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5S and Car Keys

April 23, 2010

I’ll ask during a 5S session what people do with their car keys when they get home. Of course they will look at me funny at first and then somebody will speak up and say something like “I leave my in the basket by the door” or “I keep them in my purse”. More people will jump in and say things like “I have a key holder by my back door” or “I keep them on my dresser.” The point here is not where they actually keep them; the point is that they always put them in the same spot.

O.k., well, maybe not always because they will tell you that if they forget to put them there then they have a hard time finding them when they need them. The key (no pun intended) here is that we put them in the same place because it is habit. Why is it a habit? Because this simplifies our lives. Once we put our keys in the normal spot we can forget about them until we need them. We don’t have to use our brain to remember where the keys are at every moment. This also reduces our stress and search time when we want to retrieve our keys.

I realized that I have been putting my keys on the key holder I made all the way back in high school wood shop class for decades. Now that’s an ingrained habit!

This of course, doesn’t work if you have teenagers that drive, the keys could end up anywhere.

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5S is Green – Part I

April 13, 2010

It’s April and Earth Day is the 22nd, so I thought it would be appropriate to have a post on “Lean is Green”. I was asked recently to give a presentation on the “Green” aspect of 5S. I thought that it shouldn’t be hard to create materials for the talk. Thoughts were already racing through my head about the green facets of 5S; how it is good for the environment, etc. What I didn’t fully realize is the powerful impact it will truly have if we all 5S.

I started to think about each “S” and the impact it has on our environment, whether it is local to our work area, facility, town, state, country or planet. A common phrase used in the green movement is “Reduce, Reuse and Recycle”. Let’s explore the first three “S’s” and how this can have an impact on what we do. We will cover the 4th and 5th “S” in an upcoming post.

Sort

How are our Red Tagged items green? It easily identifies what we have too many of. It shows where there is a waste of resources and reduces unneeded consumption. These extra items are an additional cost to the company; money that could be spent elsewhere for more important things.

Just like using 5S Red Tags for items not needed in the work area, Joe Rizzo from the Jackson Lean Consortium asked us to come up with a tag for Environmental, Health and Safety (EHS) items. These EHS Tags are used to identify potential hazards. The tags include an area for “Reasons for Tagging” with check boxes for: defect, expired, not needed, not properly stowed, old/obsolete, unknown material, other. There is also an area for “Disposition” with check boxes for: notify EHS, send out for proper disposition, send to lab for identification, store in flammable cabinet, and others.

Our 5S Red Tag Holding Area is a great way for us to practice “Reuse and Recycle”; that’s one of the main purposes of our Red Tag Holding Area. If you need an item for your work area or department, stop by your 5S Red Tag Holding Area first before you go straight to purchasing. I have seen many holding areas that have perfectly good items that need a home. If you or your colleagues can’t use the items in the holding area, consider donating them to a local charity or homeless shelter. It was easy for us to find things to send to Haiti after the earthquake; every little bit helps.

Minimize – usage of nonrenewable resources, total byproducts, toxic byproducts, byproducts that cannot be reused, and the use of product materials and packaging (including shipping materials) that may be discarded. (1)

Maximizing: the value usage of nonrenewable resources when they must be used, the value usage of renewable resources, the value usage of materials, the reuse of scrap raw materials, the usage of byproducts, and the reuse of product materials and packaging after use.(1)

Set-in-Order

One of the green benefits of Set-in-Order is that we only have what we need, in the correct amount at the right location. This allows us to carry less unneeded inventory. It also allows us to visually know when to reorder an item. Make sure you have the proper storage area for your EHS items and make sure they are properly labeled. A quick example is a “Flammables” cabinet to store potentially hazardous items.

Shine

Everyone knows that Shine means to “Clean & Inspect” (not just clean). So during the inspection portion we can be looking for leaks.

During one Waste Walk (Gemba Walk) in a factory during the summer we noticed that an operator had an air nozzle blowing directly on his drink. When we asked what that was for, he looked at us like we were foolish and said “To keep my drink cool!” I might not have the exact figures, but I remember hearing something like a ¼” air leak will cost the company $10,000 per year. If you have excessive air leaks it will make the compressor run longer and thus, a greater usage of electricity which equals a higher utility bill. I’m sure we could have found a much cheaper way to keep the operator’s drink cool.

