5-S

5S is a method for organizing a workplace, especially a shared workplace and keeping it organized.  It's sometimes referred to as a housekeeping methodology, however this characterization can be misleading, as workplace organization goes beyond housekeeping.

The key targets of 5S are workplace morale and efficiency.  The assertion of 5S is, by assigning everything a location, time is not wasted by looking for things.  Additionally, it is quickly obvious when something is missing from its designated location.  Advocates of 5S believe the benefits of this methodology come from deciding what should be kept, usually comes from a dialog about standardization which builds a clear understanding, between employees, of how work should be done.  It also instills ownership of the process in each employee. 

Six Sigma

Six Sigma is a structured improvement technique to deliver high quality products and services while removing inefficiency.  It has delivered significant benefits to some of the world's most successful companies including GE and Motorola.

Six Sigma has two key methods: DMAIC and DMADV.  DMAIC is used to improve an existing business process; DMADV is used to create new product or process designs.

DMAIC

DMADV

Pull/Kanban System

A visually driven method for controlling the flow of resources in a production process by replacing only what has been consumed. Production schedules are customer order-driven based on actual demand rather than forecasting. A method of controlling the flow of resources by indirectly linking dissimilar functions, through the use of visual controls (kanbans), replacing only what has been consumed at the demand rate of the customer.

Kaizen

“To Make Better”. Small incremental changes that add up to big improvements, usually low-cost / no-cost solutions that can be implemented every day. It becomes a philosophical shift in doing work, constantly looking for a better way.

TPM (Total Productive Maintenance)

A method to proactively maintain machines and equipment at their peak productivity and reduce equipment downtime to zero. A systematic approach to the elimination of equipment-related waste.

POUS (Point of Use Storage)

Raw materials, parts, tooling and gauging, stored at the workstation where they are used using a visual, small-batch replenishment systems.

Quick Changeover, Setup Reduction

The time between the last good piece off the current run, and the first good piece off the next run.

Standardized Work

Repeatable and reliable operations, safely carried out, with all tasks organized in the best known sequence, using the most effective combination of people, material, machines, and methods.

Visual Controls

Simple visual signals that give the operator the information to make the right decision. They are efficient, self-regulating, and worker-managed.

Teams

Cross-trained and multi-skilled employees with a continuous improvement philosophy practicing process quality, not inspection, which promotes camaraderie and improved morale with the organization focused on a common goal.

Mistake Proofing

Low-cost, highly reliable innovations that will detect abnormal situations before they occur, or if they occur, will stop the machines or operators, preventing the production of defective product.

Quality at the Source

Operators inspect product before passing it to the next workstation.

Continuous Improvement (CIP)

Plan-do-check-act cycle. Define the problem, define the current situation, visualize the ideal situation, and define measurement targets.

Eight Wastes

• Defects: Strive to avoid re-work.
• Overproduction: Produce only the exact amount the customer wants, when they want it.
• Waiting: Eliminate delays, long set-ups, and planned downtime of machines, processes, or people.
• Non value-added processing: Do as little as required in each step to the product as possible, to add the most value to it.
• Transportation: Eliminate movement of materials and information that doesn’t add value to the products.
• Inventory: Make sure there is a steady flow to the customer.
• Motion: Eliminate unnecessary movement of people.
• Employee Underutilization: Utilize people as efficiently as possible.