A 5S Champion for a large tire manufacturer you would certainly know reached out to me asking for some advice. They have a 1 million square foot manufacturing facility. They've broken the area down into over 150 zones. Each zone has to go through a robust 5S certification process which takes several months. Imagine the effort that went into certifying the entire plant?!. Unfortunately, their 5S process has slipped quite a bit over the past year. as manpower for the 5S support team was cut. A… Continue
Added by David Visco on March 13, 2017 at 1:33pm —
During a recent seminar I conducted for AME on "How to Sustain 5S" I was asked "how do you handle using colored visual controls and standards for color blind employees?" What an interesting question. One audience member suggested that was one of the reasons OSHA incorporated striping for hazards. While this makes sense, it doesn't really address the non-hazard color coding companies use for standardizing lanes, zones, WIP, etc.
Any thoughts on this? Has your company had to… Continue
Added by David Visco on March 6, 2017 at 12:59pm —
I'm hosting a "How to Sustain Your 5S Improvements" workshop for AME (The Association for Manufacturing Excellence) http://www.ame.org/event/ame-dine-learn-how-finally-sustain-your-5s-improvements on Tuesday February 21st at 6:00 p.m. in Tewksbury, Ma. Check out more information on AME's … Continue
Added by David Visco on January 30, 2017 at 2:10pm —
One of the most challenging Set in Order steps for 5S practitioners is getting floor tape to last in heavily traveled areas. I've written a free report found here about this exact topic but for now here's a quick tip.
Assuming your using heavy duty tape with pressure sensitive adhesive make sure to tamp the tape into the surface.… Continue
Added by David Visco on January 25, 2017 at 9:42am —
Here’s a quick trick to stay focused on an area you’re looking to improve.
Let’s say you’re interested in improving the sustainability of your 5S process. One way to do this is to go the gemba (where the work is done) and find something done right. For example, maybe during your walk you find a tool placed properly on a shadow board or you see someone from your team replacing some… Continue
Added by David Visco on November 28, 2016 at 2:10pm —
The fifth 5S Management Must is to Focus on the People and their 5S Efforts.
As with any improvement process it's important to remember that there are real people involved. Beyond them just being co-workers many of them are fathers, mothers, or someone's son or daughter. They're human beings. The best practice to motivate people is to praise them on their efforts. Let them know you noticed. It's really that simple. When you see someone follow the 5S standards such as putting… Continue
Added by David Visco on October 19, 2016 at 9:53am —
I found this article from Robert Simonis at KCE Consulting and Industry Week well worth sharing.
“Is that bolt from a production part?” I asked. My colleague said, “No, some maintenance guy must have dropped it.”
The bolt looked common enough, lying there under the conveyor, and the impulse of the group doing the 5S walk was to throw it into the scrap metal hopper. If it had been a production part it would lead to…
Added by David Visco on October 18, 2016 at 2:38pm —
Here is a fantastic post about the true value of Lean by one of the leader's in the field, Scott Gauvin, CEO of Macresco.
Added by David Visco on September 21, 2016 at 11:53am —
The fourth management MUST to sustain 5S is for them to Support 5S. As a recap, the first three MUSTS are:
1. Get on the floor - go to gemba
2. Go through 5S training
3. Be a part of the 5S Team
Today, I'll talk about the fourth 5S Management Must which is to Support 5S. What do I mean by support? It's really quite simple. Managers must give their staff the time and materials to follow through with 5S activities. Let's look at these… Continue
Added by David Visco on August 22, 2016 at 4:03pm —
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… Continue
Added by David Visco on July 19, 2016 at 3:38pm —
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… Continue
Added by David Visco on July 14, 2016 at 11:35am —
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.
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… Continue
Added by David Visco on June 27, 2016 at 2:10pm —
Here is a great article on why 5S is soooooo much more than just a housekeeping program
Added by David Visco on June 2, 2016 at 12:00pm —
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 —
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.
Added by David Visco on May 10, 2016 at 12:22pm —
Congratulations to Alina who won a $100 Visa Gift Card for sending in the following 5S improvement. Thanks to everyone that submitted photos. …
Added by David Visco on May 4, 2016 at 9:42am —
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? … Continue
Added by David Visco on May 4, 2016 at 8:00am —
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… Continue
Added by David Visco on April 22, 2016 at 12:00pm —
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… Continue
Added by David Visco on April 18, 2016 at 4:39pm —
Added by David Visco on March 15, 2016 at 8:41pm —