Microsoft 6S Training

User Manual: 6S

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COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

6S Training Overview

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Why Implement 6S?
† Customers’

needs constantly change.
† Companies compete to meet these needs.
† To survive, we must stay competitive.
† This means improving products and services
and lowering costs.
† The 6S system is a good starting point for all
improvement programs.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Typical Resistances to 6S
1.

2.
3.

Implementing Sort and Set in Order will not boost
output.
Why concern ourselves with triviality?
My filing system is a mess – but I know my way
around it!

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Typical Resistances to 6S
4.

5.

6.

6S’s and related improvements are just for the
factory.
We’re too busy to spend time on Sort and Set in
Order.
We don’t need the 6S’s – We’re making money,
so just let us do our work!

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

What is 6S?
A process for creating and maintaining an
organized, clean, and high performance
work place, which serves as a foundation
for continuous improvement activities

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

What Is 5 S
5 Japanese Words
„ Seiri

- Sort (Housekeeping)

„ Seiton
„ Seiso

- Set in Order (Workplace Organization)

- Shine (Cleanup)

„ Seiketsu

- Standardize (Keep Cleanliness)

„ Shitsuke

- Sustain (Discipline)

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Elements of a 6S Program
1.

Safety – Throughout the entire process safety is number 1.

2.

Sort - Clearly distinguishing between what is necessary and what is
unnecessary and disposing of the unnecessary.

3.

Set in Order - Organizing the necessary items so that they can be used and
returned easily.

4.

Shine - Cleaning floors, equipment, and furniture in all areas of the
workplace.

5.

Standardize - Maintaining and improving the standards of the first three S’s.

6.

Sustain - Achieving the discipline or habit of properly maintaining the
correct 6S procedure.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

6S Wheel

SORT
(Organization)
Clearly distinguish
needed and
unneeded items
and eliminate
the latter

This is the
condition we
support when
we maintain the
first three pillars

SET IN ORDER
(Orderliness)
Keep needed
items in the
correct place to
allow for easy
and immediate
retrieval

SUSTAIN
(Discipline)

Make a habit of
maintaining
established
procedures

STANDARDIZE
(Standardized
Cleanup)

Keep the
workshop
swept and
clean

SHINE
(Cleanliness)

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Benefits of 6S
†

Individuals: a safer work environment, more pleasant
workplace, more satisfying jobs, and a process that makes
sense.

†

Company: higher quality, lower costs, greater customer
satisfaction.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Implementing 6S
†

†

Role of Management:
„ Educating, creating teams, scheduling time,
providing resources, encouragement, and
recognition.
Role of Associate:
„ Encouraging coworkers, participating, implementing,
contributing ideas, and promoting 6S efforts.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Sort
†

†
†

†

†
†

Discourage people from being
defensive.
Be fair - all areas get tagged.
Remove any unneeded items
from the area.
Allow for personal / decorative
items per established policies.
Leave only the bare essentials!
When in doubt, throw it out!

Before

After

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Defects
WAITING

Repair or
Rework

Any non-work time
waiting for tools,
supplies, parts, etc..

PROCESSING
Doing more work than
is necessary

Types
of
Waste

INVENTORY

MOTION
Any wasted motion
to pick up parts or
stack parts. Also
wasted walking

OVERPRODUCTION
Producing more
than is needed
before it is needed

Transportation
Maintaining excess
inventory of raw mat’ls, Wasted effort to transport
materials, parts, or
parts in process, or
finished goods into or
finished goods.
out of storage, or
between
processes.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Lean = Eliminating the Wastes
Typically 95% of Total Lead Time is
Non-Value Added!!!
RUN
TIME

Order Processing, Transport, Storage, Waiting, Rework,
Machine Setup, Inspection, Machine Breakdowns, etc…

Total Lead Time

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Method for Sorting
†

Use a red tag for the item to be removed.
„ Ask three questions about each item:
† Is

it needed?
† In what quantity?
† Where should it be located?

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

RED TAG
Category

1. Equipment
7. Quassi products
2. Jigs and tools
8. Finished products
3. Measuring instruments 9. Quassi material
4. Materials
10. Office products
5. Parts
11. Paper, pens, etc.
6. In-process inventory

Item name
Manufacturing
No.
Quantity

Units

Reason

1. Not needed
2. Defective
3. Not need soon
4. Scrap material
5. Use known

Disposal by:

Department/Division/Section

Disposal method:

1. Discard
2. Return
3. Move to red-tag storage site
4. Move to separate storage site
5 Other

Today's date:

Posting date:

Red-tag file number

Value

$
6. Other

Disposal date:

Disposal
complete
(initials)

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Red Tags

†

†
†

Record tag information in the Red Tag Log for
disposition tracking
Record the reason the item is tagged
Don’t red tag people!

