5S - tool lean manufacturing. 5S system for organizing and rationalizing the workplace. Rationalization Was developed in post-war Japan. The 5S tool is the five steps to bring order to the organization and effective organization jobs (whether industrial or office). - technology for creating an effective workplace

5s is five Japanese words Seiri () "sorting" a clear division of things into necessary and unnecessary and getting rid of the latter. Seiton () "keeping order" (neatness) organizing the storage of necessary things, which allows you to quickly and easily find and use them. Seiso () "cleanliness" (cleaning) keeping the workplace clean and tidy. Seiketsu () "standardization" (maintaining order) necessary condition for execution first three rules. standardization Shitsuke () "improvement" (forming a habit) cultivating the habit of accurately following the established rules, procedures and technological operations. - technology for creating an effective workplace

Promotes more effective implementation operations Improve workplace standards and organization Increase employee satisfaction with operations Increase safety environment Promotes continuous improvement and elimination of waste Goals of 5S implementation:

Get rid of unnecessary Place items where they are needed Make workplace as if it were new Maintain the workplace in a “new” state, make this operation part of the work procedure Develop this practice throughout the organization. Make sure that this process is managed, checked, improved. - technology for creating an effective workplace

When in doubt, throw it away! Sorting Purpose: Keep only the items needed for the activity in the workplace Sorting is always the first step, the basic principle of a good workplace organization. Decide what is necessary and what is not. Move things that are not obviously necessary to the quarantine zone until you find out their purpose. Remove unnecessary items immediately. Garbage does not need to be analyzed! !

–Superfluous items require additional storage space and attention –Than more quantity unnecessary items, the more difficult it is to sort them according to the criterion of necessity - Long-term storage of products leads to their deterioration and obsolescence - Extra items interfere with current activities! Examples of wastage arising from unnecessary items in the work area

Its place for each item and each item in its place! Organizing Purpose: Arranging items in such a way that it is easy for any worker to find, use and return them to their place. The order in the working area excludes: Waste of time searching for information, materials, tools. Excess inventory by having all materials in place and properly labeled Possibility to mix up different parts/information by storing them in well-defined locations.

! – If items are used in a complex, then they should be stored together, and in the sequence of use. –It is necessary to carefully consider the correct and convenient arrangement of items –It is necessary to store items taking into account the frequency of their use: Frequently used items - in the working area (week, month) Rarely used items - away from the working area - 1 time per six months (in a warehouse, in storage) -Storage space should be sufficient to easily take items and put them back -Store items should be based on the principle of functionality or purpose: The principle of functionality - the joint storage of items with similar functions object. Principles of storage of objects

Informing about the location of objects To focus on the location various items three main methods are used: Paint marking: Highlighting the location of objects with a specific color. Mostly this method used to indicate places on the floor and in the aisles. Road signs method: Uses the principle of pointing to objects (what, where and how much). Outlining: A way to show where and what items are stored. To do this, at the place where the item is stored, its outline is drawn, which, when the item is returned, will indicate exactly where to put it.

Keeping in order The best cleaning is when you don't have to clean! Purpose: maintenance of the working area in complete cleanliness and serviceability Clean workspace– safe space Create a clean, comfortable work environment wherever you and students want to work. Solve the problem at the source of its occurrence Problems can be identified at the very beginning, as soon as they appeared and did not entail more significant consequences

Standardization Keeping things in order Creating order Sorting Solve problems not in minutes, but in hours, but solve forever! Standardization Goal: To achieve stability of the results of the first three steps. Make sure the standard is maintained and developed. Create a standard that describes the responsibilities and main activities associated with the organization of the workplace for all types of workers

There is no limit to perfection Improvement Goal: To achieve that the implementation of the procedures of the methodology has become a habit. To increase the effectiveness of the implementation of this step, you should: Visualize achieved result from the implementation of 5S. Show everyone that it works! Monitor adherence to 5S methodology rules by conducting periodic audits Train employees on 5S principles Motivate and encourage employees to continuously improve Calculate the savings from implementing 5S

Head of department Auditor Name of manager Name of auditor Date: EvaluationComments Step 1 - SEIRI 1. All unnecessary things removed or marked 2. All unnecessary things moved to a new location or disposed of 3. Locations for materials, stackers, etc. identified. 4. Missing list developed items. Step 2 - SEITON 1. All paths and aisles are accessible and clear 2. All means of production are clean and functional 3. Workplaces are kept clean 4. Workplaces for production waste and its recycling are available and functional Example of a 5S audit document

Step 3 - SEISO 1. Cleaning and maintenance schedules are in place and followed 2. Work areas for work stations are delineated and marked 3. Order is maintained through visualization Step 4 - SEIKETSU 1. All unnecessary items are removed regularly 2. Storage areas are set for minimum demand and used in the right purposes 3. All markings and symbols are up to date 4. Employees follow health and safety regulations and instructions Step 5 - SHITSUKE audit Overall score in points Set target Example of a 5S audit document

5C is the management philosophy with which effective production begins and without which it simply cannot exist.

