All Blog Posts (121)

7 5S Management Musts to Sustainment - Part 2

As part of the ongoing segment on the 7 5S Managements Musts please find below the 2nd and third  MUST:

Management MUST go through 5S Training and be part of a 5S Team. 

While this may go without saying, it's worth repeating that it is critical that managers of areas implementing 5S get trained on 5S. By trained I don't just mean reading a book, watching a video, reading a blog or sitting in on a meeting. I'm talking about in the trenches, learn on the job in…

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Added by David Visco on July 19, 2016 at 3:38pm — No Comments

Manufacturing is BACK in the US

Reading an article in the recent @AMEconnect Target Magazine about Reshoring. The media would have you believe that we have a lost the bulk of our manufacturing jobs to China or Mexico. In fact, the article says the U.S. is still the second largest manufacturer in the world. Since the recession, manufacturing employment is up by 900,000 and overall output is up 20 percent.

Here's a fact that surprised me from the article as well. Walmart, who everyone believes has nothing but…

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Added by David Visco on July 14, 2016 at 11:35am — No Comments

7 5S Management Musts to Sustainment - Part 1

Sustaining is commonly regarded the most difficult part of 5S. In that regard, I've listed below what I call "Management Musts" for sustaining 5S. 

Management MUST:

1. Get out on the shop floor (go to gemba)

2. Go through 5S training 

3. Be part of a 5S team

4. Support 5S

5. Focus on the people and their 5S efforts

6. Hold people accountable

7. Not "do 5S to them"

Every few days, I'll post detail about one of…

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Added by David Visco on June 27, 2016 at 2:10pm — No Comments

5S = Failure?

Hi all!

I thought you might enjoy a guest post I wrote for Mark Graban's Leanblog.org site concerning the 5S program at a former employer of mine.

Read the Guest Post Here!

Added by Paul Critchley on June 2, 2016 at 2:56pm — 1 Comment

5S is Not a Housekeeping Program

Here is a great article on why 5S is soooooo much more than just a housekeeping program

http://www.industryweek.com/lean-six-sigma/5s-without-5y-just-housekeeping

Added by David Visco on June 2, 2016 at 12:00pm — No Comments

5S First?

5S First? Fantastic article I dug up from Bruce Hamilton (aka The Toast Guy). Check this out https://oldleandude.com/2012/01/12/5s-first/ @gbmp1 @ameconnect 

Added by David Visco on May 17, 2016 at 12:48pm — No Comments

When 5S Fails

I found this article interesting on the concept of how easily it is to kill a 5S program. Have you seen this in your own company? If so, share your experience. 

http://m.industryweek.com/lean-six-sigma/use-housekeeping-kill-5s?NL=I

Added by David Visco on May 10, 2016 at 12:22pm — No Comments

Congratulations to our 5S Best Practices Photo Contest Winner - Alina Kachur

Congratulations to Alina who won a $100 Visa Gift Card for sending in the following 5S improvement. Thanks to everyone that submitted photos. …

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Added by David Visco on May 4, 2016 at 9:42am — No Comments

8 Wastes?! Are there more? Perhaps less?

Here's a new poster  from The 5S Store depicting The 8 Wastes. Curious if you think there are more these 8? Or, for that matter, is 8 too many? …

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Added by David Visco on May 4, 2016 at 8:00am — No Comments

Conflict is the Root of All Waste

As the VP of the AME Northeast Region #@ameconnect I get to meet thought leaders locally and from around the county. This past Tuesday Scott Gauvin from Macresco provided our AME Members with a fantastic workshop "Conflict is the Root of All Waste". 

Gauvin stated that "for every $10,000 spent on labor, $3500 of it is waste due to unresolved conflict". Throughout the day he…

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Added by David Visco on April 22, 2016 at 12:00pm — No Comments

Room reorganization

The former Shipping and receiving office was in neglect and disarray. It is currently used by New Business Development. The room has been recently cleaned and reorganized.

