module5_6S.ppt

1、Lean and Environment Training Modules,Version 1.0 January 2006,Next Page,Lean and Environment Training Module 5,6S (5S+Safety),Previous Page,Next Page,3,Purpose of This Module,Learn why Environment, Health, and Safety (EHS) should be an integral part of 6S implementation Learn how to identify EHS is

2、sues during the Sort process the first pillar of 6S Learn how to incorporate EHS into 6S inspections and audits of the Shine and Sustain pillars,4,What is 6S?,6S is modeled after the 5S process improvement system designed to reduce waste and optimize productivity in the workplace by: Creating and ma

3、intaining organization and orderliness Using visual cues to achieve more consistent operational results Reducing defects and making accidents less likely 6S uses the five pillars of 5S and an added pillar for Safety,More on 6S,5,The Six Pillars of 6S,Sort (Get rid of it): Separate what is needed in

4、the work area from what is not; eliminate the latter Set in order (Organize): Organize what remains Shine (Clean and Solve): Clean and inspect Safety (Respect workplace and employees): Create a safe place to work Standardize (Make consistent): Standardize the cleaning, inspection, and safety practic

5、es Sustain (Keep it up): Make 6S a way of life,More on each Pillar,6,Relationship of the 6S Pillars,7,Why Should EHS be an Integral Part of 6S?,Expanding the scope of 6S to include EHS concerns can help your company to: Reduce the chance paint, solvent, or other chemicals expire before they can be u

6、sed Make defects less likely, so less energy and materials are wasted Avoid productivity losses from injuries and occupational health hazards by providing clean and accident-free work areas Meet or exceed your companys environmental performance and waste reduction goals,8,TO CONSIDER,Name at least t

7、hree ways your company could use 6S to improve its environmental performance and reduce wastes. What metrics could you use to track EHS improvements from 6S activities? What ideas do you have for improving your work area?,Previous Page,9,Tools for Incorporating EHS into 6S,Use yellow-tagging to iden

8、tify EHS issues during the Sort process Expand 6S inspections of the Shine pillar to include EHS issues Expand 6S audits performed as part of the Sustain pillar to include EHS issues Identify additional ways to implement EHS within 6S,10,Use Yellow Tagging to Identify EHSIssues during the Sort Proce

9、ss,The objective of the Sort pillar is to identify items that are not needed in the work area and get rid of them This is done through a process called red-tagging A yellow-tag strategy can be used at the same time red-tagging takes place to identify any EHS issues,11,What is Yellow-Tagging?,Yellow-

10、tagging is a simple strategy used to: Identify environmental wastes and items that may be harmful to human health or the environment in the work area Evaluate the need for these items Evaluate potential alternatives for these items Address them appropriately This is a supplement to red-tagging- key

11、differences include the scope of projects, criteria used, and options for disposal or reuse,12,The Four Steps of Yellow-Tagging,Identify yellow-tag targets and criteria Make and attach yellow tags Evaluate and take care of yellow-tagged items Document and share the results,13,Step 1: Identify Yellow

12、-Tag Targets,Two types of targets should be identified: The physical areas where tagging will take place The specific types of items that will be evaluated Potential items to consider yellow-tagging include: EHS hazards in the workplace Chemicals and other hazardous materials Environmental wastes,14

13、,and Criteria,After choosing targets, criteria for evaluating yellow-tagged items needs to be agreed upon. This could include: The risk of an item The availability of alternatives Opportunities for improved environmental performance,15,Step 2: Make and Attach Yellow Tags,Can be as simple as yellow s

14、ticky notes stating the reason for the yellow tag Can contain standard data that your company uses for tracking materials Key is to include data that will allow your company to evaluate performance improvements from 6S and support your companys overall materials tracking system,16,An Example of a Ye

15、llow Tag,17,Step 3: Evaluate and Address Yellow-Tagged Items,If you find an EHS issue during yellow-tagging, ask “why” five times to identify the root cause of it Then ask “how” to address the root cause If an item is both unnecessary (red-tagged) and hazardous (yellow-tagged), follow appropriate pr

16、ocedures for disposal of hazardous wastes If items are yellow tagged but not a red tagged (i.e.necessary but hazardous), find out if you can avoid using those materials or if there is a less toxic alternative,Ask “Why” 5 Times,18,Step 4: Document and Share the Results,Document necessary information

17、from the yellow-tagging process in a log book or other system Track the improvements and savings that have resulted from yellow-tagging Share your results with others to show what you have achieved and to generate ideas for future improvements,19,TO CONSIDER,Name three types of items and three locat