5C is in second place after mapping in terms of popularity in TechnoNIKOL. We started the implementation of 5C in the Company about 10 years ago and continue to this day. This tool helps achieve customer satisfaction, cost leadership, security, high performance labor. Problems are not visible until the workplace is organized. Cleaning and tidying the workplace helps uncover problems, and finding problems is the first step to improvement. 5C are five words that begin with the letter "c":

Step 1 - "sorting" - a clear division of things into necessary and unnecessary and getting rid of the latter.

Step 2 - "keeping order" (neatness) - organizing the storage of necessary things, which makes it quick and easy to find and use them.

Step 4 - "standardization" (maintenance of order) - the implementation of the established procedures of the first three steps.

Step 5 - "improvement" or "self-discipline" (forming a habit) - improving, maintaining the results achieved previously.

Figure 1. Organization of the workspace according to the 5C principle

The main goals of 5S:

1. Ensuring cleanliness in the workplace.
2. Saving time, mainly for searching for what is needed in the work.
3. Ensuring safe work, reducing the number of accidents.
4. Increasing the level of product quality, reducing the number of defects.
5. Creating a comfortable psychological climate stimulating the desire to work.
6. Exclusion of all types of losses.
7. Increasing labor productivity (which in turn leads to an increase in the profits of the enterprise and, accordingly, an increase in the level of income of workers).

Step 1 "1C"

Sorting involves:

1. Separation of all items in the operating area into necessary and unnecessary.
2. Removal of unnecessary items from the operating area.

To remove unnecessary items from the operating area, first initial stage implementation, we used the so-called “red label campaign”, when a red label (flag) is glued or hung out on each item - a candidate for removal. All employees of the department where the sorting took place were involved in this process, as a result, they identified items that:

• must be immediately taken out, thrown away, disposed of;
• should be moved to a more suitable storage location;
• must be abandoned and their places must be created and designated.

For items with red flags, a “quarantine zone” was organized, which was sorted out once a month. Items that had lain in the quarantine zone for more than 30 days were either moved to a permanent storage location, usually in a storage area, or sold and sometimes disposed of.

The red label can be a regular red sticker with the date the item was moved to the quarantine zone, or it can be more complex in form: with information about the unit, the reasons for moving to the quarantine zone, those responsible, etc. An example of a red label in Figure 2.

Figure 2. "Quarantine zone" with items placed in it with red flags

Step 2 "2C"

It is not enough to put everything in its place once, this order must be observed always and by everyone. When going around workplaces at the initial stage of 5C implementation, there were many problems with the return of tools and inventory to their place. Gone certain time while we have chosen the optimal location for items in the operating area, which allowed any employee to easily use, quickly find and return documentation, tools, materials, and components to their place. When marking the place of storage of items, they tried to use the principles that allow, at the first glance at any of the places, to immediately determine what should be there, what is the number of items and the period of their storage. For these purposes, we used different methods visualizations:

1. Outlining objects - drawing the outline of an object on the surface where this object should be stored

Figure 3. Quality table, mineral insulation production, Ryazan

Figure 4. Outlining objects on the quality table, the production of mineral insulation, Ryazan

Figure 5. Stand with tools, locksmith shop, Yurga

Figure 6. Tool stand (vertical placement and storage of tools), production site, Khabarovsk

Figure 7. Table with tools (horizontal placement and storage of tools), production site, Khabarovsk

2. Color coding, in which different types of tools and fixtures correspond to different colors

Figure 8. Photo of centrifuge connectors with a mating part matching in color, mineral insulation production, Ryazan

Figure 9. Color marking of pipelines at the binder preparation site, Khabarovsk

3. Paint markings to highlight storage space on floors and/or aisles

Figure 10. Designation of storage places for saws in production shop, Ryazan

Figure 11. Locksmith shop, production of mineral insulation, Zainsk

Figure 12. Open storage area, production of mineral insulation, Ryazan

Figure 13. Warehouse of spare parts, production of mineral insulation, Yurga

Paint marking is also used to mark dividing lines between work areas or traffic lanes.

