module5_6S.ppt

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1、Lean and Environment Training ModulesVersion 1.0 January 2006Next PageLean and Environment Training Module 56S(5S+Safety)Previous PageNext PageLean and Environment Toolkit|January 2006|Slide 3Purpose of This ModuleLearn why Environment,Health,and Safety(EHS)should be an integral part of 6S implement

2、ationLearn how to identify EHS issues during the Sort process the first pillar of 6SLearn how to incorporate EHS into 6S inspections and audits of the Shine and Sustain pillarsPrevious PageNext Page3Lean and Environment Toolkit|January 2006|Slide 4What is 6S?6S is modeled after the 5S process improv

3、ement system designed to reduce waste and optimize productivity in the workplace by:Creating and maintaining organization and orderlinessUsing visual cues to achieve more consistent operational resultsReducing defects and making accidents less likely6S uses the five pillars of 5S and an added pillar

4、 for SafetyMore on 6SPrevious PageNext Page4Lean and Environment Toolkit|January 2006|Slide 5The Six Pillars of 6S1.Sort(Get rid of it):Separate what is needed in the work area from what is not;eliminate the latter2.Set in order(Organize):Organize what remains3.Shine(Clean and Solve):Clean and inspe

5、ct4.Safety(Respect workplace and employees):Create a safe place to work5.Standardize(Make consistent):Standardize the cleaning,inspection,and safety practices6.Sustain(Keep it up):Make 6S a way of lifePrevious PageNext PageMore on each Pillar5Lean and Environment Toolkit|January 2006|Slide 6Relation

6、ship of the 6S PillarsPrevious PageNext Page6Lean and Environment Toolkit|January 2006|Slide 7Why Should EHS be an Integral Part of 6S?Expanding the scope of 6S to include EHS concerns can help your company to:Reduce the chance paint,solvent,or other chemicals expire before they can be usedMake defe

7、cts less likely,so less energy and materials are wastedAvoid productivity losses from injuries and occupational health hazards by providing clean and accident-free work areasMeet or exceed your companys environmental performance and waste reduction goalsPrevious PageNext Page7Lean and Environment To

8、olkit|January 2006|Slide 8TO CONSIDERName at least three ways your company could use 6S to improve its environmental performance and reduce wastes.What metrics could you use to track EHS improvements from 6S activities?What ideas do you have for improving your work area?Previous PagePrevious PageNex

9、t Page8Lean and Environment Toolkit|January 2006|Slide 9Tools for Incorporating EHS into 6S1.Use yellow-tagging to identify EHS issues during the Sort process2.Expand 6S inspections of the Shine pillar to include EHS issues3.Expand 6S audits performed as part of the Sustain pillar to include EHS iss

10、ues4.Identify additional ways to implement EHS within 6SPrevious PageNext Page9Lean and Environment Toolkit|January 2006|Slide 101.Use Yellow Tagging to Identify EHSIssues during the Sort ProcessThe objective of the Sort pillar is to identify items that are not needed in the work area and get rid of

11、 themThis is done through a process called red-taggingA yellow-tag strategy can be used at the same time red-tagging takes place to identify any EHS issuesPrevious PageNext Page10Lean and Environment Toolkit|January 2006|Slide 11What is Yellow-Tagging?Yellow-tagging is a simple strategy used to:Iden

12、tify environmental wastes and items that may be harmful to human health or the environment in the work areaEvaluate the need for these itemsEvaluate potential alternatives for these itemsAddress them appropriatelyThis is a supplement to red-tagging-key differences include the scope of projects,crite

13、ria used,and options for disposal or reusePrevious PageNext Page11Lean and Environment Toolkit|January 2006|Slide 12The Four Steps of Yellow-Tagging1.Identify yellow-tag targets and criteria2.Make and attach yellow tags3.Evaluate and take care of yellow-tagged items4.Document and share the resultsPr

14、evious PageNext Page12Lean and Environment Toolkit|January 2006|Slide 13Step 1:Identify Yellow-Tag Targets Two types of targets should be identified:The physical areas where tagging will take placeThe specific types of items that will be evaluated Potential items to consider yellow-tagging include:E

15、HS hazards in the workplaceChemicals and other hazardous materialsEnvironmental wastesPrevious PageNext Page13Lean and Environment Toolkit|January 2006|Slide 14and CriteriaPrevious PageNext PageAfter choosing targets,criteria for evaluating yellow-tagged items needs to be agreed upon.This could incl

16、ude:The risk of an itemThe availability of alternativesOpportunities for improved environmental performance14Lean and Environment Toolkit|January 2006|Slide 15Step 2:Make and Attach Yellow TagsPrevious PageNext PageCan be as simple as yellow sticky notes stating the reason for the yellow tag Can con

