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This is the final installment of five tips to help select the correct tool board.

#5 Labeling and Color-coding

This is how your tool board becomes a waste killing machine. This is probably my favorite part of making an effective and efficient tool board that associates will actually use and put tools back. As part of 5S workplace organization, the second “S” is “set-in-Order. The saying for this is “A place for everything and everything in its place!” This ensures that you have the right tool when you want it, where you want it. There is no time wasted looking for the right tool.

15-minutes_Time_Wasted_Searching_for_ToolsAccording to a recent poll, 57% of respondents stated that 15 minutes or more were lost looking for tools. Now, that’s pure waste.

Organize your tools, but take it one step further – label and color-code them. These are low cost solutions versus the waste of searching or replacing lost tools. As part of the fourth “S” in 5S, “standardize” your system. By using tool shadows and labels everyone will know where the proper tool is and more importantly where it goes. When the tool is returned to the board any one will know the correct spot to put it back. Another tip is to use Tool Tracer™ Tool Shadows with the exclusive Tool ID Band™ (patent pending). This way if you have multiple tool boards, you can color-code the board according to work area or process. So if a “blue” tool is in a “red” area it is easily seen and corrected.

Tool_Tracer_Shipping_StationDon’t forget to label your board. Make the labels a nice contrasting color like black & white, black & yellow, blue & white and so on. Also, make sure the labels and printing are large enough to see from a distance. The header for the tool board should be about 1-1//2” – 2-1/2” high. The labels for the actual tools should be a minimum of 12pt font, 18pt is better. Find what works for your area.

A well labeled board with the proper tool shadows will make your workplace more product, organized and reduce stress!

Don’t forget to check out 5S Supply for tool boards and Tool Tracer™ Tool Shadows.

BesTape_By-the-Case_II_Header

Our promotion last month “BesTape Buy the Case” was such a hit that we decided to extend and expand the promotion!

Get ready for the sequel – “BesTape Buy the Case – Part II: The Mix Up”

5S Supply has a limited time offer of $70 off the regular price when you purchase BesTape, “the best darn floor tape – ever” by the case. Buy 5 rolls and get one free! Now you can mix and match any combination colors you want: red, yellow, green, blue, and white.

If you want 3 rolls of yellow, 1 red, 1 blue and 1 white – no problem
If you want 5 rolls of yellow and 1 red – no problem
If you want 2 rolls of yellow, 1 red, 1 green, 1 blue and 1 white – no problem
You get the picture!

Plus a Special “Sequel” Bonus – if you buy 2 cases we will throw in a set of 5Ssymbols for free!

The 2” wide rolls come six to a case and are 100’ long; this gives you 600′ to visually mark your workplace including: warehouse areas, production areas, standard stock and work-in-process locations, safety concerns and many more.

BesTape is already priced lower all the other similar premium tapes. Here is your chance to really give it a try anywhere in your facility!

Check it out at>> BesTape by-the-case II

QuikBoards are perfect for Product and 5S Scheduling

QuikBoards are perfect for creating a customized solution for production scheduling or 5S activities. The Scheduling and 5S boards have optional pre-printed magnet sets. All the boards are magnetic and dry-erase for maximum usability.

“While working on countless production smoothing or 5S kaizens, I always had to develop a whiteboard from scratch to roll out the new production schedule or 5S assignments. It usually took several hours away from the improvement activity cutting tape strips and sticking labels on magnets. QuikBoards allow kaizen team members to focus their time working on process improvements and very quickly assemble a customized schedule/assignment board that matches their process requirements.” – Scott Morrison, Inventor, QuikBoards

Production Scheduling Boards – Versatile board can be used to evenly schedule 8-hour, 12-hour, 16-hour, and 24-hour time blocks over one, two, or three weeks. The 36″ x 48″ schedule board has room for posting 8-1/2″ x 11″ charts.

The Scheduling Boards come in three different sizes:

  • 24″ H x 18″ W
  • 36″ H x 24″ W
  • 48″ H x 36″ W

Schedule Board Magnet Sets – Magnets for posting 24-hour Standard and Military times, seven day weeks, changeover time blocks, and a variety of subjects (set-ups, raw materials, finished goods, etc.).

5S Activity Board – Board can be used to evenly schedule 5S assignments over shifts, days, and weeks. This is the way to help Sustain a 5S system!

5S Board: 24″ H x 18″ W

5S Board Magnet Sets – Magnets for posting shifts, days, weeks, and a variety of tasks (sort, set in order, shine, standardize, sustain, inspect, mop, etc.).

Stop by 5S Supply to see these and other great products for your Lean implementation.