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Red Tag Holding Areas
† An

area set aside to store red-tagged items
that need to be evaluated.

† Two

kinds:

„ Central

Red-Tag holding area
„ Local Red-Tag holding area

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Steps in Red-Tagging
Step 1:
† Step 2:
† Step 3:
† Step 4:
† Step 5:
† Step 6:
† Step 7:
†

Launch the red-tag project.
Identify the red-tag targets.
Set red-tag criteria.
Make red tags.
Attach the red tags.
Evaluate the red-tagged items.
Document the results of red-tagging.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Set in Order

†
†

†

A place for everything and everything in its place.
Arrange things so they are easy to find, use, and put
away.
Work place organization is apparent through use of
lines, labels, color-coding, shadow boards,
photographs, etc.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Elements of Set in Order
† Set

in Order and Standardization

† Visual

Controls

† Principles

of Deciding Locations

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Set in Order and Standardization
† Standardization

means doing things in a

consistent way.
† Set

in Order is the core of standardization.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Visual Controls
†

Devices or methods which show, at a glance,
how work should be done and/or where items
should be placed.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Principles of Deciding Locations
† Get

rid of waste by storing jigs, tools, and
dies.
† Get rid of unnecessary motion: “motion
improvement.”
† Get rid of whole operations: “radical
improvement.”

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Using the 6S Map to Decide Locations
†
†
†
†
†

Make a floor plan of the work space.
Draw arrows showing the work flow.
Evaluate this “spaghetti diagram.”
Experiment drawing new layouts.
Decide on a new layout and implement it.

NEW

OLD
6

OUT

3

Cleaning

Roller

Deburring
Grinder #2

4
Heat
Treatment

5
2

Grinder #2

2

Grinder #1

3

Heat
Treatment

4

1

Loader

5

IN
Grinder #1

Cleaning

1

6

Loader

Deburring

IN

OUT

Roller

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Strategies for Identifying Locations

Signboard Strategy
† Painting Strategy
† “After” 6S map
† Color-coding strategy
† Outlining Strategy
†

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Shine
Clean EVERYTHING!
† Inspect and repair while you clean.
† Scan the work place.
†

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Planning a Shine Campaign
† Step

1:
† Step 2:
† Step 3:
† Step 4:
† Step 5:

Decide Shine targets.
Decide Shine assignments.
Decide Shine methods.
Prepare Shine tools.
Implement Shine activities.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Shine Means Inspection
†

†

When you clean an area, you also do some inspection of
machinery, equipment, and working conditions.
Including inspection with shine procedures turns
“cleaning” into “cleaning/inspection.”

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Steps in Cleaning/Inspection
† Step

1: Decide cleaning/inspection targets.
† Step 2: Assign cleaning/inspection jobs.
† Step 3: Determine cleaning/inspection methods.
† Step 4: Implement cleaning/inspection.
† Step 5: Correct equipment problems.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

New Tools and Techniques
† 6S

Schedule
† Five-Minute Shine
† Cleaning/Inspection Checklist
† Checklist of Needed Maintenance Activities.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Standardize
† Maintain

Sort, Set in Order, and Shine.
† Standardize methods to ensure the
improvements become a way of life.
† Create or revise check sheets and operator
instructions.
† Scan the work place.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Tools and Techniques
† 6S

Job Cycle Charts
† Visual 6S
† The Five-Minute 6S
† 6S Checklist for Factories

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Taking It to the Next Level: Prevention
† Preventive

Sort Procedures

† Preventive

Set in Order Procedures

† Preventive

Shine Procedures

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Other New Tools and Techniques
†5

Whys and 1 How Approach (5W1H)
† Suspension
† Incorporation
† Use Elimination
† Preventative Shine

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Sustain
†
†
†
†

Renewal and improvement.
Build on earlier accomplishments.
Make a habit of using correct procedures.
Without discipline, improvements cannot be
sustained. For example:
„ Audits
„ Work place scans
„ Team reviews and reports
„ Recognition

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Creating Conditions for Sustain
† Awareness
† Time
† Structure
† Support
† Rewards

and Recognition
† Satisfaction and Excitement

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Tools and Techniques to Sustain
Slogans
† Posters
† Photo Exhibits and Storyboards
† Newsletters
† Pocket Manuals
† Department Tours
† 6S Months
†

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Points to Remember
† Establish

guidelines and develop the
discipline to maintain them.
† If you always do what you’ve always done,
you’ll always get what you’ve always got.
† If nothing is done, nothing will improve.
† Develop habits that won’t be forgotten.

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Sort
Is this
Heaven?

No, it’s
Midland Forge

6 S’s

6.

Set In Order

Safety
Shine

Sustain

Standardize

COLUMBUS McKINNON CORPORATION
MIDLAND FORGE DIVISION

Questions ???
Thank You
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