5S Warehouse Implementation Success Story

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Carlton Technologies 5S Warehouse/Shipping/Receiving Implementation 6/27/2016

Transcript of 5S Warehouse Implementation Success Story

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Carlton Technologies5S Warehouse/Shipping/Receiving Implementation

6/27/2016

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• On June 24th & 25th a team of 11 folks embarked on their first continuous improvement event. This event focused on implementing 5S in the warehouse and shipping/receiving.• The rest of the slides show their progress on implementing 5S( Sort, Set, Shine, Standardize, and Sustain), which is a continuous improvement technique for organization.

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• The Team– Over 45 years of combined Carlton experience– Over 220 years of overall combined work experience

• This Team Can Do Anything!!

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Overview

• 5S is a systematic process. It’s the first step in continuous improvement and lean journey• If you cannot do 5S…you cannot do the other principles of continuous improvement and lean

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Carlton Technologies Set Floor Marking Standards

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SortSort

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Carlton TechnologiesBEFORE AFTER

• 20 items tagged and moved to the red tag area. • Freed up 125 sqft

SORT!!SORT!!

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SetSet

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Carlton TechnologiesBEFORE AFTER

• Notice the bun racks with green locations. Green designates finished goods.SET!!SET!!

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Carlton TechnologiesBEFORE AFTER

• Shipping area before and after….great job team!!

SET!!SET!!

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Carlton TechnologiesAFTER

• Shipping area great example of shadow board so those critical tools aren’t lost. SET!!SET!!

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Carlton TechnologiesBEFORE AFTER

• Receiving area before and after….great job team!!• Work area marked, scrap area, and locations for product

SET!!SET!!

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Carlton TechnologiesBEFORE AFTER

• Chris Tunks making sure we stay aware of hazardous areas around the dock. Black/Yellow markings!!SET!!SET!!

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Carlton TechnologiesAFTER

• Antonio and Amy setting locations on the floor and creating shadowboards!! SET!!SET!!

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Carlton TechnologiesAFTER

• Amazing job in the warehouse!! LEE AND CECE MAKING THE WAREHOUSE VISUAL!!

SET!!SET!!

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ShineShine

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– Step 1 – Preparation• Complete Sorting/Set• Prepare cleaning supplies and materials

– Step 2 – Determine Shine Targets in Area• Usually grouped into three categories …

– Spaces – Office or shop floor areas including floors, walls, windows, lights, shelves, etc.– Equipment – Machines, tooling, general tools, transfer carts, etc.– Other Items – Cabinets, desks, raw materials, detail parts, production hardware, etc.

– Step 3 – Determine Shine Methods• Define what will be cleaned in each area and what supplies and equipment will be used• Initial cleaning takes longer, but once completed, daily cleaning should be a focused, timely activity• Create standards for shine procedures to enable people to use time more efficiently

– Step 4 – Prepare Cleaning Supplies• Should be obtained and made readily available to those conducting shine activities.• Supplies used for daily cleaning activities should be stored in places where they are easy to find, use and return

Carlton Technologies Shine

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– Step 5 – Start to Shine• Some Suggestions

– Sweep dirt from floor cracks, corners, etc.– Mop and wax floors as needed– Wipe off dust from walls, windows and doors– Be thorough about cleaning dirt, oil, grease, rust shavings from all surfaces (especially machinery)– Paint equipment as needed– Establish a visual location for freestanding items

Carlton Technologies Shine

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StandardizeStandardize

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Carlton Technologies

• Examples of standardized jobs to do daily/weekly/monthly to ensure area stays like the picture!!• Team commitment• #thisteamisnevergoingbackwards

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SustainSustain

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Carlton Technologies Sustain

Sustain Key To-Do’sSustain Key To-Do’s

• Sustain• Action log created, use this to keep open items from slipping.• See your 5S champion for questions. CeCe is champion for warehouse/shipping/receiving• Carlton team members will be doing weekly walks to assess areas, provide feedback, and offer improvement suggestions

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NO SHADOWBOARD OR CHECKLISTS

SHADOWBOARD AND CHECKLISTS

Carlton Technologies Action Log Example

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SummarySummary

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Carlton Technologies Summary

• In 2 very focused days the team was able to accomplish all the steps of 5S. There are very few open items and we look forward to sharing what we learned with others and getting more areas implemented.

• Hats off: Lee, CeCe, Cal, Mitch, Kelsey, Amy, Antonio, Andy, Chris, Jeremie!!! Your dedication and commitment to continuous improvement activities is much appreciated. We look forward to seeing you continue your learnings.