17、tain standard data that your company uses for tracking materialsKey is to include data that will allow your company to evaluate performance improvements from 6S and support your companys overall materials tracking system15Lean and Environment Toolkit|January 2006|Slide 16An Example of a Yellow TagPr

18、evious PageNext Page16Lean and Environment Toolkit|January 2006|Slide 17Step 3:Evaluate and Address Yellow-Tagged ItemsIf you find an EHS issue during yellow-tagging,ask“why”five times to identify the root cause of itThen ask“how”to address the root causeIf an item is both unnecessary(red-tagged)and

19、 hazardous(yellow-tagged),follow appropriate procedures for disposal of hazardous wastesIf items are yellow tagged but not a red tagged(i.e.necessary but hazardous),find out if you can avoid using those materials or if there is a less toxic alternativePrevious PageNext PageAsk“Why”5 Times17Lean and

20、Environment Toolkit|January 2006|Slide 18Step 4:Document and Share the ResultsDocument necessary information from the yellow-tagging process in a log book or other systemTrack the improvements and savings that have resulted from yellow-taggingShare your results with others to show what you have achi

21、eved and to generate ideas for future improvementsPrevious PageNext Page18Lean and Environment Toolkit|January 2006|Slide 19TO CONSIDERName three types of items and three locations that you could target for yellow-tagging at your company.What criteria would you use for identifying EHS issues with ye

22、llow tags?Name three improvements or savings that would result from a yellow-tagging activity at your company.Previous PagePrevious PageNext Page19Lean and Environment Toolkit|January 2006|Slide 20Tools for Incorporating EHS into 6S1.Use yellow-tagging to identify EHS issues during the Sort process2

23、.Expand 6S inspections of the Shine pillar to include EHS issues3.Expand 6S audits performed as part of the Sustain pillar to include EHS issues4.Identify additional ways to implement EHS within 6SPrevious PageNext Page20Lean and Environment Toolkit|January 2006|Slide 212.Expand 6S Inspections of th

24、e Shine Pillar to Include EHS Issues Previous PageNext PageShine activities include daily cleaning and inspection by workers in their work areaInvolve EHS personnel in developing specific inspection checklist items for each work areaQuestions should integrate EHS management procedures and waste iden

25、tification opportunities into daily inspectionsParticularly useful for the 10 Common Manufacturing Processes with Environmental Opportunities10 Common Processes21Lean and Environment Toolkit|January 2006|Slide 22Tools for Incorporating EHS into 6S1.Use yellow-tagging to identify EHS issues during th

26、e Sort process2.Expand 6S inspections of the Shine pillar to include EHS issues3.Expand 6S audits performed as part of the Sustain pillar to include EHS issues4.Identify additional ways to implement EHS within 6SPrevious PageNext Page22Lean and Environment Toolkit|January 2006|Slide 233.Expand 6S Au

27、dits Performed as Part of the Sustain Pillar to Include EHS IssuesSustain activities include weekly or other periodic audits to assess progress with 6S implementationInvolve EHS personnel in creating plant-wide inspection and audit questions and checklistsQuestions should ensure that environmental w

28、astes and risk are routinely identified,properly managed,and eliminated where possibleQuestions can also be used to train 6S inspectors and auditors,or to provide background for a broader rating categoryPrevious PageNext PageKey Questions23Lean and Environment Toolkit|January 2006|Slide 24Example 6S

29、 Audit Checklist with EHS ItemsClick here for the full example checklist:http:/www.epa.gov/lean/toolkit/app-e.htmPrevious PageNext Page24Lean and Environment Toolkit|January 2006|Slide 25Tools for Incorporating EHS into 6S1.Use yellow-tagging to identify EHS issues during the Sort process2.Expand 6S

30、 inspections of the Shine pillar to include EHS issues3.Expand 6S audits performed as part of the Sustain pillar to include EHS issues4.Identify additional ways to implement EHS within 6SPrevious PageNext Page25Lean and Environment Toolkit|January 2006|Slide 264.Identify Additional Ways to Implement

31、 EHS within 6SThere are many small things you can do to incorporate EHS in the 6S process.Here are just a few example:Use low-toxic paint in white or a light color-this can help save lighting and energy costsUse different colored containers for hazardous waste,recycling,and other non-hazardous waste

32、sMark aerosol cans with colored dots to indicate where to dispose themUse environmentally friendly cleaning suppliesPrevious PageNext Page26Lean and Environment Toolkit|January 2006|Slide 27TO CONSIDERHow well do 6S inspections and audits assess EHS activities and performance in your company?What ap

33、proach might be most appropriate for incorporating EHS considerations into 6S assessment tools in your company?Previous PagePrevious PageNext Page27Lean and Environment Toolkit|January 2006|Slide 28Reflections on Integrating EHS and 6SThe 6S pillars work together to increase productivity,reduce defe