Added by Brian Milligan on April 20, 2016 at 12:23pm — 9 Comments

Why 5S Fails - a quick and easy solution

5S start and stop happens more times than I'd like to admit. I've talked to hundreds of practitioners over the years and most know what the problem is - lack of management support. While this is an obvious answer it's by no means the only one. There are many causes for a 5S program to fail. A significant part of management support that often get's overlooked is the need to hold people accountable. It's the missing ingredient. 

If for example, a manager sees…

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Added by David Visco on April 18, 2016 at 4:39pm — No Comments

The Real Purpose of Visual Management

Great article from the folks at Duggan Associates.

http://www.qualitydigest.com/inside/operations-article/093015-real-purpose-visual-management-tools.html#

Added by David Visco on March 15, 2016 at 8:41pm — No Comments

Significant 5S improvement example but ...

This customer recently went through the first three phases of a 5S initiative:

Sort

Set In Order

Shine

They did a fantastic job! The owners of the company were involved and really got behind the initiative  - A key ingredient for 5S success which is unfortunately missing from many 5S programs.

Recently, I was going back through some of the before and after images they sent me and noticed something amiss. Can you see what it is? Take a…

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Added by David Visco on February 16, 2016 at 5:47pm — No Comments

5S in the Office - a disaster waiting to happen

A customer reached out to me the other day to ask if there was a 5S rule on employees having pictures of family members on their desks and work area. Her guess was that it's not allowed. 

Talk about the potential for giving 5S a bad name. Wow! "it's not allowed?!" This goes to a much deeper issue regarding the benefit of 5S in…

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Added by David Visco on September 11, 2015 at 3:38pm — No Comments

Secret ingredient for 5S Success

It's been a strong belief of mine for quite some time that one of the secret ingredients needed for 5S Success is Accountability. Managers all the way up the chain have to hold their direct reports accountable for abiding by the 5S standards. For example, if a Warehouse Supervisor sees a subordinate place a pallet jack two feet away from the taped out, pre-determined and labeled location that Supervisor MUST pull that subordinate aside and speak to him/her. The second that the Supervisor…

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Added by David Visco on August 21, 2015 at 12:38pm — No Comments

Quick 5S question that will prove valuable to you

I'm curious to learn what everyone's most significant 5S challenge is. With regards to your 5S program please fill in the blanks in the sentence below. I'll respond with potential solutions and share the results. 

Here's the sentence:

"If I could just (fill in the blank) but I can't because (fill in the blank)"

For example:

If I could just get my 5S audits done but I can't because I simply don't have the…

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Added by David Visco on May 29, 2015 at 10:30am — 3 Comments

10 tips to liven up standardized work

Our employees are responsible for the team’s success and management is responsible for its failures; to perform is always to be the best, optimize and do a better job tomorrow. In operations, we use standardized work, among other things, to always go further.

1.       Be accountable for your team’s performance

Originally, the manager generates an economic performance. This isn’t new (enunciated by Pete Drucker in 1954 in his book, Practice of…

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Added by Flexpipe on April 28, 2015 at 9:00am — No Comments

5S Complacency

What do you do to keep folks from becoming complacent with 5S? I've toured companies that have maintained 5S at a high level while also seeing those that got bored with it. What does your company do to keep people enthusiastic about…

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Added by David Visco on March 12, 2015 at 10:30am — No Comments

Rotten Oranges

I read this interesting analogy the other day in the book Clinical 5S. Humans like to keep areas clean that they have personally invested time cleaning. On the same note a dirty area can spread to other areas. Consider what happens if you add a rotten orange into a basket of good oranges. In no time, the good oranges will turn rotten. Same concept applies to 5S and the workplace. Get rid of your rotten oranges and then maintain it to keep everything looking clean and orderly. If you allow…

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Added by David Visco on March 10, 2015 at 10:00am — No Comments

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