5S Project Proposal

INSTRUCTIONS

5S PROJECT DIRECTIONS

Overview:

This 5S project is about identifying and implementing a 5S program either at work or at home or other understandable process of your choice. Students should begin working on the 5S project

The process you choose will ideally be a work process where you can complete all 5 S's. This means you can create Standardization (5S #4) and a Sustain plan (5S #5).

Past successful projects include, but are not limited to:

Home

Kitchen	Garage	Children's playroom
Home office	Workshop	Barn / Farm equipment and storage
Arts and crafts room	Sewing room	Entire household!

Work

Machine set up / changeover process	Assembly processes	Warehouse
Retail return area	Quality control	Office (personal)
Office (multiple people)	Training room and process	Exercise equipment room in company provided exercise room

Your write-up should include

1. A title such as "Quality Control Laboratory and Mobile Test Equipment" or "Home Kitchen"
2. What will be included and not included, such as "Project will include the entire QC Lab, lab processes, including mobile equipment, and the interfaces with the required software. The project will not include anything we cannot control such as the software", or "Project will include my entire kitchen and how it is organized, including how we buy and store food, and anything else we can address that will help us make our kitchen more efficient."
3. The problem you are trying to solve. Use the Waste Template and 5S Template below to help you define your problem. This will be as best as you can define right now such as, "We frequently lose items in the QC lab, cannot find them, try to use them at the same time, have different methods and means to do our jobs. Our lab is a mess and we are frustrated and not able to complete our jobs because of it", or "Our kitchen is disorganized and we have too many of some things, and too little of others. We have equipment, pans, cutlery, and other items we never or seldom use. It seems whenever we try to cook a meal we repeat steps, forget things, cannot find things, etc.. It is a mess and we are all tired of it."
4. How you plan to finish the first 2 S's (Sort, Set-In-Order) and as much of the 3rd S (Shine) as possible by Module 5 when your 5S Project Progress Report is due.
5. The attached are the Six Sigma Global Institute templates you will use for this project.

This template can be used to apply the principles of Five S. The abbreviation "DNA" represents "Does Not Apply" and can be checked when a particular statement is not relevant for the process under review. Each statement can be ranked as Low, Medium or High. A ranking of Low implies that the statement is not representative of that process. A ranking of High implies that the statement is a strong indication of how it applies to a process. Rankings are weighted in the following way: Low is weighted as 1 Med is weighted as 3 High is weighted as 5 As a result of these weightings, a High rating is considered to have five times as much impact on achieving Five S goals as a LOW rating. This template can be used to conduct periodic audits of a process and thereby compare total scores achieved over several time periods.

Five S Audit and Scorecard RATING SORT DNA LOW MED HIGH 1 Items in the workplace are stored in the right order. 2 Unnecessary items are not within easy reach. 3 Information on computer screens are logically organized. 4 Data to support work processes can easily be retrieved. STRAIGHTEN 1 All steps are organized to promote process efficiency. 2 Frequently used data files can be accessed quickly. 3 Information systems support logical flow of work. 4 Physical process flow is logical from beginning to end. SHINE 1 Workplace is kept clear of unnecessary work. 2 Staff encourage others to maintain a clean workplace. 3 A person is assigned to oversee a clean and organized workplace. 4 Desktops, computers, equipment and machines kept clean. STANDARDIZE 1 Staff are encouraged to standardize what they do. 2 Staff help others to standardize procedures. 3 Standards are clear. 4 Continual effort to standardize procedures. SUSTAIN 1 Work processes are documented. 2 Staff have been trained. 3 Controls in place to assure compliance with standards. 4 Procedures regularly reviewed to keep them up-to-date. Count 0 0 0 Weighted Score 0

Seven Wastes TRANSPORTATION Degree of Urgency Low Medium High INVENTORY Degree of Urgency Low Medium High MOTION Degree of Urgency Low Medium High WAITING Degree of Urgency Low Medium High OVER-PROCESSING Degree of Urgency Low Medium High OVER-PRODUCTION Degree of Urgency Low Medium High DEFECTS Degree of Urgency Low Medium High The Seven Wastes represent areas in which wasteful practices are likely to occur. It is often useful to review each of these areas and identify which are relevant. Since resources are always limited when solving problems and redesigning process, it also helps to rank these areas (X) from least to most urgent. This source of waste explores the extent to which the movement of goods or people through processes is inefficient and could be made more efficient through better process layout or transitioning to more efficient modes of movement. Not only does inventory take space, but it represents idle cash tied up in products before they can be further processed and sold. In addition, high levels of inventory expose the company to losses from obsolescence. Where in the process can idle inventory be found and how can it be reduced or eliminated? Wasted motion caused delays, bottlenecks and higher processing costs. The challenge is to identify where in the process unnecessary motion of components, staff or customers occurs and to redesign process flow to eliminate these sources of waste. People waiting for their turn, parts waiting to be processed through a machine, and items waiting to be tested at a repair depot are all examples of waiting. The problem with waiting is that it increases processing time and unnecessarily affects the efficiency of the process. Over-processing occurs when unnecessary steps are taken for which the customer would otherwise be unwilling to pay. Health care systems have been criticized for ordering too many tests and consumer's often have to provide more data than is necessary when communicating with a company. Producing too much is often a temptation. It minimizes stockout costs since few if any customers would be disappointed when stock is unavailable. But the goal of any processing system must be to produce just the right amount of output, not too little and not too much. Defects in manufacturing or services processes increase the cost of production and if they are undetected and passed to the consumer can significantly affect the Cost of Poor Quality and as a result impact the brand.

Seven Wastes TRANSPORTATION Degree of Urgency Low Medium High INVENTORY Degree of Urgency Low Medium High MOTION Degree of Urgency Low Medium High WAITING Degree of Urgency Low Medium High OVER-PROCESSING Degree of Urgency Low Medium High OVER-PRODUCTION Degree of Urgency Low Meduim High DEFECTS Degree of Urgency Low Meduim High

YOUTUBE VIDEO : https://www.youtube.com/watch?v=dKrWiG-wCy4&list=PL6D8NPljNdS83LkfwWX_4qzUx8LMFAosq&index=1

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