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The ultimate workplace organization tool

By Noman Husain, LEAN Coach

 

One of the most effective and widely used Lean tools is 5S. 5S is a workplace organization and visual controls methodology that refer to five Japanese words—seiri, seiton, seiso, seiketsu, and shitsuke.

 

Although Toyota is credited with the development and popularization of 5S methodology, however, the origin of 5S is rooted in the works of American pioneers who were studied by Japanese managers including Sakichi Toyoda, Kiichiro Toyoda and Taaichi Ohno. Among the notable Americans were Frederick W. Taylor's Scientific Management (1911) and Henry Ford (1922). Indeed, Ford's CANDO program (Cleaning up, Arranging, Neatness, Discipline, Ongoing Improvement), which builds on Taylor's work, appears as the obvious origin for 5S.

 

Phases of 5S:

1. Sort (Seiri)

2. Store (Seiton)

3. Shine (Seiso)

4. Standardize (Seiketsu)

5. Sustain (Shitsuke)

 

1. Sort

Sorting is separating the essential materials from the nonessential. Nonessential items are those not needed for present production. The procedure that involves identifying the nonessential items in a work area is called “tagging.” The goal of sorting is to simplify the work environment and break the ‘just in case’ mentality. When in doubt, move it out!

 

2. Store

Storing involves organizing the essential materials in the workplace. This phase can also be referred to as Simplifying. Make it visual and obvious if something is out of place. Make it easy for everyone to find and use them – use “30 second” rule. The goal of storing is to eliminate wasted time looking for materials and tools. A place for everything and everything in its place.

 

 

3. Shine

Shine is cleaning the work area and keeping it clean on a regular basis. It is regimented, scheduled cleaning of the entire work area. The purpose of shine is to rid the workplace of all dust and dirt (dirt is often the root cause of premature equipment wear and product failure). A cleaner workplace allows for quicker problem detection and is a safer workplace. A key point is that maintaining cleanliness should be part of the daily work - not an occasional activity initiated when things get too messy.

 

4. Standardize

Standardize means to set up the rules for Sort, Store and Shine, implement the rules on a consistent basis and maintain the workplace at a level in which non conformities become obvious. Standards must be simple and easy to follow. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's.

 

5. Sustain

To sustain is to perform the Five S’s on an ongoing and systematic basis until it become a way of life. Sustaining is the continuation of sort, straighten, shine and standard. Measurement drives behavior, and if we do not pay attention to the sustainment it will degrade. This is the most difficult step. If nothing is done, nothing will improve

 

Implementing and maintaining 5S will pay huge dividends to the company by creating safer workplace, increasing productivity, reducing waste and improving morale.

Meeting our customers’ needs through global collaboration
global collaboration
 

By Rich Boaz, Manager, Controls Engineering

 

At Comau, we’ve thrived over the past few years through adapting to our customers’ needs and the market, not only from a product and value perspective but, more importantly, through the collective efforts of our people.

 

Customer Development Collaboration

While Comau was historically organized by product line, today we operate as one unit to meet customers’ needs in various locations and industries. For example, our Powertrain and BodyWelding groups work together to develop solutions to assembly challenges for our customers in industries like aerospace, heavy industry, packaging, etc. Combining the skills of our people and the technical know-how from each area of the company has allowed Comau to win orders that we may not have been able to bid on if operating independently.

 

Shared Resources

With Proposal, Engineering, and Program Management teams operating in nearly every time zone, Comau is able to share resources needed to bid, manage and execute a program based on skills and cost competitiveness. For example, engineering and build can be done in Italy for a portion of a job, while testing and complete installation can be done in the U.S., leveraging the key areas of the company to provide the most cost effective and efficient solution.

 

Product and Customer Development

While our historic partners remain essential to our business, there has been a significant investment in time and resources to help develop game changing solutions for our customers in industries like aerospace, rail transport, construction vehicles, solar energy, and wind energy. These initiatives couldn’t be put into place without collaboration between our distributed offices and their skills. Heavy emphasis has been placed on co-development which leads to better communication, understanding, and implementation of what is purchased. These activities help transform a customer-supplier relationship into a partnership.

 

Technology Sharing

An example of a shared technology between our BodyWelding and Assembly Group and Powertrain Group utilizes our own vision system to perform robotized piston insertion on an existing line with large part-to-part locating variance.  This system was developed jointly between two Comau groups, generating new business for our company.

 

Comau has an extensive base of experience in terms of technical solutions, and in our people.  Knowledge and proven solutions must be shared globally. Through web based applications, we are able to share data, hard and soft designs, as well as general collaboration and our knowledge bases online.  