Figure 14. Workshop for the production of mineral insulation, Ryazan

Step 3 "3C"

There is such a saying “it’s clean not where they sweep, but where they don’t litter”. Of course, cleanliness involves cleaning workplaces, making equipment and workplace tidy enough to carry out control, but the main thing was to create such conditions under which the formation of dirt and dust was reduced to the minimum allowable amount. This process is still ongoing, and many proposals are being submitted on this topic to improve the equipment or the workplace.

It would seem that everyone understands the benefits of cleaning:

• a clean workplace that is pleasant to work in (which increases emotional condition employee and makes the workplace more attractive);
• constant readiness for work of everything that may be required to perform production tasks;
• ensuring the safety of work (for example, spilled engine oil and puddles on the floor can lead to injury);
• ensuring the operability of the equipment (there is no risk of dust and dirt getting into the working mechanisms);
• absence of marriage.

However, the transition from persuasion to action, especially in old factories with 50 years of history, was anything but easy. In all departments, we carry out cleanliness checks in accordance with predetermined cleanliness criteria (cleanliness in the office and in the production hall are not the same), which are indicated in the checklist. The checklist at a number of sites describes in detail the content and procedure for cleaning up, there are photographs of the places where they were carried out:

To facilitate periodic inspection, checklists have been affixed next to the relevant equipment to quickly check for correct filling and correct identified deficiencies.

There is another simple tool to control the workplace cleanliness standard - this is a photograph of the workplace in the form in which it should be. Below is an example.

Figure 15. Purity standard, mineral insulation production, Ryazan

Step 4 "4C"

Standardization - the creation of a unified approach to the implementation of tasks and procedures. The main purpose of this phase is to prevent a backtracking on the ongoing implementation of the first three phases. To standardize means to develop such checklist which everyone understands and is easy to use. Below is an example of a tabular part of a checklist for a manufacturing unit and an office.

Checklist for the production department

office checklist

Compliance with the requirements of 5C is part of the professional certification of workers and engineers and has long turned into a general cultural norm- from the director's office to production and auxiliary premises.

Figure 16. Workplace standard in the industrial area of ​​Ryazan

Figure 17. 5C board in a warehouse finished products, production of mineral insulation, Khabarovsk

Figure 18. Workplace standard for chief power engineer, mineral insulation production, Khabarovsk

Figure 19. Workplace safety standard, mineral insulation production, Chelyabinsk

Step 5 "5S"

The fifth stage is improvement or self-discipline, maintaining the results achieved earlier. The stability of the 5C system does not depend on how well the procedures of the first four stages are implemented, but on whether the first four stages are supported by the fifth.

Unlike the first four Cs, improvement cannot be implemented as a technique, the results of improvement cannot be measured, but it is possible to create conditions that will encourage employees to continue working within the 5C system. TechnoNIKOL Company uses for this different instruments: 5C slogans, 5C posters, information boards "WAS" - "BECOMING", 5C mailing lists, visits to departments where 5C is being implemented, etc.

Figure 20. 5C posters, mineral insulation production, Cherkasy

Figure 21. Fragment of the information board 5C "WAS" - "BECOMING", Ryazan

Figure 22. Attachment of personal responsibility in the warehouse of finished products, Zainsk

Translation - Olga Goncharova, portal "Manufacturing control"

Original article: World Academy of Science, Engineering and Technology 59 2011

Lean manufacturing: 5S system

5S- it is one of the methods of lean production and a system for improving the production process, the main goals of which are to reduce losses, organize the workplace and increase labor productivity. The 5S system involves organizing the workplace and using visual cues to achieve better performance. As part of a culture of continuous improvement, 5S is usually the first lean method that organizations adopt to facilitate the adoption of other lean methods that optimize workflow and workflows.

The system includes 5 components: Sorting ( Seiri), Keeping the order ( Saiton), Keeping clean ( Seiso), Standardization ( Seiketsu) and Improvement ( Shitsuke). Together, they form a methodology for organizing, streamlining, developing and maintaining a productive work environment. Standard instructions, templates, best experience businesses you can find inpractical guide to implementing 5S .

5S system components:

1. Sorting: getting rid of unnecessary things and cleaning the workplace.
2. Order keeping: organizing the storage of necessary things, which makes it quick and easy to find and use them.
3. Keeping it clean: keeping the workplace clean and tidy.
4. Standardization: Documentation of technological operations, the use of standard tools and the introduction and promotion of best practices.
5. Perfection: maintaining the improvement process, controlling technological operations and introducing the 5S system into the corporate culture.

AT daily work companies, the 5S system allows you to maintain organization and transparency - essential conditions continuous and efficient production process. The successful implementation of this lean method also improves working conditions and encourages workers to become more productive and reduce waste, unplanned downtime and work in progress.