18、ions that you could target for yellow-tagging at your company. What criteria would you use for identifying EHS issues with yellow tags? Name three improvements or savings that would result from a yellow-tagging activity at your company.,Previous Page,20,Tools for Incorporating EHS into 6S,Use yellow

19、-tagging to identify EHS issues during the Sort process Expand 6S inspections of the Shine pillar to include EHS issues Expand 6S audits performed as part of the Sustain pillar to include EHS issues Identify additional ways to implement EHS within 6S,21,2. Expand 6S Inspections of the Shine Pillar t

20、o Include EHS Issues,Shine activities include daily cleaning and inspection by workers in their work area Involve EHS personnel in developing specific inspection checklist items for each work area Questions should integrate EHS management procedures and waste identification opportunities into daily

21、inspections Particularly useful for the 10 Common Manufacturing Processes with Environmental Opportunities,10 Common Processes,22,Tools for Incorporating EHS into 6S,Use yellow-tagging to identify EHS issues during the Sort process Expand 6S inspections of the Shine pillar to include EHS issues Expa

22、nd 6S audits performed as part of the Sustain pillar to include EHS issues Identify additional ways to implement EHS within 6S,23,3. Expand 6S Audits Performed as Part of the Sustain Pillar to Include EHS Issues,Sustain activities include weekly or other periodic audits to assess progress with 6S im

23、plementation Involve EHS personnel in creating plant-wide inspection and audit questions and checklists Questions should ensure that environmental wastes and risk are routinely identified, properly managed, and eliminated where possible Questions can also be used to train 6S inspectors and auditors,

24、 or to provide background for a broader rating category,Key Questions,24,Example 6S Audit Checklist with EHS Items,Click here for the full example checklist: /lean/toolkit/app-e.htm,25,Tools for Incorporating EHS into 6S,Use yellow-tagging to identify EHS issues during the Sort proc

25、ess Expand 6S inspections of the Shine pillar to include EHS issues Expand 6S audits performed as part of the Sustain pillar to include EHS issues Identify additional ways to implement EHS within 6S,26,4. Identify Additional Ways to Implement EHS within 6S,There are many small things you can do to i

26、ncorporate EHS in the 6S process. Here are just a few example: Use low-toxic paint in white or a light color - this can help save lighting and energy costs Use different colored containers for hazardous waste, recycling, and other non-hazardous wastes Mark aerosol cans with colored dots to indicate

27、where to dispose them Use environmentally friendly cleaning supplies,27,TO CONSIDER,How well do 6S inspections and audits assess EHS activities and performance in your company? What approach might be most appropriate for incorporating EHS considerations into 6S assessment tools in your company?,Prev

28、ious Page,Previous Page,Next Page,28,Reflections on Integrating EHS and 6S,The 6S pillars work together to increase productivity, reduce defects, make accidents less likely, save time, and reduce costs When expanded to include EHS issues, they can help reduce hazards and improve environmental perfor

29、mance By explicitly incorporating EHS issues into all six pillars during 6S inspections, you can eliminate more waste and risk at your company creating a safer and more efficient workplace,29,Reflections on Integrating EHS and 6S, Continued,What did you learn from this training module that was parti

30、cularly useful? Do you need any more information to understand how to incorporate EHS into 6S? Would any other tools be helpful?,30,EPA Lean and Environment Training Modules,For more information about EPAs Lean and Environment Training Modules, visit: /lean EPA is interested in learning f

31、rom organizations experiences with lean and environment, and welcomes your comments on this training module Please contact EPA by using the form found at /lean/auxfiles/contact.htm,Previous Page,31,More on 6S,Based upon the five pillars (5S) of the visual workplace in the Toyota Pro

32、duction System “Cleans up” and organizes the workplace basically in its existing configuration Typically the starting point for shop-floor transformation Provides a methodology for organizing, cleaning, developing, and sustaining a productive work environment Encourages workers to improve the physic

33、al setting of their work and teaches them to reduce waste, unplanned downtime, and in-process inventory,Back to Main Presentation,Next Page,32,6S References,Hirano, Hiroyuki. 5 Pillars of the Visual Workplace. Portland, OR: Productivity Press, 1995. Peterson, Jim, Roland Smith, Ph.D. The 5S Pocket G

34、uide. Portland, OR: Productivity Press,1998. Productivity Press Development Team. 5S for Operators: 5 Pillars of the Visual Workplace. Portland, OR: Productivity Press, 1996. Productivity Press Development Team. 5S for Safety Implementation Toolkit: Creating Safe Conditions Using the 5S System. Port

