
Poor workplace organization
Long setup times
Unplanned maintenance
Lack of communication
Customer requirement
not clearly defined
Unclear goals Weak process control
Poor Quality
Culture
Lack of Investment in
training

7. 6-S Number’s Game
 This sheet represents our current work place.
 Our job during a 20 second shift, is to strike out the numbers 1 to 49
in correct sequence (e.g. 1, 2, 3,……., 48, 49)
 Record your individual score, along with the best and worst score
from the group.
The original game was developed by RWD Technologies Ltd.

8. 10
13
23
27
30
47
51
58
62
79
40
1

9. 6-S Number Game
How do you feel about your score???
What appeared to get in the way of achieving a higher score?

10. Sort (Seiri)
Is everything here really needed?
Why Sort ??
Remove un-needed inventory which occupies space

11. Leaders Role in Implementing “Sorting”
Define what’s necessary and unnecessary?
Item Tagged by: ________________________
Name of Item: __________________________
Date: _________________________________
Location of Item: ________________________
Reason for Red tagging (Check One)
For Office Use Only:
Item No. ___________________________
Disposition:_________________________
__________________________________
Obsolete
Defective
Scrap
Trash
Unneeded
Used once/day
Used once/week
Used < once/month
Seldom Used
Use Unknown
Red Tagging Identify unnecessary items that need to be either thrown out, recycled, sold or relocated
 Allocate a central Red Tag area.
 Include disposal instructions.
 Appoint a review board for
questionable items.
 Leave items in the workplace
 Set their final location later in the 6S
process
 Allocate an area close to workplace
 Review on specific date
 Store occasionally used items in out
of way locations

12. 6-S Number’s Game
STEP 1: SORT
 Our initial analysis shows numbers 50 – 90 are not essential to our daily tasks.
Hence they are removed from the work area
 Same rule apply: Strike out numbers 1 to 49 in sequence during a 20 second shift.
 Record your individual score, along with the best and worst score from the group.

13. 10
13
23
27
30
47
40
1

14. 6-S Number’s Game
How do you feel about your score???
What appeared to get in the way of achieving a higher score?

15. Why Set in Order
Set in Order (Seiton)
Is there a place for everything and is everything in its place?
Before After

16. Leaders Role in Implementing “Set-in-Order”
Determine location for all items
Calculate quantities of each item
Shelving and racking system
Items have specific locations
Shadow boards
Label storage locations
Labelling and Signboards,
Floor Taping, Color Coding
Usage levels Location
Frequently
used
Place near point of use
Used
Sometimes
Place distant from point of use
Rarely Used Placed separately (marked and
labeled clearly for later use)

17. 6-S Number’s Game
STEP 2: Set in Order
 We have installed some racking on the job site using a 3 x 3 grid.
 We have organized the numbers such that number 1 is located in the bottom left
hand corner and the numbers are sequenced from bottom to top and left to right.
For example: #1 in the bottom left, #2 in the middle left, #3 in the top left
#4 in the bottom middle, #5 in the middle middle, …. And so on.
 Same rule apply: Strike out numbers 1 to 49 in sequence during a 20 second shift.
 For each specific step in the 6S process, record your individual score, along with
the best and worst score from the group.

18. 10
13
23
27
30
47
40
1

19. 6-S Number’s Game
How do you feel about your score???
What appeared to get in the way of achieving a higher score?

20. Sweep / Shine (Seiso)
Is your workplace clean from dirt, grease, and dust from the floor, machine, and material?
Why Sweep / Shine ??
Before After End of Shift

21. Leaders Role in Implementing “Sweep/Shine”
 Map of the area and divide into cleaning zones
 Checklist of cleaning activity per person per zone
 Cleaning Schedule Sheet (Planned v/s Actual)
 Establish min. requirements/standards for cleaning
 Provide cleaning supplies (e.g. brooms, dust pans,
garbage cans, rags, degreasers, and floor cleaners)
Cleaning Zones
Mopping work area
Plan for Cleaning - Who, What, How

22. 6-S Number’s Game
STEP 3: Sweep / Shine
 We have initiated a cleaning system to sweep the work area on a daily basis.
 We have organized the numbers such that number 1 is located in the bottom left
hand corner and the numbers are sequenced from bottom to top and left to right.
 Same rule apply: Strike out numbers 1 to 49 in sequence during a 20 second shift.
 Record your individual score, along with the best and worst score from the group.

23. 10
13
23
27
30
47
40
1

24. 6-S Number’s Game
How do you feel about your score???
What appeared to get in the way of achieving a higher score?