 

Comau routinely assembles employees from around the world for workshops that promote sharing of experiences and team building. Our ability to make our skills and information accessible to our employees in different locations and different skill areas is one of the reasons Comau is competitive today and a viable entity for years to come.  

 

 

 

 

 

The Gulf Oil Spill – A Lesson in Failure to Innovate From Innovating to Win

 The following blog post is from Innovating to Win: Observations from the front line on building the high performance innovation organization

It’s horrifying to think that it has been almost 70 days since the Deepwater Horizon oil rig exploded on April 20th and little substantive progress has been achieved in stemming the ecological disaster of Brobdingnagian proportion.  Crude oil continues to spew forth from the broken underwater pipe.  Gooey masses of toxic sludge wash up on our shores.  The flora and fauna that comprise the fragile ecosystem are helpless as they are buried in oil.

Surely, a unique catastrophe such as this which poses challenges unlike any which have been seen before requires fresh thinking, inventive approaches, novel solutions—in a word: innovation.  Yet, where is the innovation?

People are viscerally angry at the Obama administration for its handling of the crisis.  Some people defend the President saying, “He really couldn’t do anything.”  The problem is that Obama could do something.  He could have used the power of the Office to drive the innovation climate needed to produce better outcomes.

The handling of Deepwater Horizon oil spill is an object lesson in ways to fail at driving innovation in time of need.  Here are some of the key takeaways that we can learn from.

Failing to recognize the problem
In the initial days after the explosion, it was clear that this was going to be a serious situation.  Yet, both BP and the Whitehouse downplayed the severity of the spill publishing estimates of the volume of oil leakage far below what the Coast Guard was estimating.  No immediate action was seen from the Administration either to hasten stoppage of the leak or to mitigate the threats to the environment.  In short, heads were firmly planted in the sand as no one publicly acknowledged the scope of what was happening.

Turning a blind eye to the situation and looking through rose tinted glasses are all too common in business.  Consider the failure of Sony to recognize the threats mp3 technology posed to the Walkman.  How many minicomputer companies vanished because they did not fully appreciate the technological and market trends of the 1980s?  You must always be looking for what looms just over the horizon.  As Andy Grove put it, “Only the paranoid survive.”

Not Invented Here syndrome
Over a dozen countries have offered assistance in cleaning up the spill.  The Administration has turned all these offers of help away.  Many individuals have stepped forward with ideas about how to stop the leak or protect the coastline.  Yet, these suggestions have been ignored.  This sort of intellectual arrogance abounds in the business world as well.  I can’t count the number times I have heard companies described as having an NIH culture.

Companies must look at their innovation systems and understand how to integrate customers and value chain partners into their R&D processes.  Open innovation is not simply about finding more ideas; it’s about extending the value creation capacity of an organization by leveraging all the resources in its innovation ecosystem.

No leadership
This is the issue that has the public riled.  Throughout the crisis, Obama has not shown any leadership.  Innovation requires leadership, that quality of being able to rally people to step outside of themselves and reach a goal that they would not have been able to achieve on their own.  But, the administration has not chosen to take the lead.  When BP was short on ideas to stop the leak, did Obama reach out to other oil companies to see if they could help or at least help understand the limits of possibility?  No.  Did Obama stand up against political pressure and waive the Jones Act?  No.  At every turn, the Administration has failed to show leadership opting instead to sit back and wait for BP to figure it out.

Lack of leadership is a leading cause for failure to establish sustainable innovation systems in companies.  Many executives will say they want innovation practice to develop from the grass roots of the engineering community.  The reality is that without the nourishment of executive leadership, the grass root are destined to whither in the parched and barren soil of institutional inertia.  Executives must lead from the front to drive the type of cultural change required to establish innovation as a value driving core competence.

All show; no substance
Don’t we all feel better knowing the Administration is going to have a blue ribbon committee explore potential criminal malfeasance at the root of the disaster?  Thank goodness BP executives have been subjected to a good tongue lashing. Huzzah, huzzah!

Right!  Everyone can see through the bread and circus approach to managing the situation.  The political consequences of this promise to be severe.  So too, are the consequences within a company when the commitment to innovation doesn’t extend beyond words and window dressing.  When it comes to a company’s innovation agenda, all employees recognize big hat, no cattle management and are highly unmotivated to pursue innovation on behalf of the company.  If you really want innovation, you must act with conviction and purpose.  You must invest in people and infrastructure to enable the environment for innovation success.

What innovation lessons do you see in the Gulf Oil Spill situation?

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