5S 方法論 1 Sort 5S 2 3 4 5 Set in Order Shine Standardize Sustain > page 1 學習目標  知道什麽是 5S 以及如何做  明白 5S 的益處 > < 5S > page 2 精益屋 Pull/Kanban Cellular/Flow Quality at Source POUS Standardized Work 5S System 5S Quick Changeover Batch Reduction Visual TPM Teams Plant Layout VSM page 3 Lean Six Sigma DMAIC 改善流程圖 Activities • Review Project Charter • Validate Problem Statement and Goals • Validate Voice of the Customer and Voice of the Business • Validate Financial Benefits • Validate High-Level Value Stream Map and Scope • Create Communication Plan • Select and Launch Team • Develop Project Schedule • Complete Define Gate Tools • Project Charter • Voice of the Customer and Kano Analysis • SIPOC Map • Project Valuation / ROIC Analysis Tools • RACI and Quad Charts • Stakeholder Analysis • Communication Plan • Effective Meeting Tools • Inquiry and Advocacy Skills • Time Lines, Milestones, and Gantt Charting • Pareto Analysis • Belbin Analysis Measure • Value Stream Map for Deeper Understanding and Focus • Identify Key Input, Process and Output Metrics • Develop Operational Definitions • Develop Data Collection Plan • Validate Measurement System • Collect Baseline Data • Determine Process Capability • Complete Measure Gate Analyze • Identify Potential Root Causes • Reduce List of Potential Root Causes • Confirm Root Cause to Output Relationship • Estimate Impact of Root Causes on Key Outputs • Prioritize Root Causes • Complete Analyze Gate Improve Control • Develop Potential Solutions • Evaluate, Select, and Optimize • Implement Mistake Proofing • Develop SOP’s, Training Plan • Develop ‘To-Be’ Value Stream • Implement Solution and Best Solutions Map(s) • Develop and Implement Pilot Solution • Confirm Attainment of Project Goals • Develop Full Scale Implementation Plan • Complete Improve Gate Ongoing Process Measurements • Identify Project Replication Opportunities • Complete Control Gate • Transition Project to Process Owner Identify and Implement Quick Improvements • Value Stream Mapping • Value of Speed (Process Cycle Efficiency / Little’s Law) • Operational Definitions • Data Collection Plan • Statistical Sampling • Measurement System Analysis (MSA) • Gage R&R • Kappa Studies • Control Charts • Histograms • Normality Test • Process Capability Analysis • Process Constraint ID and Takt Time Analysis • Cause and Effect Analysis • FMEA • Hypothesis Tests/Conf. Intervals • Simple and Multiple Regression • ANOVA • Components of Variation • Conquering Product and Process Complexity • Queuing Theory Kaizen, 5S, NVA Analysis, Generic Pull Systems, Four Step Rapid Setup Method • Replenishment Pull/Kanban • Stocking Strategy • Process Flow Improvement • Process Balancing • Analytical Batch Sizing • Total Productive Maintenance • Design of Experiments (DOE) • Solution Selection Matrix • Mistake-Proofing/ Zero Defects • Standard Operating Procedures (SOP’s) • Process Control Plans • Visual Process Control Tools • Statistical Process Controls (SPC) • Solution Replication • Project Transition Model • Team Feedback Session • Piloting and Simulation < 5S and Process Controls > Define > page 4 5S Steps Sort Set in Order Shine Standardize Sustain Step 1 SEIRI ( 分離與消除 – SORT) 明確的區分出不必要與必要的項目并消除不必要的。 Step 2 SEITON ( 安置與識別 – SET IN ORDER) 安置必要的項目以便於讓任何人都能快速的找到。 Step 3 SEISO ( 每日清掃工作– SHINE) 創建一個潔淨的工作場所。 Step 4 SEIKETSU ( 長期堅持前三步與安全 – STANDARDIZE) 標準化清掃活動以便於行動明確且易於執行。創建并維持一個安全的工作環境。 Step 5 SHITSUKI ( 實現習慣性的遵從– SUSTAIN) 維持高執行力，高品質及安全的工作環境。使用可視化的績效測量工具。 > < 5S > page 5 “ 從三月份 開始就一直 在那” 請來幫助 愛麗絲 必要的嗎 ? 書籍雜誌 網絡應用 放地上的文 件夾 ? Locatio ns marked Only Current Work on Desk Top > < 5S > page 6 5S 改善前與改善后 > < 5S > page 7 5S 的益處  實施 5S 能夠 :  創建一個整潔有序的工作場所  提高安全性  提升效率  提升品質  增強員工士氣 5S game  有助於工作方法的標準化 > < 5S > page 8 5S 減少浪費 實施目視化 管理 1. Overproduction 7. Inventory 改善品質及設備 可靠性 6. Defects 5. Motion 改善工作健康安全 條件 消除尋找 , 減少挑 選整理的時間 ... 2. Waiting 減少搬運， 優化空間 ... 3. Transportation 4. Over processing 提升制程的可 見性 < 5S > 顯現并識別 庫存 > page 9 Step 1: Sort 整理定義 Sort (Seiri)- 找出不需要的 . - 分類，然後挑選出來。 - “ 如果有疑問，就扔掉” --- 如果是你整理：你僅需留下基本要 件。 - 從工作現場移走所有不需要的項目。 ( 文檔，工具，設備，部 件)  不意味著你僅需移走你知道的不再使用的項目。  不意味著你只需按照一個整潔的模式去簡單的整理東西。 Separate the Necessary from the Unnecessary > < 5S > page 10 整理案例 < 5S > Step 1: Sort > page 11 Step 1: Sort 整理的益處  現場能減少擁堵，易於工作。  阻礙人員間溝通交流的壁壘消除。  減少尋找部件與工具的時間。  不必要的設備移除能遞減維護成本。  改進制程的流動性 > <