MetroMatematicas Herding Cats - A Practical Exercise in 5S.pptx

For the good of humanity and the blue planet, first the evolution of the 3 Natural Intelligences(3iN – Rational, Emotional and Instinctive) of the predictor brain of children, adolescents and young students.

1. MetroMatematicas

2. Introduce the “5S” concept Understand “5S” and why it’s important Be prepared to engage in a local “5S” exercise s 2 Objectives

3. How do we get things done?

4. How about on your computer?

5. What is 5S? 5 Technique (and culture change!) to organize and sustain an environment in which everything has a place, is in its place, and is ready for use

6. The 5S set Sort Remove unnecessary items Set in Order Designate locations for each item 6 Sustain Ingrain 5S into the culture through training and ongoing discipline Shine Clean the work space Standardize Create visual controls and policies to ensure consistent, standard behavior for item usage and storage

7. Junk & Waste Separating the wanted and unwanted Repairable Wanted Items No Use Repair Discard To next step Sort

8. How often things are used. What is the life if the material. Cost of the material While sorting keep in mind : Sort

9. Consequences of not Sorting: The wanted is hard to find , when required. More space is demanded. Unwanted items cause misidentification. Misidentification causes errors in operation. Maintenance cost of the equipments increases. Sort

10. The right location where the things will be used. FIFO (First in First out) arrangement. Labeling of the area and the equipment is very important. Keep proper gaps between two things to avoid confusion. While doing Seiton keep in mind : Set In Order

11. Consequences of not Setting In Order: Things are seldom available when needed Items get lost Items get mixed up Visual control not possible Failure to achieve targets Set In Order

12. While doing Seiso keep in mind : Cleaning should be done regularly. Use the best cleaning agent . All the nooks and corners should be cleaned. Keep all the labels intact. All the labels should correct, visible and legible to all. Shine

13. Sweep your workplace thoroughly so that there is no dust/dirt/scrap anywhere. The area should say “ Who I’m” and its neatness should give you a natural welcome. Shine

14. Always aim at maintaining the standard level of cleanliness, hygiene and visual control. Keep all the 4 M’s ( Man., Machine, Material and Method) intact, a lapse in any one of them will make you loose the rest of the three. Standardize

15. While doing keep in mind : The standards should be arrived at unanimously. Always keep the standards flexible to changes and improvements. Standards should be known to all and displayed. Standardize

16. If you are disciplined. : Rules will always be followed. Laid down targets will be achieved. Improvements will be promoted . The number of defects will be reduced. The cost will not increase. Sustain

17. How to practice: Train all team members on 4-S Correct wrong practices on the spot Punctuality is the backbone of 5S Follow work instructions. Sustain

18. Herding Cats: A P r ac ti ca l E x e r c is e i n 5S “ We are too busy mopping the floor to turn off the faucet.”

19. Scenario : You are a cat rancher. During a recent windstorm, your f ence blew down, and your 49 prized “show” cats have been mixed in with another group of regular “farm” cats. You need to find each of your “show” cats and put them in their corral. Because cats have a distinct sense of social hierarchy, you must herd each cat in order of their social status . Fortunately , each cat wears a sweater with its number on it. 5S Exercise: Cat Herding

20. 9 5S Exercise: Instructions When instructed, take the activity sheet and cross off as many numbers as you can in the allotted time to represent each cat you have successfully herded. Cross off each number in correct sequence. Do not rotate the page. When time is called, count the amount of digits you have crossed off.

21. 5S Exercise - Round 1: The typical workplace… 10 Source: lean.org 10 13 27 30 51 58 62 23 47 79 40

22. 11 1. Sort Remove all items from the workplace that are not needed 1. Define What’s N ecessa r y Challenge what people think is needed! 2. Define What’s Un necessary Consider the “48 hour” rule for retention 3. Remove What’s U nne c e ss ary When in doubt, throw it out!

23. 5S Exercise - Round 2: Sort 12 Source: lean.org 13 27 30 23 47 40 10

24. 2. Set in order Find a place for everything, and put everything in its place Determine locations for all items Frequency = easiest to get Locate near activity Calculate quantities of each item Place items in storage locations Avoid table / counter tops Consider ergonomic impacts Label storage locations

25. 3. Shine Maintain a clean and safe working environment Clean o Sweep, mop, dust, clear garbage o Fix facilities Plan o Create Shine schedules o Assign Shine responsibilities Sustain o Inspect / enforce Shine accountabilities o Error-proof cleaning and maintenance

26. 5S Exercise - Round 3: Set in Order & Shine 15 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 1 19 20 21 22 23 24 25 26 28 29 30 32 33 34 35 36 37 38 39 41 42 43 44 45 46 47 48 49 4 31 27 18 9

27. 4. Standardize Create visual controls and policies to ensure consistent, standard behavior for item usage and storage Make Sort , Set in Order , and Shine part of daily work: Policies and training Visual controls Checklists Layouts Standardization should encourage: Simplicity Repeatability Lack of variation Accountability

28. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 28 5S Exercise - Round 4: Standardize & Sustain

29. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 43 44 45 46 47 48 49 50 51 52 53 54 54 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 40

30. 5S Exercise - Round 3: Set in Order & Shine 15 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 1 19 20 21 22 23 24 25 26 28 29 30 32 33 34 35 36 37 38 39 41 43 44 45 46 47 48 49 4 31 27 9

31. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 43 44 45 46 47 48 49 31 5S Exercise - Round 4: Standardize & Sustain

32. On your blank piece of paper in front of you draw a pig Standardized Work

33. Are all the pigs the same? Were the work directions clear? How was the training you were given to draw your pig? Do you think we could improve the training and directions to get our result to be closer to the same? Did anyone come around to watch and help you with your drawing Standardized Work

34. Standardized Work

35. Standardized Work

36. Does everyone’s pig look similar? Did the written standard work directions and or pictures help the result? Were the instructions helpful? Did having a template help? Any ideas to improve the process ? Standardized Work

37. PDCA

38. 5. Sustain 38 Ingrain 5S into the culture through training and ongoing discipline : Control Communicate Train Monitor Improve What would you have to do or stop doing to sustain these in your environment?

39. P r ac ti ca l E x e r c is e 2 i n 5S

40. Write Clearly

41. Organizing Your Work

42. Think About It First Problem: Triangle MNO is an isosceles triangle with MN = NO = x cm. A line segment, drawn from the midpoint of MO perpendicular to MN , intersects MN at point P with NP : PM = 4 : 1. What is the length of the altitude drawn from point N to MO?