The result of the successful implementation of the 5S system is a significant reduction in the materials and space required for the implementation of production processes. The system involves storing tools and materials in dedicated, color-coded storage areas such as baskets and drawers. Such conditions provide the basis for the successful implementation of other lean manufacturing methods: Total Equipment Care, Flexible automated production, production just in time. Also, the 5S system prepares the ground and optimizes the organization of processes for the implementation 6 sigma methods.

The use of this system ensures the improvement of production indicators, namely:

• Transparent technological route
• Clean workplace
• Reduced setup time
• Cycle time reduction
• Increasing the working space
• Reducing the number of accidents
• Reduction of lost working time
• Improving equipment reliability

An example of using the 5S system

This project was carried out within the framework of research program teachers production faculty University of Jordan. The program provides funding for projects implemented by the faculty of the university on the basis of local enterprises. Project duration - 3 months summer trimester. In consultation with the representatives of the enterprise, faculty members find out what problems need to be solved and in what areas improvement is needed. A detailed “diagnostic study” is then submitted to the faculty administration, outlining the project idea, objectives, approach, intended outcomes, and the enterprise's commitment to the project. Approved projects are funded by faculty sponsors. The authors of the project cooperate with the enterprise to achieve the goals of the project. A detailed final report summarizing the results of the work done is submitted to the administration of the faculty and the heads of the enterprise.

The purpose of this project is the analysis of the production process and the organization of jobs at the Amman Prefabricated Structures Factory, which produces structures such as modular buildings, houses, offices and transformer boxes. Figure 1 is an example of a factory product.

The use of modular structures has many advantages that make them more attractive than traditional structures: they can be quickly assembled and disassembled, and reused in various projects; they are durable, earthquake resistant, light weight, etc.

Rice. 1. Modular design example

A. Needs analysis

The idea for this project was born out of an urgent need for a transformation at the Prefabricated Structure Factory to cope with the growing demand and the insistent demands of workers for better working conditions. Due to the increased demand for Last year problems such as an undefined process route, excess waste, disorganized jobs and an unhealthy working environment have occurred in the factory, which as a result led to an increase in the cost of production, deterioration labor discipline and delay in the delivery of goods. Therefore, the project is aimed at streamlining the production process, reducing the amount of waste, improving working environment and organization of jobs. The 5S system was chosen as a methodology for achieving the project goals.

The prefabricated factory faced problems such as fluctuating output and frequent changes in equipment settings due to fluctuating product parameters and equipment characteristics. As a result, a lot of time and effort is spent on changing and setting up production line configurations, as well as difficulties with production line rollback, workflow control, workplace organization, cleanliness and transparency of the process. All this has Negative consequences: leads to deterioration of materials, loss of resources and the need for their disposal, as well as overloading the production process and increasing the tension of workers. This means that there is a need to analyze production processes and redesign the plant in such a way that it meets the requirements of manufacturing products with flexible parameters and keeping workplaces clean and tidy, as well as to facilitate the control of the work process. Figure 2 shows the production waste and inventory stored on the shop floor.

Rice. 2. An example of the storage of production waste and inventory in the workshop

B. Project objectives

The prefabricated structure factory strives to increase the efficiency of production and installation by improving the production process and competent layout of the workspace. This is the most important step on the way of the enterprise to success in all aspects of activity. In this way, this project is aimed at studying the production process in the workshop of the Prefabricated Structures Factory, identifying existing problems and their impact on the efficiency of the production system. From the point of view of the organization, the project provides for the development of a workshop layout that takes into account the features of in-line production, with a minimum possible changes the existing layout, as well as reducing the cost of setting up production, which will lead to more convenient enterprise management and control over work processes. For the management of the factory, the optimization of technological parameters (inventory, equipment location, sequence of operations, cycle time, etc.) was not a priority. From the point of view of the organization of the workshop space, the goal of the project is to optimize workplaces and improve the working conditions of workers at the machines, which will help improve production discipline, order fulfillment and communication in the team.

Based on an assessment of the state of the enterprise, the project will determine necessary measures on rationalization and reconfiguration of the production process and reorganization of the workplace. The main purpose of using the 5S system is to increase the efficiency of the production process as a whole.

B. Methodology

A simple but effective methodology is used to achieve the project objectives. The scope of the project is determined after a thorough study of the enterprise and the production process and detailed discussions with the management of the enterprise, engineers, heads of departments and workers. All participants considered the project necessary and important step for the enterprise. The main difficulty was how to necessary changes in the workflow. In this regard, the project took a simple yet practical approach to implement changes in the main shop of the enterprise, simplify the workflow and give impetus to further continuous improvement. The main provisions of the methodology are as follows:

1. Observe the work process in the enterprise, evaluate it and highlight the main problems in its organization.
2. Determine the structure of the current production process.
3. Assess the severity of problems with the organization of the workplace based on personal observations, as well as conversations with heads of departments, foremen of production sites and workers.
4. Use the 5S system to improve the production process and technological configuration.
5. Discuss the measures taken with the management of the enterprise.
6. Evaluate the results and present them to the management of the enterprise in the form of a report.

