IMPROVEMENT OF A SHIPYARD WITH INTRODUCING THE 5S METHOD

Prof. Dr. Ivica Vea, Prof. Dr. Boenko Bili University of Split, Croatia Prof. Dr. Franci u, University of Maribor, Slovenia September 28th, 2009, Ohrid

Agenda

1. 2. 3. 4.

Toyota Production System 5S Case study Conclusion

Agenda

1. 2. 3. 4.

Toyota Production System 5S Case study Conclusion

The Toyota Production System

TOYOTA

The five main principles of Toyoda

Development of Toyota Production System

Sakichi Toyodas Contribution - Jidoka

House of Lean

The seven wastes

Heijunka

Andon

Single Minute Exchange of Die (SMED)

Single Minute Exchange of Die (SMED)

Simultaneous work between worker and machines

Wall slogans
3 S Speed, simple, slim
- urediti

5S

- pravo mjesto - isto a - organizacija - disciplinirati

Quality Cost Delivery Safety

New models

Agenda

1. 2. 3. 4.

Toyota Production System 5S Case study Conclusion

What are the five S ? 1. SEIRI (Sorting out)

- Identification of best physical organisation of workplace.

2. SEITON (Systemic Arrangements)

- Implementation of optimum organisation identified in Seiri .

3. SEISO (Cleanliness)
- Cleaning-up the workplace completely.

4. SEIKETSU (Maintain a Serene Atmosphere)

- Audit, review & actions by which we maintain the first three Ss.

5. SHITSUKE (Stick to Self-discipline)

- Train people to follow good housekeeping autonomously.

Progress indicators of 5-S implementation

There is constant and continuous cleaning from wall to wall. The walk area is immaculate. Tools, materials and parts are laid-out squarely. The causes of dirt are removed. Employees are disciplined to keep the place clean. The machinery and equipment are kept clean. Storage areas are clearly designated and identified by numbers or codes. Storage area shows many parallel lines, and right angles. Cleaning-up of machinery and equipment completed. The walk-ways are clear and the factory is clean. But tools, parts and machine accessories are disorganized in the cabinets, shelves or storage area. Floor cleaning-up is completed, sorting out and throwing away unwanted things started. Still clutter is found by the walls, the pass ways are not clear.

Start: Cigarette butts, scraps of paper, cotton waste, hand tools, materials, and parts are scattered around factory / office floor

Benefits of 5S
n n n n

Reduce waste hidden in the plant Improve quality and safety Reduce lead time and cost Increase profit

1. Seiri sort
n

n n

Ensuring each item in a workplace is in its proper place or identified as unnecessary and removed. Sort items by frequency of use Get rid of unnecessary stuff
q q q q

Bare essentials for the job Red Tag system Can tasks be simplified? Do we label items, and dispose of waste frequently?

before

after

2. Seiton set in order

n n

Time spent looking for things, putting away Arrange materials and equipment so that they are easy to find and use
q q q q

Prepare and label storage areas Use paint, outlines, color-coded Consider ergonomics of reaching items Frequent, infrequent users

Before

After

3. Seiso shine

n n n

n n n n

Repair, clean & shine work area (Everyone is a janitor) Important for safety Maintenance problems such as oil leaks can identified before they cause problems. Schedule for cleaning, sweeping, wiping off Cleaning inspection checklists Workspace always ready to work See workspace through customers eyes

4. Seiketsu standardize

n n n

n n

Formalize procedures and practices to create consistency and ensure all steps are performed correctly. Prevention steps for clutter Otherwise improvements from first 3 lost Everyone knows what they are responsible for doing, when and how Visual 5S see status at a glance Safe apparel, no wasted resources

5. Shitsuke sustain

n n n n

Keep the processes going through training, communication, and organization structures Allocate time for maintaining Create awareness of improvements Management support for maintaining Training, rewards

Visual Management
n n

Indicators for tools, parts, and production activities Placed in plain sight of all workers so everyone can understand status of system at a glance If a machine goes down, or a part is defective or delayed, immediate action can be taken

Agenda

1. 2. 3. 4.

Toyota Production System 5S Case study Conclusion

Shows the state in which the workplaces were before and after sorting

Setting in order by the use of visual method

Before

After

The machinery processing unit before and after sorting and setting in order

Way to 6 S

Agenda

1. 2. 3. 4.

Toyota Production System 5S Case study Conclusion

The results of implementing the 5S method (1)

n

Increase of finances (extra income): accumulation of financial resources provided by selling the technically out of date, uneconomical, and no longer in use means of work The increase of usable workplace: surface of 250m2 freed by removing unnecessary means of work and materials. The reduction of firm expenses: the reduction of costs of safety at work and fire protection (the costs of evaluation and attestation) Apart from these economy results, during the realization of the pilot programme other positive moves were made. But it should be pointed out that during the realization of the above steps some obstacles appeared which slowed down considerably the implementation.

The results of implementing the 5S method (2)

Insufficient awareness of the importance of quality managing of the resources Passive participation of preparation, service and administrative services in the processes of change Absence of clearly defined processes and interrupted directory chains The absence of knowledge about modern management (project and innovating management) These obstacles are not insuperably, but they require long-term education about the importance of managing the resources of which the organization disposes. More important results can be expected in long-terms.

Conclusion

The implementing of the 5S method resulted in sum-total financial savings and the increase of free work spaces. But the results are related to short-term effects of the first three stages of the method while for the next two stages and long-term effects some there are some obstacles. Mainly they are obvious from cultural differences between Japanese and Croatian way of living, so greater education and animation of the employees is required while implementing the method.

Application of 5S in the best shipyards in the world

Application of 5S in the best shipyards in the world

Thank you for your attention!

Thank you for your attention!

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