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 new GM came in and decertified the entire plant! Thus, the reason for the 5S Champion's call. His staff has been reduced so now he is an army of one. How, is he supposed to work with such a large place and get them back on track while conducting sufficient audits and training to keep them certified?
My suggestion was to tap other departments to build a flexible audit team whereby they'd tackle a certain number of audits and training per month depending on how many auditors can be made available.
I checked in with him recently and he was thrilled to report that simple idea of tapping other departments has worked well. They've recertified about 25% of the plant and are on track to have the 5S process firmly back in place by the end of the year.
Curious if you have any further suggestions for him.
Thanks in advance.
5S Best Practices