The main goal of the project is to increase the efficiency of the production process at the enterprise. In addition, it is planned to improve the organization of the workplace and the production process in order to modernize technological operations, simplify shop management and improve communication in the team. As for the net profit of the Prefabricated Structures Factory, the project is aimed at increasing the efficiency of the production process, minimizing excess production, reducing the time and cost of setting up equipment, and optimizing the disposal of expensive assets and resources. Further rise productivity and profitability of the enterprise is impossible without the introduction of a program to motivate workers.

AT initial phase project, the scheme of the production process was determined, for which the enterprise was divided into 10 sections. This was necessary to draw up a plan for the placement of equipment, determine work areas and prepare for the implementation of the 5S system in all areas of the enterprise. After that, events were held to raise awareness of the company's staff regarding lean manufacturing and the 5S system in particular, such as meetings and seminars for engineers, craftsmen and workers. Once everyone was familiar with the project goals, lean principles, time frame, and project milestones, a campaign to clean up the facility, inside and out, began. The cleaning of the production premises and surrounding areas was necessary to free up aisles, increase workspace and transform workplaces in the eyes of workers and visitors. These three steps were preparatory stage for the implementation of the 5S system on certain areas enterprises. It took an average of a week to significantly transform each site. Several meetings were held with the management of the enterprise to discuss the success of the project and exchange ideas. To ensure the sustainability of the implementation of the 5S system, special questionnaires were developed. All activities were documented and reflected in the final report submitted to the management of the enterprise and the administration of the faculty.

Using System 5S

It's often easy to talk about how Lean and 5S work. However, putting these methods into practice is not so easy, because the 5S system is not just a methodology. It implies a change in the entire culture of the enterprise, as a result of which its entire team is aimed at moving forward, towards success and improvement. Therefore, it is necessary at the very beginning to explain to the workers and management why the 5S system is being introduced. As a result diagnostic study conducted at the Prefabricated Structures Factory, were identified the following problems, indicating the need to implement a 5S system:

• the space is cluttered with tools and accessories;
• unused materials and tools are stacked between workplaces;
• unnecessary inventory is stored on the floor;
• excessive tools and machines complicate the workflow;
• the equipment is contaminated and is a storage place for various inventory;
• necessary equipment, such as tools, is difficult to find.

Based on the data from the diagnostic study, the main reasons for using the 5S system in the Prefabricated Construction Factory to improve the production process were the following:

1. the 5S system simplifies the production process as a result of cleaning, sorting, ordering;
2. 5S creates the infrastructure needed for enterprise-wide improvements;
3. 5S system is necessary for adjustment process flow and redevelopment of the workspace;
4. the 5S system is necessary to increase the motivation and dedication of workers;
5. the 5S system is the key to a clean working environment;
6. the 5S system is necessary to implement safety measures and reduce the number of accidents at work;
7. The 5S system is a way to reduce waste by:

• waste minimization and reuse;
• minimizing the time and effort spent searching for the necessary inventory or materials;
• disposal of surplus inventories.

It should be mentioned that 5S system- this is not a list of activities that need to be carried out from time to time. This system you have to practice constantly. Therefore, to achieve the best results, it is rational to use a step-by-step approach to the implementation of the 5S system. Here short description project stages.

1. Defining the structure of the production process and the layout of the premises.
2. Explaining the principles of the 5S system to the enterprise team.
3. General cleaning of industrial premises and adjacent territories.
4. Application of the 5S system in all 10 areas of the enterprise.
5. Using the card control checks to implement the 5S system and test its operation.
6. Waste reduction (less waste and reuse of materials).
7. Freeing up space (freeing up the main aisle, clearing space for materials to be reused, freeing up workshop space, providing storage space for materials).
8. Creating a cleaner and safer working environment.
9. Creation of base for motivation of workers.
10. Improvement of the working environment.

At the stage of determining the structure of the production process, the territory of the enterprise is divided into 10 zones / sections in accordance with specialization and technological route. Each section is separated from the other by special markings and has access to the main aisle, which facilitates the production process and simplifies the transportation of materials. As shown in Figure 3, the facility is divided into the following sections.