34、cts,make accidents less likely,save time,and reduce costsWhen expanded to include EHS issues,they can help reduce hazards and improve environmental performanceBy explicitly incorporating EHS issues into all six pillars during 6S inspections,you can eliminate more waste and risk at your company creat

35、ing a safer and more efficient workplacePrevious PageNext Page28Lean and Environment Toolkit|January 2006|Slide 29Reflections on Integrating EHS and 6S,ContinuedWhat did you learn from this training module that was particularly useful?Do you need any more information to understand how to incorporate

36、 EHS into 6S?Would any other tools be helpful?Previous PageNext Page29Lean and Environment Toolkit|January 2006|Slide 30EPA Lean and Environment Training ModulesFor more information about EPAs Lean and Environment Training Modules,visit:www.epa.gov/lean EPA is interested in learning from organizatio

37、ns experiences with lean and environment,and welcomes your comments on this training modulePlease contact EPA by using the form found at http:/www.epa.gov/lean/auxfiles/contact.htmPrevious Page30Lean and Environment Toolkit|January 2006DETAILSMore on 6SBased upon the five pillars(5S)of the visual wo

38、rkplace in the Toyota Production System“Cleans up”and organizes the workplace basically in its existing configurationTypically the starting point for shop-floor transformationProvides a methodology for organizing,cleaning,developing,and sustaining a productive work environmentEncourages workers to i

39、mprove the physical setting of their work and teaches them to reduce waste,unplanned downtime,and in-process inventoryBack to Main PresentationNext Page31Lean and Environment Toolkit|January 2006DETAILS6S ReferencesHirano,Hiroyuki.5 Pillars of the Visual Workplace.Portland,OR:Productivity Press,1995

40、.Peterson,Jim,Roland Smith,Ph.D.The 5S Pocket Guide.Portland,OR:Productivity Press,1998.Productivity Press Development Team.5S for Operators:5 Pillars of the Visual Workplace.Portland,OR:Productivity Press,1996.Productivity Press Development Team.5S for Safety Implementation Toolkit:Creating Safe Co

41、nditions Using the 5S System.Portland,OR:Productivity Press,2000.Productivity Press Development Team.5S for Safety:New Eyes for the Shop Floor.Portland,OR:Productivity Press,1999.Back to Main PresentationPrevious Page32Lean and Environment Toolkit|January 2006DETAILSPillar 1:Sort(Get rid of it)Focus

42、es on eliminating unnecessary items from the workplace that are not needed for current production operations Uses visual methods such as red-tagging to identify these unneeded itemsInvolves evaluating the necessity of each item in a work area and dealing with it appropriatelyCan help reclaim valuabl

43、e floor space and eliminate broken tools,scrap,and excess raw materialNext PageBack to Main Presentation33Lean and Environment Toolkit|January 2006DETAILSPillar 2:Set in Order(Organize)Focuses on creating efficient and effective storage methodsArranges items so that they are easy to useLabels items

44、so that they are easy to find and put awayCan only be implemented once the first pillar,Sort,has cleared the work area of unneeded itemsStrategies include:Affixing labels and placards to designate proper storage locationsOutlining work areas and locationsInstalling modular shelving and cabinetsNext

45、PagePrevious PageBack to Main Presentation34Lean and Environment Toolkit|January 2006DETAILSPillar 3:Shine(Clean and solve)Focuses on thoroughly cleaning the work areaDaily follow-up cleaning is necessary to sustain improvementsEnables workers to notice malfunctions in equipment such as leaks,vibrat

46、ions,breakages,and misalignments that could lead to loss of productionIt is a good idea to establish Shine targets,assignments,methods,and tools before beginning the Shine pillarNext PagePrevious PageBack to Main Presentation35Lean and Environment Toolkit|January 2006DETAILSPillar 4:Safety(Respect w

47、orkplace and employee)Focuses on eliminating hazards and creating a safe environment to workOnce the workplace has been organized and cleaned,potential dangers become easier to recognizeA separate“safety sweep”should be performed to identify,label,and deal with hazardsSafety measures can also be imp

48、lemented in conjunction with strategies in the other five pillarsNext PagePrevious PageBack to Main Presentation36Lean and Environment Toolkit|January 2006DETAILSPillar 5:Standardize(Make consistent)Used to maintain the first three pillarsFocuses on creating a consistent approach with which tasks an

49、d procedures are performedThe first step is to assign 6S job responsibilities and integrate 6S duties into regular work duties using tools such as:job cycle chartsvisual cues(e.g.,signs,placards,display scoreboards)checklistsThe next step is to prevent:accumulation of unneeded itemsprocedures from b

50、reaking downequipment and materials from getting dirtyNext PagePrevious PageBack to Main Presentation37Lean and Environment Toolkit|January 2006DETAILSPillar 6:Sustain(Keep it up)Makes a habit of properly maintaining correct proceduresOften the most difficult pillar to implement and achieveSustain f