35、land, OR: Productivity Press, 2000. Productivity Press Development Team. 5S for Safety: New Eyes for the Shop Floor. Portland, OR: Productivity Press, 1999.,Back to Main Presentation,Previous Page,33,Pillar 1: Sort (Get rid of it),Focuses on eliminating unnecessary items from the workplace that are

36、not needed for current production operations Uses visual methods such as red-tagging to identify these unneeded items Involves evaluating the necessity of each item in a work area and dealing with it appropriately Can help reclaim valuable floor space and eliminate broken tools, scrap, and excess ra

37、w material,Next Page,Back to Main Presentation,34,Pillar 2: Set in Order (Organize),Focuses on creating efficient and effective storage methods Arranges items so that they are easy to use Labels items so that they are easy to find and put away Can only be implemented once the first pillar, Sort, has

38、 cleared the work area of unneeded items Strategies include: Affixing labels and placards to designate proper storage locations Outlining work areas and locations Installing modular shelving and cabinets,Next Page,Previous Page,Back to Main Presentation,35,Pillar 3: Shine (Clean and solve),Focuses o

39、n thoroughly cleaning the work area Daily follow-up cleaning is necessary to sustain improvements Enables workers to notice malfunctions in equipment such as leaks, vibrations, breakages, and misalignments that could lead to loss of production It is a good idea to establish Shine targets, assignment

40、s, methods, and tools before beginning the Shine pillar,Next Page,Previous Page,Back to Main Presentation,36,Pillar 4: Safety (Respect workplace and employee),Focuses on eliminating hazards and creating a safe environment to work Once the workplace has been organized and cleaned, potential dangers b

41、ecome easier to recognize A separate “safety sweep” should be performed to identify, label, and deal with hazards Safety measures can also be implemented in conjunction with strategies in the other five pillars,Next Page,Previous Page,Back to Main Presentation,37,Pillar 5: Standardize (Make consiste

42、nt),Used to maintain the first three pillars Focuses on creating a consistent approach with which tasks and procedures are performed The first step is to assign 6S job responsibilities and integrate 6S duties into regular work duties using tools such as: job cycle charts visual cues (e.g., signs, pl

43、acards, display scoreboards) checklists The next step is to prevent: accumulation of unneeded items procedures from breaking down equipment and materials from getting dirty,Next Page,Previous Page,Back to Main Presentation,38,Pillar 6: Sustain (Keep it up),Makes a habit of properly maintaining corre

44、ct procedures Often the most difficult pillar to implement and achieve Sustain focuses on defining a new status quo and standard of workplace organization Without the Sustain pillar, the achievements of the other pillars will not last long Tools for sustaining 6S include: signs and posters newslette

45、rs pocket manuals team and management check-ins performance reviews department tours,Previous Page,Back to Main Presentation,39,Ask “Why” Five Times1,Why are we using so much water?The parts need to be cleaned before painting. Why do the parts need to be cleaned?The parts fail quality checks if they

46、 arent cleaned before being painted. Why do the parts fail quality checks?The paint doesnt adhere when part surfaces are not prepared properly. Why do the surfaces of the part need to be prepared?The surfaces get contaminated with oils used in the previous process. Why are oils used in the previous

47、process?The oils are used to prevent corrosion during storage. 1Based on an example from Robert B. Pojasek, “Asking Why Five Times,” Environmental Quality Management (Autumn 2000): 83.,Back to Main Presentation,40,10 Common Manufacturing Processes with Environmental Opportunities,Back to Main Presen

48、tation,Metal casting Chemical and heat treatment of materials Metal fabrication and machining Cleaning and surface preparation Bonding and sealing,Welding Metal finishing and plating Painting and coating Waste management Chemical and hazardous materials management,41,Key 6S Inspection and Audit Ques

49、tions for Eliminating Environmental Waste and Risk,Sort (Get rid of it) Are potentially risky items and environmental wastes yellow-tagged? Are all red-tagged items being disposed of properly, including those that must be managed as hazardous or universal wastes?,Next Page,Back to Main Presentation,

50、42,Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk,Set in Order (Organize) Are material containers clean, stored off the floor, closed, properly stacked, and stored/staged in the proper areas? Are all containers with chemicals or wastes covered or sealed when not in use? Are all containers with materials, chemicals, and/or wastes properly labeled? Are initial accumulation points for hazardous