Published on February 26, 2014
5S Numbers Game Robert Baird Lean Teams USA +1 215 353 0696 26-Feb-14 www.leanteamsusa.com 1
The worksheet on the following page represents the current state of our work place (no peaking) • Your job is to use a pen or pencil to Strike Out the numbers 1 to 49 in Correct Sequence • You will have 30 seconds to complete this task • The Time Keeper will tell you when to start and announce the end of your task at the 30 second mark • When time has been called, ask each person to call out the highest number they crossed out and record these individual scores on a white board or flip chart • Circle the Lowest Score – this is the Teams' Official Score for this round 2 www.leanteamsusa.com 26/02/2014
Round 1 Results • How do you feel about your score? • What appeared to get in the way of achieving a higher score? 4 www.leanteamsusa.com 26/02/2014
5S Step #1 Sort • We are going to implement 5S in this work area. The first step is to Sort • Our initial analysis shows numbers 50 to 90 are not essential to our daily tasks…they have been removed from the work area • In a moment, you will repeat the Strike Out task in the Sorted Work Place on the following page. • Same rules apply: Use a pen to strike out numbers 1to 49 in sequence during a 30 second shift • Record your individual scores and circle the lowest as your Official Team Score for the round 5 www.leanteamsusa.com 26/02/2014
Round 2 Results • How do you feel about your score? • What appeared to get in the way of achieving a higher score? 7 www.leanteamsusa.com 26/02/2014
Step #2 Straighten • Having achieved some improvement, we will now move to the next 5S step Straighten • We have installed some racking in the work area using a 3 x 3 grid • We have organized the numbers so that Number 1 is located in the top left hand corner and the numbers are sequenced from top to bottom and left to right – Example: #1 in the top left, 2 in the top middle, and 3 in the top right, then 4 in the left middle, 5 in middle middle… and so on • Same rules apply: Strike out numbers 1 to 49 in sequence during a 30 second shift. Lowest individual score is your Official Team Score. 8 www.leanteamsusa.com 26/02/2014
Round 3 Results • How do you feel about your score? • What appeared to get in the way of achieving a higher score? 10 www.leanteamsusa.com 26/02/2014
5S Step #3 Sweep Cleanliness. Sweep the floors, continuous cleaning of equipment, paint if necessary, and in general, make sure everything in the work areas and offices stay clean Related to our numbers game this step has already been completed….Great Job! 26-Feb-14 www.leanteamsusa.com 11
5S Step #4 Standardize • After in-depth Work Flow Analysis, we have installed the more detailed racking system on the next page… no peeking • This allows us to re-organize the numbers in a standard fashion which will ease the completion of your task. • Same rules apply: Strike out numbers 1 to 49 in sequence during a 30 second shift. Lowest individual score is your Official Team Score. 12 www.leanteamsusa.com 26/02/2014
Round 4 Results • How do you feel about your score? • What appeared to get in the way of achieving a higher score? • Can you think of other mechanisms to improve the work area even further? 14 www.leanteamsusa.com 26/02/2014
5S and Flow What benefits can you expect from application of 5S to this work area? • We have recently discovered two numbers are missing! We cannot finish our job without these numbers – so first we have to find them • Your Team Task: Identify the two missing numbers as quickly as possible 15 www.leanteamsusa.com 26/02/2014
5S and Flow • In a moment you will….Start the timer • Flip to the next page • Find the two missing numbers as a team – call them out as you identify them • Every 30 seconds is a Shift of work • Timer, please announce the number of shifts out loud as the Team works to find the missing numbers • Stop the timer when the numbers are found and announce the total shifts required to complete the tasks 16 www.leanteamsusa.com 26/02/2014
Round 5 Results • How do you feel about your score? • What appeared to get in the way of achieving a higher score? 18 www.leanteamsusa.com 26/02/2014
5S and Flow • Let’s try that again in the work area that has experienced your Sort, Straighten, and Standardize • In a moment you will….Turn the page • Start the timer • Find the two missing numbers • Count the number of 30 second shifts the task requires this time 19 www.leanteamsusa.com 26/02/2014
Round 6 Results • How do you feel about your score? • What appeared to get in the way of achieving a higher score? 21 www.leanteamsusa.com 26/02/2014
5S Numbers game summary • What did we learn? • What else? • How might you incorporate the 5S process into your current work area • What difference would you expect it to make? 22 www.leanteamsusa.com 26/02/2014
The Fifth S is Sustain • Imagine you have applied the 5S process to your current work area and seen improvements as you did in this exercise • What would you have to do –or have to stop doing- to SUSTAIN these changes? 23 www.leanteamsusa.com 26/02/2014
5S 1. Sort 2. Straighten 5. Sustain 3. Sweep 4. Standardize 26-Feb-14 www.leanteamsusa.com 24
Guaranteed ROI From Lean Teams USA Contact Us • Lean Teams USA Lean Consulting • View My Profile on LinkedIn • Lean Teams USA +1 215 353 0696 26-Feb-14 www.leanteamsusa.com 25
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