 

Here’s a quick list of things related to 5S and Lean that you can easily do to celebrate Earth Day and make your workplace (and our planet) better.

  1. RTS-103_02_ThumbnailGo to your 5S Red Tag Holding Area and see if there is something there that can be recycled. Maybe there is something that you could re-purpose or use in your work area. This will save your organization money from having to buy a new item and you extended the life of an item you already have.
  2. Organize some consumable items in your work area. Determine the best location for them. Consider using Point-of-Use-Storage (or a Kanban System – like Kanban Indicator Bins); this will help reduce motionKBN-001_In_Rack_View and transportation waste. Determine how many you actually need and who replenishes  hem. This alone may help you reduce the unnecessary inventory you carry and reduce the waste of inventory or storage.
  3. Put a “Shine” on your workplace. Clean and inspect your work area – this not only will make your spot seem nicer and more pleasant to be in, it can also help improve the air quality, reduce allergens and germs.
  4. Create Standards for a task in your work area. Work with your team to determine the best way to get a task done and then standardize it. This will help you be more efficient and effective plus everyone will do it the same way so it makes it more consistent and easier to train new people.
  5. RTS-106_02_ThumbnailKeep 5S going by sustaining your efforts. Consider using our exclusive 5S Sustain Campaign Board. You can assign 5S related tasks to team members each week to keep 5S forefront in their minds while help to continuously improve your work space.

Remember to Reduce-Reuse-Recycle! 5S and Lean are a great way to help.

One major problem organizations face when trying to implement 5S is knowing how to do it correctly. Let me give you five tips on how to setup an effective 5S System.

System-Processes-Tools-Results-Culture

1. Realize that 5S is a system

5S should never just be thought of as just a Kaizen Event or program. Programs come and go and they have a connotation of having an end date. Nor should 5S be a series of disconnect 5S events to clean your workplace. Like any living system, you need to nurture and take care of it. You have to realize that for 5S to truly sustain you need to understand that it is a system made up of process that use tools to get results that change or improve your culture (see figure on right).

2. Set-up a 5S Design Team

Don’t expect 5S just to grow organically just because you think everyone should know what 5S is and how to apply it. I recommend that you implement a 5S Design Team to direct the efforts of your 5S System. Have them develop your 5S Vision, Goals, Objectives, 5S Implementation Plan, Communication Plan, Learning Plan and Reward & Recognition Plan.

For more information on 5S Design Teams and how to setup your 5S System send us a message at trainer@5Ssupply.com and ask about our “5S Total Support System.”

3. Take the time to make the time for 5S

Comments like “Do you want us to do our work or do 5S” shows that people don’t understand the importance of an effective 5S System. I read a study that mentioned people spend about 28 minutes a day searching for items. If we can reduce the search time by implementing 5S, we automatically have found time to perform 5S. If we can save 10-15 minutes a day by not searching for things, then we just created 10-15 minutes per day for 5S. The key is to use that time for 5S and not some other activity. As the 5S sensei Hiroyuki Hurano said “Behind all workplace successes or failures are the 5S.”

4. Spend more time on the 4th “S” Standardize

I hear it all the time, “Tony, we have 5S but can’t seem to sustain it.” Having done this for many years and trying to apply the good old PDCA cycle, I tell the person that they should re-look at their Standardize efforts. As part of Standardize, you need to make up the rules for the first three “S’s” (Sort, Set-in-Order, and Shine) but more importantly you need to follow and enforce the rules. This is the secret. If you can’t do this, then of course you can’t sustain. The power of setting standards is that you immediately see when something is abnormal or out-of-standard. Once this is recognized, you can fix it. If you don’t set standards, how will everyone know if something is wrong or what needs to be improved? Do yourself a favor and spend more effective time on the fourth S – Standardize.

5S Sustain Campaign Board

5. To Sustain you have to make Sustain an integral part of your 5S System

I remember talking with a Lean consultant friend of mine about 5S Red Tags (used in the first “S” Sort). He said he usually just had his team cut red construction paper to make red tags. I asked him that if the tags were just made for the Kaizen Event how anyone on the team would think that 5S is forever? I mentioned that we have pre-printed 5S Red Tags  that are easy to get (in several styles). These look much more professional and fitting of a world-class 5S System. I also told him about our 5S Red Tag Stations, Holding Area Kits and our exclusive 5S Sustain Campaign Board. When the tools you use make things looks more permanent then it is easier for people to understand that 5S is not just a one-time thing. This is a simple way to help Sustain your 5S System.

I hope these tips helped. For more, you can download a free copy of our benchmarking report “The Very Best of 5S”.

