Lean: Set-in-Order
The lean 5S system contains 5-steps to achieving a more organized, controlled and efficient manufacturing plant. These steps are Sort, Set-in-Order, Shine, Standardize and Sustain and in this article, I discuss my favorite step in the 5S process, Set-in-Order.
Your kaizen team did a great job sorting out unneeded items and now they need to find a proper place for all of the items required for production. This is where “Set-in-Order” comes into play. The things that you need to store at the production line may include items such as equipment, workstations, raw materials, Work-in-Process materials, changeover parts, tools, inspection gages, and information.
A WORD OF CAUTION
You only want to store things in the production area if you absolutely need them for production purposes. Everything else should be stored elsewhere or removed from the plant. Think about an efficient restaurant operation. They don’t store a bunch of unneeded stuff in the kitchen because it would just be in the way and slow the staff down. It’s the same with a manufacturing process. You only want to store what you need, where you need it and in the quantities that you need. Extra stuff just gets in the way and slows people down.
Also, cabinets with doors that close are a bad idea. These cabinets are the first place people dump stuff, to hide it from view. Eventually, you will lose control and regress in your 5S progress. Instead, look for storage methods that allow for visual control, such as peg boards and shadow locations.
WHERE AND HOW DO YOU STORE PRODUCTION ITEMS?
To find the ideal locations to store things, consider these factors:
First, consider the pathways and work areas that are required for production. Make sure that people and forklifts have efficient means to get to where they need to go in support of production. You never want to place something in a location that will cause a safety risk or impede efficiency.
Second, you want to place items as close to the point-of-use (POU) as possible. Minimize the walking distance that people need to travel to get things. If a raw material is used at a certain point in the process, then the storage location for that material should be near-by. If a tool or gage is often used for a certain task, then store that item right where it is needed instead of in a central toolbox or workstation. Remember, with this set-in-order step, minimize walking distance.
Third, if certain items are only required at changeovers, or required while producing specific products, then consider using organized kits for the tools and parts. When these items are not needed, they are stored away from the point-of-use and when the process requires it, the kit can be located closer to the point-of-use.
Lastly, use shadow locations and label them. What do you use a shadow location for? It’s simple, EVERYTHING!!! You want to have a shadow location for materials, parts, tools, gage, manuals, computers and even trash cans on the floor. At first, just put things where you think they should go. Take some pictures and test it out for a week or so. Let the kaizen team adjust the locations as they see fit. Once finalized, tape-out and label the locations, or better yet, paint the locations.
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