25. Standardize (Seiketsu)
Is there one right way to do the work?
Why Standardize
Danger Stop, Emergency Stop, electrical panels
Caution Potential Danger of serious injury
Warning Energized equipment, proceed with caution
Safety First Aid and Safety Equipment
Facility and Safety Signage (OSHA compliant)
X-Ray X-Ray, Alpha, Beta, Gamma, Photon Radiation
Floor and Aisle Marking (OSHA compliant)
Defect, Scrap, Red Tag Area
Aisleways, Traffic lanes
Material or product inspection
Raw material, WIP, Finished goods
Present special physical or health risk (use caution)
Keep clear for operational purpose (non safety related)
Keep clear safety reasons (emergency access,
firefighting equipments etc)
Storage System

26. Leaders Role in Implementing “Standards”
 Update documentation to reflect changes
– Defined audit requirements
– Description/picture of the defined standard for the work area
 Make sure all stake holders are aware of the new standard
Clearly labelled Nuts/Bolts
storage bins

27. 6-S Number’s Game
STEP 4: Standardize
 After in-depth Work Flow Analysis, we have installed a more detailed racking
system.
 This allows us to re-organize the numbers in a standard fashion which will ease
the completion of the task
 Same rule apply: Strike out numbers 1 to 49 in sequence during a 20 second shift.
 Record your individual timing, along with the best and worst timing from the group.

28. 10
13
23 27 30
47
40
1

29. 6-S Number’s Game
How do you feel about your score???
What appeared to get in the way of achieving a higher score?

30. Safety
Is safety a universal responsibility of all employees?
Why Safety??

31. Leaders Role in Implementing “Safety”
 Provide Basic Safety Awareness Training
 Identify Hazard locations
 Provide counter measures
 Install Machine guards
 Wear personal protective equipment
 Conduct periodic safety audits and evaluations
 Develop incident tracking and investigate process(es) to eliminate root cause
No Job is so
important or so
urgent that we
cannot take the
time to
Do it SAFELY

32. 6-S Number’s Game
STEP 5: Safety
 After a review of the resources used in the process, we have provided safer
writing instruments.
 Same rule apply: Strike out numbers 1 to 49 in sequence during a 20 second shift.
 Record your individual timing, along with the best and worst timing from the group.

33. 10
13
23 27 30
47
40
1

34. 6-S Number’s Game
How do you feel about your score???
What appeared to get in the way of achieving a higher score?

35. Sustain
Is there an habit of properly maintaining procedures?
Why Sustain ??

36. Leaders Role in Implementing “Sustainability”
SMARTS approach
Awareness:
Time:
Management
Support:
Recognition:
Satisfaction:
Structured Plan: 6S Audit plan monitored and modified where necessary
Full and continuing support in terms of leadership, resources and
recognition
Understand the 6S steps and the importance of sustaining them
Efforts of the 6S team must be recognized by management
Employees must be given time in their work schedules for 6S
related activities
Execution of 6S initiatives and benefits must be measured and
shared with the organization

37. 6-S Number’s Game
STEP 6: UnSustain
 We have recently discovered that two numbers necessary for the completion of the
project are missing.
 Identify the two missing numbers as quickly as possible.
 Record your individual timing, along with the best and worst timing from the group.

38. 10
13
23
27
30
47
40
1

39. 6-S Number’s Game
STEP 6: Sustain
 We have recently discovered that two numbers necessary for the completion of the
project are missing.
 Identify the two missing numbers as quickly as possible.
 This time let’s identify the two missing numbers in a workshop that has
implemented Sort – Set in Order – Shine – Standardize - Safety

40. 10
13
23 27 30
47
40
1

41. 6-S Number’s Game
STEP 6: Implement Sustain practice to another work area
 This sheet represents our newly improved work place.
 Our job during a 20 second shift, is to strike out the numbers 51 to 99 in correct
sequence (e.g. 51, 52, …., 98, 99)
 The team score will be represented by the lowest individual score achieved.
 Same rule apply: Strike out numbers 51 to 99 in sequence during a 20 second shift.
 Record your individual timing, along with the best and worst timing from the group.

42. 60
73 77 80
97
90
63

43. What’s the benefit of 6-S Visual Control
Benefits to the Employee
 Provides opportunity to deliver creative inputs
 Work place is made cleaner, safer and simpler
 Increases job satisfaction
 Improves communication
Benefits to the Organization
Reduces
 Waste
 Downtime
 Defects
 Changeover
time
 Delays
Improves
 Safety
 Visual Control
 Process Control
 Standardization
 Delivery
Performance

44. Quantifiable Improvements using 6-S Visual Control
 96% decrease in defects
 80% decrease in flow distance
 70% cut in material handling
 68% reduction in rack storage
 60% in floor space
 50% decrease in annual physical inventory
 45% decrease in number of forklifts
 15% increase in throughput
 12% decrease in engineering cycle times
Source: www.visualworkplace.com, QMIVisual-Lean Institute

45. QUESTIONS???
Thank You!