Methods for Implementing 5S in On-Site Management

Start with 3S.

As we mentioned earlier, in order to successfully implement 5S, we must first start with the most basic 3S (sorting, rectifying, cleaning), and then gradually promote cleaning and self-discipline after completing 3S. Because, in the field, sorting and organizing a certain type of item or work is the first step required to complete.

It is then decided where to place these items and how to keep them, and how they should be controlled and remediated on this basis. Based on the above, decide on the method of tidying up and tidying up according to local conditions, remove unnecessary items, and then thoroughly clean them.

These are the most basic steps to start implementing 5S, perhaps not so perfect at the beginning of the process, we can continue to supplement the implementation process, and finally meet the requirements suitable for the actual situation of the enterprise. Of course, this requires us to mobilize all employees to use their brains to find a way to lay a solid foundation for the implementation of 5S.

Compliance with procedures

Complying with the rules is not that simple, and while the truth is simple, it is not so satisfying in many situations. In the management scene, we can often hear such and such reasons as “don’t give an example”, “this will do”, “because there is really no way, just like this…” and so on, and it is a headache to put aside what they should do, because sometimes the reasons they give are not unreasonable, and some seem to be more objective.

However, as long as we think about it, there are many things that can be accomplished with our own initiative, and the crux of the problem is the lack of consciousness to comply with the rules. Therefore, to educate employees that all factory regulations should be followed, which is not only a requirement of 5S, but also a must for the success of the enterprise.

We can make demands on employees from the following aspects:

1. Complete the task on time and do not agree to delay time.
2. Have a beginning and an end to the work undertaken.
3. The configuration of the work site should be clear to all employees.
4. All employees should grasp the cleaning state of the work site, equipment, and components.
5. Let all employees know the methods and relevant regulations for the use and return of on-site items and follow them.

Third, avoid waste caused by duplication of work.

Keep the necessary things in place, this is the principle of tidying up and putting things in order. If there are useless things everywhere, it will increase the difficulty of management and cause waste of workforce.

“Sorting” and “rectifying” are easy to understand and attach importance to the root cause of waste caused by repeated labor, but there is a kind of waste that is often overlooked, that is, needlessly improving the quality of products; Effortless use of high-quality materials; Waste caused by needlessly increasing machining accuracy. These habits are not paid attention to because there is a cloak of “improving product quality”, which requires a reacquaintance with the need to improve product quality.

You can proceed as follows:

1. Whether the selected materials and sizes are wasteful, and whether there are unnecessarily high requirements for their processing accuracy, they should be reconfirmed.
2. The design does not consider the unnecessary performance of the product.
3. Reduce the processing process that does not affect the quality and performance of the product.
4. Improve the utilization rate of raw materials.
5. Explore the importance of hindering quality, factors of production and processing methods.
6. Create opportunities for joint discussion between production, design, and technology.

Streamlining ineffectiveness in 5S, focusing on sorting out items that are not yet necessary on site, the biggest problem for the entire company is the problem of warehouse management.

Cleaning

Moreover, what is indispensable in “warehouse management” is the determination and processing of “whether it is required”.

Much of the reason “clean-up” and “clear-out” are sometimes poorly done is that it is not clear whether and when these things are needed. Extraordinary is a great difficulty in distinguishing items that are not necessary now and may be needed later.

However, we only need to clearly stipulate that those “defective products”, “waste products” and “long-term idle crystals” among the unnecessary items “on site” can be placed in a specific area.

If you check the workforce arrangement or the placement of items on the work site, you will find that there are many wasteful places, such as indirect operations such as picking, putting, and finding items, and there is a lot to improve. How to minimize this waste to improve work efficiency is a topic that we should seriously study, and the use of 5S is one of the methods.

In order to carry out the work efficiently, it is necessary to fully arrange the work site, make full use of the preparation time of the work, and consider the continuity of the operation. Of course, there must be no way to be late for a meeting.