1. woodworking
2. Foam handling
3. Welding fasteners
4. Folding machines
5. Sheet metal processing
6. Door installation
7. Presses
8. Frame manufacturing
9. metalworking
10. Stock

Rice. 3. Division of the Prefabricated Structures Factory into sectors

Initially, the company did not have clear boundaries between work areas. There were difficulties in moving materials from one site to another. A crane was used to transport heavy structures and their parts. The final assembly of the structures was carried out outside the workshop on the territory of the enterprise. Workplaces were characterized by pollution and clutter with waste from production and processing. The redevelopment provides for the cleaning of the main passage, the elimination of interference with the production process, the marking of sectors, and the increase in space for working with tools and materials. These areas of the enterprise are well organized, the main passage is cleared and clearly marked.

After determining the structure of the production process and streamlining it, the implementation of the 5S system began at each of the 10 sites of the enterprise. An action plan was outlined, with the help of which the methodology and principles of the 5S system were transformed into practical advice that the workers had to follow. This stage The project proved to be the most difficult. It was required to work with the staff of the enterprise at the cultural level. Workers and management had to understand the importance of the activities carried out as part of the implementation of the 5S system in order to achieve significant changes for the better. It was decided to focus efforts on the implementation of the 5S system in one area of ​​​​the enterprise - woodworking - in order to raise awareness of workers about the methods and principles of lean manufacturing and demonstrate to them visible results application of the 5S system, which would further incline them to cooperate and help increase confidence in innovations.

At the initial stage, cleaning and tidying of workplaces is carried out, while the workers themselves observe this and ask questions about why they take certain actions and whether this is part of the certification program. It was explained to them that the workplace needs to be tidy, that this is not part of the plant performance appraisal program, and that efforts to keep the workplace clean and tidy will be rewarded according to the employee motivation program. As a result, workers began to take part in ongoing changes in the woodworking sector. Operators from other sites passed practical training with specific instructions on what needs to be done to keep the site clean and tidy. This procedure was recorded in the protocol, printed out and placed within sight at the polling stations.

Figure 4 shows a plan of a woodworking site, and Figure 3 shows a view of the site after cleaning according to the 5S system. After reviewing the plan and photograph, it becomes clear that the result of the 5S system is a clean and organized workplace. Improved inlet and outlet flow and cell layout are provided for easier machine control and process monitoring. The central aisle has been cleared, making it easier free movement carts carrying materials.

A few days later, the entire staff of the enterprise noticed that the woodworking area had changed: it had become cleaner and more organized. Labor productivity and labor discipline of the workers in this section have also undergone changes for the better. It is time to explain this principle to everyone else and begin the gradual implementation of the 5S system in other areas. The process went smoothly. A new layout is being developed for all sites, and lean manufacturing principles are applied everywhere. In combination with a comprehensive cleaning of production facilities and adjacent areas, a month later the company looks completely different. Some say it's like a completely different factory.

Rice. 4. Improved layout of the woodworking area

Rice. 5. Application of the 5S system in the woodworking area

In order to implement the 5S system in a sustainable and effective way and to test its functioning in all areas of the Prefabricated Structures Factory, it was necessary to develop a checklist that would help determine how real situation cases corresponds to the system implementation plan described above.

Control results for each site are reflected in pivot table(Fig. 6), as well as in tables individually developed for each site. Such a table helps to see the result achieved - an improved technological route, a transparent production process and a cleaner and safer production environment. The workshop also took steps to free up space, create and label storage areas, mark aisles, increase security measures and ensure the smooth flow of the production process.

Rice. 6. Control results

Conclusion

This article provides an example practical application 5S systems at the Prefabricated Structures Factory. Some aspects of production required rapid intervention and improvement of the production process (combination of single-piece production and assembly operations). The production process is confusing and complicated by the variety of products produced, the growing demand, the strategy of push production and the peculiarities of the processing of wood and metals. As a result, the plant became a warehouse of dirty machines and surplus materials, waste products and parts for rework, which were stored on the floor of the workshop, occupied the working space and created obstacles to the normal production process. In such conditions, it was not possible to make improvements, use the principles of kaizen and apply a system for ensuring the quality and reliability of products.

Thus, the main goals of the project are the organization and simplification of the production process. Lean 5S is used to create an infrastructure for continuous improvement. As part of the project, the 5S system was applied for three months at 10 sites of the Prefabricated Structures Factory in order to streamline and improve the production process at the enterprise. Each site has been thoroughly cleaned, a new layout has been developed, and the principles of using the 5S system are outlined using clear and accessible tables and instructions. As a result, there are significant changes in the workshop space, increasing labor productivity and labor discipline. This approach can find application in other industries, as well as in offices and the service sector.

How workplace organization, and tell you what is Japanese 5S system (5S), which allows you to optimize the workflow and .

