Lean Manufacturing Tools – I : 5S and Waste
$ 150.00
(Price inclusive of 90 day access, Completion certificate & course handout)
IN PARTNERSHIP WITH
Description
INTRODUCTION
This course on Lean Manufacturing Tools – I : 5S and Waste is part of the Lean Manufacturing Tools Specialization series that is designed to give an introductory and intermediate level of familiarization on Lean manufacturing which is based on principles of the Toyota Production System.
5S is a 5 step process used to arrange work areas to optimize performance and safety.
The 5S’s are: Sort, Set in order, Shine , Standardize, Sustain.
Sort through and sort out – In this first step the team needs to eliminate all unnecessary items from the work area. Many things are used once in a while and NOT every day. They are kept but in storage outside the work area so they can be found when needed but they are not taking up valuable space in the work area.
Set things in place – To simplify things here we mean to determine fixed locations and quality of all necessary tools, support equipment, and inventory. Another way of saying this is a place for everything (necessary) and everything in its place.
Shine – Make sorting, cleaning and checking a part of your daily routine. This includes preventative cleaning and maintenance. By the way this is talking about the people working the process. Janitors and cleaning crews have no idea how the areas equipment or tools are working and thus if the “true operator” cleans and does simple maintenance they will see leaks and wear that other will never see.
Standardize the processes – Establish standard processes and clear rules to maintain work place order. Review your rules continually so you can revise them to eliminate waste as customer focus/needs change.
Sustain the Gains – Establish a vision for management to have everyone continually apply 5S’s to what they do. This means training everyone in how to apply the 5S’s. Keep a 5S’s awareness and discipline throughout the company.
Waste reduction is an effective way to increase profitability. From a customer’s point of view, value-added work is a process that adds value by producing goods or providing a service that a customer is willing to pay for.
Toyota Production System identifies the wastages that occur and group them into 7 major categories.
- Transportation
- Inventory
- Motion
- Waiting
- Over-production
- Over-processing
- Defects
LEARNING OBJECTIVES
The course is designed as a very powerful pedagogic package interspersed with videos so that all related principles are captured as very important learning.
An understanding of the principles is essential for all – both in management and technical workforce.
On completion of this course, the user will have a good knowledge of
- 5S – which is largely confused as a housekeeping methodology; the course will explain why it is very crucial to make problems visible
- wastes associated in manufacturing
- Toyota 7-wastes concept
This course is ALSO part of the is a Bundled Specialization course titled Lean Manufacturing Tools Specialization.
After this series, the participant can appreciate any course on TPS or lean manufacturing which are at intermediate or advanced levels.
ALL of our courses in this series is developed based on decades of front-line industry experience of the instructor.
WHO SHOULD TAKE THIS COURSE
Anyone who is involved with any process, be it manufacturing or transactional. Several TPS principles can be applied in any context. It is uniformly applicable across any function. This course is equally important to any operator or management staff, , especially a new employee
You might also want to consider to take the course on Six Sigma Specialization along with this course.
COURSE CONTENT
- INTRODUCTION
- 5s – WHAT & WHY
- What is 5s
- Why implement 5s
- 1s – SORT (Sei-ri)
- What is Sort (Sei-ri)
- Opportunities for 1s
- How to start 1s
- Red Tag
- Red Tag Implementation steps
- Common findings in 1s
- Benefits of 1s
- 2s – SET IN ORDER (Sei-ton)
- What is Set-in-order (Sei-ton)
- Objective of 2s
- Benefits of 2s
- Implementation of 2s
- Presence of Good 2s
- 2s – Case Study #1
- 2s – Case Study #2
- 2s – Case Study #3
- 2s – Case Study #4
- 2s – Case Study #5
- 2s – Case Study #6
- 2s – Case Study #7
- 2s – Case Study #8
- 3s – SHINE (Sei-so)
- What is Shine (Sei-so)
- Common findings during effective cleaning
- Transformation by effective cleaning
- Absence of Good 3s
- Methodology to implement 3s
- Measures to maintain 3s
- 4s – STANDARDIZE (Sei-ke-tsu)
- What is Standardize (Sei-ke-tsu)
- Objective and benefits of 4s
- What is to be standardized
- Methodology to practice 4s
- Visual boards – with standards
- 5s – SUSTAIN (Shi-tsu-ke)
- What is Sustain (Shi-tsu-ke)
- Effective 5s
- Summary – not only cleaning or checking
- THE 7 WASTES – BASICS
- What is “7-Wastes”
- Pricing Strategy
- Value
- Value adding activities
- 3 M’s in Lean Manufacturing
- THE 7 WASTES – DETAILS
- Waste – Summary
- Transport
- Inventory
- Inventory – hidden problems
- Movement (motion)
- Waiting
- Over-processing
- Over-production
- Defects
- REFERENCES & COURSE HANDOUTS
- FINAL QUIZ