Let me know what you think. – Tony

The following post is from our comprehensive benchmarking survey and free eBook “The Very Best of 5S”.

Happy 5S Team

Happy 5S Team

The respondents were very generous with their suggestions on how to gain managements support. Here is an unabridged sampling of the ideas:

  1. Get them to do audits
  2. TRY to get them to come to lean presentation and/or opening closing sessions for Kaizen events
  3. They have been told to participate as part of their work goals
  4. Demonstrate the non-value time reduced by searching for items. The positive gains for staff and the patients [customers].
  5. Show results and find savings
  6. Steering Committee Meetings, strategic project directly tied to profit
  7. Presentation of the program, benefits and savings, customer appeal and smoother operation of company and reduction of concerns.
  8. It all needs to come down to money saved or made.
  9. Showing results of other areas.
  10. Encourage them to be actively engaged in the process & process audits; along with quick hit results via before and after conditions
  11. Adding it to their performance and tying it to their bonus.
  12. Conduct a 6S event so they can observe the results
  13. Find out what works and then have to share and promote those improvements
  14. Continuous improvement leads to better results and positive results always draw attention
  15. Quick Kaizen style power points demonstrating the power of simple fixes and how it impacts KPI’s and employee morale.
  16. I promote Go and See and before and after photos.  Once they see what we have accomplished they have a better understanding.  I have led some very successful kaizen teams in the year I have been here which is has built their trust in the program.
  17. 5S Report outs at Monthly Management Meeting updates.  Report outs to the Board of Directors. Sharing results.
  18. Pictured results are worth a thousand words…
  19. Via teaching
  20. Communicate our success with other internal locations.  Leadership can use this as bragging rights and motivation for other sites to step-up.
  21. Linking the 5S initiatives to the productivity of the area and showing financial benefits.
  22. Communication and tie in to vision—and tell a real story/experience
  23. Cost benefit/savings/bonus.
  24. Sell the positive gains.
  25. Keep suggesting ideas and find someone in the upper levels who can carry your messages forward.
  26. Data, we are a data driven company; audit results from our external auditor are reviewed by the entire plant.
  27. In our organization it actually took restructuring of lower level managers to increase the support for 5S.  However that shows the executive level cared and wanted a change to take place.  Now we have full support and mandates that help us when we deal directly with the shop floor.
  28. Take executive management on tour of the facility, have the staff tell them about what they have accomplished.
  29. Quantify improvements.  We measured cycle time to complete a process in the area before and after 6S.  This helped gain their approval for the efforts required to 6S the shop as well as their support in the program itself.
  30. The best way to obtain management’s support is to show them the benefit of a good 5S program and how it will affect the bottom line of the company – Money. Proper 5S will eliminate searching, choosing, walking, sitting, turning, laying down, and climbing. Also when customers come to visit they will be more impressed with a company utilizing proper 5S instead of items sitting all around.

To overcome or reduce initial resistance from management, we suggest working closely with the front-line supervisors. Determine what problems 5S would solve for them and help them get the results or solutions they are looking for related to 5S.

 

The Very Best of 5S Benchmarking ReportIn the upcoming posts I plan to give some concise information related to our newly published eBook “The Very Best of 5S” which is based off of our comprehensive 5S Benchmarking Survey conducted in 2011.

For a complimentary copy please click here>> “The Very Best of 5S” Benchmarking report

Let’s start off with the Executive Summary

This manuscript is an in-depth report on 5S Workplace Organization and Standardization. It sheds light on how organizations have successfully created a 5S system or the obstacles and solutions they used to overcome them. Of those surveyed, the overall rank of the effectiveness of their 5S system is a 3 on a scale of 1-5 (1=low, 5=high). This is a clear indication that there is much room for improvement. There are many suggestions and comments presented here to help coach and guide organizations as they improve their 5S systems. The level of cooperation for 5S initiatives is initially low but increases with time with the most resistance coming from the supervisor level. Contrary to this is that upper management is generally supportive of a 5S system, but the top reasons for obstacles for implementation are “lack of management support” and “not enough time.” Another finding is that the amount of training spent on 5S training is relatively low (typically two hours or less). It seems that organizations have a hard time quantifying benefits from 5S (other than 5S Audits). Companies that did calculate the financial benefits proved that the return on investment far exceeds the cost of training, supplies and manpower. The lack of reward & recognition and the ability to engrain 5S into the organization’s culture is another impediment that must be overcome. Over 50 “best practices” are shared and many suggestions on how to properly create a 5S system or improve your current one are included.

So check out the report, share it with your colleagues and friends, have discussions and give us feedback on what you see. – Tony