The Japanese have always been famous high efficiency and labor productivity. Japan uses its own approaches to the workflow, its own, one of which is precisely the correct organization of the workplace.

The 5S system was developed in Japan in postwar period when it was necessary to quickly restore the country after large-scale upheavals. It is actively used in many Japanese enterprises and to this day, moreover, it has become so popular that it has successfully “migrated” to many other countries of the world. Consider what the 5S system is, how it can be useful to each of us, and how to apply it in everyday work to increase personal efficiency.

The Japanese 5S system is a competent approach to the organization of the workplace, which includes 5 components that allow you to use it as efficiently as possible, achieve maximum productivity while saving time and energy.

The organization of the workplace according to the 5S system can be schematically represented as follows:

Now I will consider in more detail what is meant and what each element of the proposed 5C system means.

The organization of the workplace according to the 5S system must comply with five rules, each of which begins with the letter “C” both in the original and in literary Russian and English translations:

1. Sorting(Seiri, Sort).

2. Order keeping(Seiton, Set in order), literally - “neatness”.

4. Standardization(Seiketsu, Standardize), literally - "maintaining order."

5. Perfection(Sitsuke, Sustain), literally - “education”, “formation of a habit”.

Consider what activities should include all 5S of the Japanese system.

Sorting.

The first element of the organization of the workspace according to the 5C system involves the division of all items into necessary and unnecessary in order to get rid of the latter.

To apply this rule, carefully inspect your desktop and everything on it, then divide all these items into 3 categories:

1. Always the right things- what you use in your workflow on a daily basis;

2. Sometimes the right things- what you use in your workflow periodically, but not often;

3. unnecessary things- something that you do not use at all in your workflow.

All items that fall into the third category must simply be removed from your desktop, and things from the first two categories should be correctly decomposed. How exactly - find out later.

Keeping order.

The second rule of the 5S system involves the distribution of items needed for work in the workplace as much as possible. convenient way in terms of their future use. These items must be located in compliance with safety standards and taking into account the possibility of the fastest and most convenient use of them. To do this, it is recommended to use 4 criteria:

1. Visible spot. Always the right things should be located on the desktop so that they are in plain sight.

2. The ability to easily pick up an item. The workplace should be organized in such a way that everyone required item a person could easily and without difficulty take from his seat.

3. The ability to easily use the item. Some necessary things must not be picked up, but simply used (for example, a monitor). Therefore, they should be arranged with ease of use in mind.

4. The ability to easily return the item to its place. According to the 5S system, at your workplace it is necessary to provide the opportunity not only to quickly take the item, but also to quickly return it to its place (for example, if you pull the bottom folder out of the stack, there will be no possibility to quickly return it back).

Following the rules for organizing the workplace according to the 5C system, it is necessary to maintain your workspace in complete purity. To do this, it is recommended to do the following:

1. Divide the workplace into zones, each of which will have its own purpose (for example, the location area computer technology, area for stationery, area for documents, etc.);

2. Regularly clean the workplace to keep it clean. To do this, you should immediately allocate 5 minutes to clean your place. It is best to do this at the end of the working day.

Standardization.

As I already wrote, in the 5S workplace organization system, standardization means maintaining order, that is, regular observance of all the listed rules of the system, accepting them as a certain working standard, deviation from which is unacceptable.

In enterprises, the introduction of standardization means fixing the rules of the 5S system in some internal normative document, binding on all employees, but in personal plan here you will have to show self-discipline and be responsible for meeting the standards in front of you.

Improvement.

In original translation last rule 5S stands for "nurturing" and "habit building". That is, it says that all these actions should gradually become a good habit, and then further they will be performed automatically, improve the efficiency of the workflow on an ongoing basis.

By the way, to develop such good habit will help you.

Undoubtedly, the organization of the workplace according to the 5S system will eliminate all existing clutter and chaos in the work process, and therefore make the use of working time more efficient and, as a result, increase labor productivity.

Of course, if we are talking on the implementation of the 5C system in the enterprise, then best result can only be achieved with the simultaneous involvement of all employees in the system. Well, on a personal level, organizing your workplace according to the 5S system is much easier: this requires only self-discipline and self-control.

Now you know what the 5S system is and how it should be applied. Hope this will help you in the process and self-improvement. Stay on where you can always get acquainted with others useful advice to achieve personal and financial plan. See you soon!

Try to organize your workplace according to the 5s system and see how much you can get done in one working day.

Today's article will be useful to those people who do not know how to organize their workplace in order to work as efficiently as possible. It was for you that in the middle of the twentieth century a magnificent 5s system.

