5S is part of the Toyota Production System. 5S is meant to reduce waste and increase productivity by organizing spaces, keeping a clean work environment, and using visual cues to improve results. In this article, we will cover the five pillars of 5S and their benefits.
1. Sort (Seiri)
The first step of 5S aims to eliminate unnecessary items from the workplace that take up space. Sorting rids the workplace of broken tools and excess materials and is usually done visually by tagging unneeded items and removing them to reclaim floor space.
2. Set in Order (Seiton)
With the sorting out of the way, it’s time to focus on creating effective storage methods. Creating efficient storage methods allows employees to pick out needed items more easily - whether that’s a tool for maintenance or in an office space, to find needed information in a timely manner.
3. Shine (Seiso)
Once strategies for organization and storage are established, the next step is to make sure to clean the work environment. A clean work environment has the benefit of allowing employees to better identify issues with equipment or identify the most recent copy of a document in digital format.
4. Standardize (Seiketsu)
After completing the first three pillars, it’s important to create consistency in the workplace by implementing best practices. Some tools that can help standardize the workplace are checklists, start-up procedures, and visual cues such as placards.
5. Sustain (Shitsuke)
The last, and often considered the most difficult, pillar of 5S is maintaining all of the pillars you have already established. It can be helpful to create newsletters, manuals, signs, and performance reviews to sustain the practices put in place.
5S is a method for increasing productivity in the workplace and reducing waste by implementing its five pillars. Here at Adonis, we offer Lean/Sigma Coaching that will equip you with a deeper understanding of how to implement 5S through the Lean & Six Sigma toolkit.
Continuous Improvement (CI) is difficult to maintain under normal circumstances, never mind when unexpected challenges arise. In this article, we will tackle some ways in which your business can continue to improve, even when times are tough.
Stay Engaged with Your Teams
Continue talking with your employees to understand what challenges they are facing - and help them navigate through solving those problems. Engage leadership to determine what roadblocks can be removed to help the team be successful.
Create Realistically Achievable Goals
As tempting as it is to reach for the stars, having realistic, sustainable goals in place prevents employees from getting discouraged and setting your company up for unrealistic expectations of growth.
Be Mindful of those Affected by the Crisis
Whether it be clients, customers, or your own employees, be sensitive to the challenges they might be facing personally or professionally by providing support and resources.
Develop a Crisis Management Plan
Last but not least, having a developed set of guidelines to fall back on in difficult circumstances can help your business continue to operate smoothly even in times of crisis. Some steps that can be considered when developing guidelines include:
Of course, the most important aspect of maintaining CI during crisis is adaptability. Being flexible as the situation changes, or even your business model, will help keep your business growing. Adonis Partners can help your company adapt through our various CI Services, which are founded on proven Lean and Six Sigma practices.
What is TPM?
TPM, or Total Productive Maintenance, is a maintenance program that combines equipment maintenance with the manufacturing process. TPM was originally created by Seiichi Nakajima in Japan and was first implemented in 1971 by Nippondenso, a Toyota parts manufacturer. It has since been adopted and adapted by various organizations.
Since production relies so heavily on machines and equipment to get jobs done, the losses that can occur from any of the machines or equipment malfunctioning leads to a loss in productivity and money. TPM aims to minimize losses, increase production, and create higher job satisfaction by adopting a unique system which involves production operators in the maintenance process.
There are 6 main losses that TPM focuses on reducing:
TPM aims to eliminate these losses by implementing the 8 pillars of TPM, which are:
Why should you care?
TPM can reduce manufacturing costs by 30% and can also increase Overall Plant Efficiency (OPE). Aside from manufacturing costs and efficiency, it also saves time lost by trying to get a broken or idling machine moving. Most importantly, it helps the business run more smoothly, while also boosting morale and increasing safety for employees. Reducing the frustration placed on workers creates a better work environment and increases productivity. The focus on efficiency, equipment maintenance, and the employee satisfaction is what makes TPM a viable maintenance program to use in the production process.