Look for fluid leaks like oil, water, hydraulic fluid, etc. Obviously, besides being a safety hazard this is adding undue costs to a company. Besides replacing the lost fluid you may have to consider the maintenance impact. What if the oil leak made the machine run hotter causing premature wear or even worse – a breakdown!

By replacing filters we can keep dust and debris from entering the machines – the machines run better and have a longer life. Or on the flipside, we can keep mist from entering a work area and causing an uninviting environment.

Don’t forget to consider using environmental friendly cleaners or solvents and better yet, prevent dirt build-up in the first place!

Conclusion

5S is truly a Lean and Green initiative. By implementing 5S we are creating the basic framework for a greener organization without using any extra effort. We help our people, environment, our town and our planet by using 5S!

Reference: 1) Lean to Green: Bridging the Gap by Chad Vincent

 What do you do for your Lean is Green efforts? Let me know.

 Stay tuned for Part II where we will cover Standardize and Sustain.

 Thanks – Tony

On the day that NUMMI closed its doors I ran across this interesting white paper written on March 3, 2010 by Professor Harley Shaiken of University of California, Berkeley as part of The Toyota NUMMI Blue Ribbon Commission. The whitepaper is called “Commitment is a Two-Way Street: Toyota, California and NUMMI”. The commission was appointed by California State Treasurer Bill Lockyer to examine Toyota’s proposed closure of NUMMI.

NUMMI Plant Closes

Whatever point-of-view you are reading the paper from, the theme that I appreciated was is commonly referred to as “respect for People” as part of the Toyota Production System.

“The plant’s most important asset is a highly skilled and experienced workforce. Their average age is 45 and they’ve worked at NUMMI an average of 13.5 years. Their talent, skill and problem-solving ability are at the heart of the famed Toyota Production System. Those assets cannot be reproduced overnight.”

Let’s all hope that these highly skilled workers get a chance to apply what they know to help other manufacturers in the years to come.

To read more go to >> http://www.irle.berkeley.edu/workingpapers/202-10.pdf

To read more go to >> http://www.irle.berkeley.edu/press/20100310_nummi.html

As promised, here are a few more examples of 5S for the office (see previous post from March 30, 2010). These ideas came from real 5S office events that I facilitated. They may seem simple, but each one definitely made an improvement for the area. The key here is continuous improvement. If you see something here that you can use or build-on, that’s great. Pay it forward and share some of your examples. That’s one thing I really like about being part of the Lean community is the willingness of people to share information and best practices. Let’s keep it up!

One Good Idea – “Stoplight” Files

Problem – People were using file folders with blue prints and other technical information that may be old, obsolete or in draft stage.  This caused massive problems if people used the wrong files for production or other activities
Solution –  They came up with a color-coding system for files:
     Red = old, obsolete, do not use for production
     Yellow = draft, not approved, changes being made
     Green = good to go

"Stoplight" files

Benefits –  There were no more mistakes related to which files to use and easier to find.

Their next step was to make them available electronically.

One Good Idea – Four-hour Filing

Problem – In an accounting department a person spent fours hours a week to file checks by supplier name “just-in-case” they needed to look at them again someday (maybe once or twice per quarter)
Solution – After verifying with their auditor, they now file by check number> If a check needs to be recalled, they look up the check number on the computer and then find it in the file.

Save time filing

Benefits – Saves almost four hours per week

One Good Idea – Printer Problems

Problem – For office equipment it was hard to determine a contact person when there is a problem, replenishment supplies are needed, etc.
Solution – Labeled equipment with important information

Useful printer information, right on the printer!

Benefits – Anyone would know who to contact if there were issues

One Good Idea – Job Jackets

Problem – Work “jackets” were disorganized and sometimes “lost”. It was hard to tell what to work on next.
Solution – Organized area using 5S and Visual controls

Reduce backlog and visually manage work with 5S!

Benefits – Eliminated backlog and reduced stress

Please let me know what you think. If you have a “One Good Idea” to share, send it along.

Thanks – Tony