I don't know about you, but I can't stand clutter in the workplace.

I never understood people whose desktops contain picturesque piles of necessary files, art books, advertising brochures, candy wrappers, cups of unfinished coffee, CDs, stationery, cosmetics and other unthinkable things that have nothing to do there at all.

I never understood how these assholes find something in the rubble on their desktop.

If you also sin by cluttering up your workplace, but really want to improve, then here you are helpful tips from the most organized nation in the world: the Japanese.

What is 5s system?

Japan's economy suffered greatly during World War II.

This country was a supporter Nazi Germany, and when the allied forces defeated Hitler's coalition, then the infrastructure and financial and economic system of Japan were destroyed almost to the ground.

And yet, despite the bleak prospects, the Japanese did not give up, but began to work twice as hard, trying to return their state as a strong player on the world stage.

There were no minerals, as well as fertile black soil in Japan, so the government relied on industry and high technology.

In order to restore the economy of the state as quickly as possible, various innovative schemes for organizing the workplace and production processes were introduced.

One of the most effective has been 5s system.

It is not named so by chance, because it is five actions that each employee of the company must perform (whether it be a courier or CEO) to organize your workspace in the most efficient way.

In some articles, I met a superficial interpretation of this system.

Like, 5s is almost the same as regular cleaning of your workplace.

On the one hand, this is true, but on the other hand, 5s is not just a technique for keeping your workspace clean.

This is a real philosophy, which is designed to make any production successful and low-cost.

5 stages 5s system

Each employee who wants to organize his workplace according to the 5s system must complete 5 stages, which are indicated Japanese characters:

整理 (Seiri), which can be translated as "sorting".

That is, the employee must divide all the materials available at his workplace into three piles: very necessary (those that are used constantly at work), partially necessary (which are used infrequently) and completely unnecessary for work (they will never be useful to you).

整頓 (Seiton) translates as "order".

You need to put things in order at your workplace (and most importantly, maintain it!) in such a way that all the things you need are in the visibility zone, are easily accessible (and not rest under rubble), and are as convenient as possible to use.

In addition, care should be taken that after application they can be easily returned to their place without spending a lot of time on it.

清掃 (Seisō).

From Japanese, this word is translated as "cleaning".

Everything is extremely simple: you must regularly (not once a month, but every day!) clean your workplace so that it is clean and tidy.

Meticulous Japanese generally clean their workplace three times a day:


• in the morning (you need to come 10-15 minutes before the start of the working day to wipe the dust and get ready for work);
• at lunch (usually the lunch break lasts 1 hour, try to keep within 50 minutes, and devote the remaining 10 minutes to cleaning your workplace);
• evening (you need to end your working day not with the phrase “Hurrah! Finally free!”, But with cleaning so that you spend as little time as possible on putting things in order in the morning).

1. 清潔 (Seiketsu) - "purity", although another translation is more popular: "standardization".

   The fact is that the Japanese are a neat and pedantic nation.

   If they introduce some kind of system, then without workers step by step instructions, the prescribed bonuses for fulfilling the instructions of the leaders are indispensable.

   And in general, in any business it is useful to have written job descriptions.

   So you will avoid explanations of boobies and lazybones, such as "But I didn't understand ...".

   躾 (Shitsuke), which translates as "education".

   That is, you, as a leader, should not just briefly explain at the planning meeting what today we are implementing some Japanese system, and as accurately as possible, with illustrations and examples, explain to employees what you want from them, as well as monitor how they follow your instructions.

   Particularly diligent should be rewarded, lagging behind should be fined.

What is the use of the 5s system?

This excellent system is in great demand not only in Japan, but also in other countries.

Hundreds of thousands of managers have implemented 5s in their companies and are convinced of the effectiveness of this system.

Through its use, you can achieve:

Alignment of indicators by the number of accidents.

It is often the clutter in the workplace that leads to injury and disability.

• The aesthetic appeal of the workplace, even if your office has simple furniture, and it would not hurt to make repairs in it.

Improving the efficiency of the workflow.

Remember how much time you spent each time trying to find desired document among the rubble on his desk.

And how, when it was necessary to return the file to the bottom folder, which rests under a pile of a dozen others.

• Reducing the time spent on the performance of a particular task, and not at the expense of quality, but by putting things in order at the workplace.

Working climate improvements.

Clutter in your home or office has a negative effect on mental condition person.

It does not add mood and the need to dig for a long time to find what you need.

And the video below shows the 5s system in pictures,

implemented at the factory in Japan.

Watch and learn!

Try and you organize your workplace according to system 5s, and you will see how much you can do during one working day and at the same time remain peppy, and not a tantrum with a twitching eye.

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