Rules and regulations

Rummaging around the job site looking for things because I don’t know where. At the work site, we have established various rules and regulations in accordance with the requirements of 5S, and as long as the rules and regulations are followed, these situations can be avoided.

On the job site, time is the most important thing for a business, and time is money. Since the manufacturing industry now shortens the time from design to finished product completion of the entire process, so that competition determines victory or defeat by efficiency, in a sense, it is to determine its victory or defeat by time, and one step ahead can occupy the commanding heights and grasp the initiative.

There are many reasons for delays, such as organizational, working methods, human reasons, etc., and it is important to find out the reasons and find countermeasures.

Follow these steps when you find a problem:

1. Find out the reason for the waste of time in the procedure at the beginning of the operation.
2. Improve and correct the operations and methods that generate waste.
3. When formulating a plan, it is necessary to clearly grasp the personnel, equipment, materials, and time required.
4. Explore effective operation methods and improve the original process.
5. In daily work, employees use shift work to seek the best working methods.

Delayed planning is the result of not accurately grasping principal factors such as personnel, equipment, resources, and time. For example, the cooperative manufacturer delays the supply, but there are no materials, etc., so for time management, the first plan should be extremely strict and without the slightest error.

Cost Awareness & 5S

There is a principal factor in waste that everyone is concerned about, and that is cost. The quality of corporate management activities is based on the determination of costs. Therefore, every employee must have a sense of cost. Have a clear familiarity with the costs of the work you are doing. Strengthening employees’ cost awareness starts with the following:

1. Clarify the unit price of manufactured products, parts, and materials.
2. Clarify the cost and time unit price of each person’s labor expenses.
3. The impact of equipment wears and tear on fixed assets.
4. The impact of improving productivity and quality on costs.

It is worth mentioning that it is necessary to prevent the act of turning public into private.

For example:

Using the company’s phone to do personal affairs; Take your company’s office supplies or even high-value items home and use them, and don’t give them back. These phenomena are very common in some enterprises. Our business leaders do not think so, think that these are small things. If they are too “stingy” if they are concerned about this kind of things, they do not know that “trickling small streams converge into rivers”, “thousands of miles of river embankments collapse in anthills”, let this phenomenon be left to develop, it will bring a lot of cost waste to the enterprise.

Everyone knows that efforts should be made to reduce costs. To take it as the direction of efforts.

We must do two things well:

• One is to reduce the established price;
• The second is to strengthen corporate management, that is, on-site management.

Reasonable arrangement and utilization of work sites

In the principle of sorting and rectification. One is to reduce the waste of space and vacant space as much as possible. If these vacant places are cleaned up. It can reduce the storage of materials, or shorten the time for access and placement. Only after sorting can it be distinguished whether the items are centralized or decentralized. Therefore, to reduce the vacant place. It is necessary to effectively organize. The items to improve the utilisation rate of the site.

Basic steps to reduce free places:

1. To decide what item to place in what position, that is, positioning.
2. To decide how much quantity to place, that is, quantitative.
3. To decide what state to place in, that is, to explore space-saving placement methods.
4. Items taken up, such as tools, tooling, fixtures, etc., can be quickly put back in their original place after use.

The main point to reduce the waste of space. The open space is to conduct another inspection on the site. To maximize the use of vacant space, and consider the following points when inspecting:

(1) whether the distance traveled by people can be shorter.

(2) whether the number of people moving can be less.

(3) Whether the handling distance of materials and parts can be shorter.

(4) whether the number of handlings can be less.

(5) whether different items can be put together.

(6) Whether the materials with large quantities, and many uses can be placed less. The production can also operate normally.

(7) The necessary items can be understood wherever they are placed.

(8) Whether the information transmission between the work site and the process can be better.

(9) Whether the full picture of the main equipment and processes can be seen in the center of the operation.

(10) Whether the necessary general materials and equipment for several work sites can be concentrated.