Secret of 5S SORT Step Revealed

5S Sort- Suriin, Piliin: HIDDEN SECRET REVEALED

In the 5S Steps, the first to be undertaken is called SORT.

5S SORT is going through all tools, materials, supplies, spares, files, etc., in the plant and workplace. Keep only essential items. Everything else not needed frequently to do job is stored or discarded or thrown away.

In the home applications,5S SORT is simply removing from your cabinets and closets items which you do not use anymore.

The immediate 5S SORT action is removing the rubbish and clutter, reduction of needed items in the workplace to bare minimum required , 5S SORT also involves initial cleaning and generally making the area tidy. By getting rid of unnecessary items and consolidating unused items, equipment, supplies, and stocks, reductions in stocks , racks , cabinets and equipment can be had, and additional space can be made available, and needed items used frequently or on regular intervals can be found easier.

REMOVE WHAT IS NOT NECESSARY, MAKE IT EASY TO FIND WHAT IS NEEDED. KEEP THE AREA UNCLUTTERED & SIMPLE through 5S SORT

Before Innovation, Six Sigma, Lean.. 5S TPM

In the quest for Manufacturing Excellence, so many companies have embarked on what is most popular, and good sounding systems available... till they find 5S TPM....

In my 28 years of Corporate/Manufacturing life.... I have seen improvement systems coming one after the other and frantically , companies always tries to jump in and join the bandwagon. Unfortunately, for most, it becomes a joy ride and they do not complete the trip. Once the leadership change, the system change. Are you with me? Did you also see this phenomenon?

ISO Quality Systems, Manufacturing Excellence, Lean Manufacturing, Short Cycle Manufacturing, Manufacturing Innovations, Six Sigma are the systems most companies try to employ. However, careful study of each of the systems mentioned will tell you that all are but a derivative or a mere subset or tool or a pillar of TPM-Total Productive Maintenance.

Many are just the same thing as TPM but just labeled and packaged differently. Some are painted with color to combat the NIH- Not Invented Here mentality and made complicated by statistical tools, and softwares.

But, the best always will continue to survive and exist. And the best is simply the simplest, step by step, methodical approach to improvement. That is TPM.

Go back to the basic. Go to the origin. Do TPM.

God bless!

Foundation of Solid 5S TPM Implementation

Earlier in my blog, I talked about 5S as one of the basic foundation of TPM Implementation. Indeed, 5S is one and another is the Total People Involvement.

Again, by Total on TPM , this means from ground up and from the top to bottom. There must not exist any gap in between or from both ends of the organization. In fact, TPM must even get linked to people on the supplier and customer side.

I have encountered companies who had been vigorously pursuing TPM but when the leadership has changed, all TPM activities halted as the new leader wants to pursue another system, which in actuality is just a derivative of TPM.

There are also many companies, who have leaders not very well aware of the TPM Systems and their roles, that they relegate TPM to their subordinates, and abdicates their primary and critical role as drivers, implementer thus breaking the chain of the system flow of TPM.

On the other end, many companies have zealous leaders who are very familiar with TPM and is raring to implement, but the people on the shop floor are not familiarized or educated on TPM and thus, the implementation is done just for the sake of compliance and not because they fully embrace the belief on the concepts and system of 5S or TPM.

We need to ensure Total People Involvement exists prior implementation and the preparatory stage of TPM which is focused on training. TPM training and education must be complied with. This will ensure total buy in and total commitment to be involved on TPM for all the employees in the company.

God bless!

5S-TPM is for Everywhere and for Everybody

5S-TPM is a "way of life". It started in Japan, but is not limited to Japanese culture. 5S TPM is also not limited to factories. 5S TPM is very applicable to stores, warehouse, clinics, hospitals, schools, private office, government offices, homes, etc. Yes, 5S TPM is applicable to your homes as well. That's why 5S TPM is a way of life, and is applicable everywhere and for everyone.

Pull out your wallet now, check what it contains. Arrange it and then insert it back to your pocket. Then, think of what you want to get from your wallet, close your eyes and without looking, get what you need. Did you get what you need? How fast did you do it?

Go to your fuse box, check out which circuit breaker corresponds to what power lines. Can you determine which is which without labeling them? Try labeling them now and you'll find it easier to search the next time.

These are simple applications of 5S TPM which can be expanded to cover anything and anywhere. You save search time by doing so.

And 5S TPM is not just about arranging and cleaning...it's all about waste reductions, loss reductions, safety and improvements.

You want to learn more about 5S TPM ....contact me... I am JIPM TPM Certified Instructor...

God bless!

5S as the TPM Foundation

TPM has two basic foundations. One is total people involvement and the other one is 5S Implementation.

However, make no mistake to believe that once you do the cleaning and arrangements of equipments, tools and workplace that you are already doing TPM.

Just like building a house, the very foundation must be made strong and stable so that the house can withstand the test of nature. Same with TPM, 5S Implementation prepares the workplace and the people.

5S TPM is also done in a systematic, step by step process. 5S TPM is not a one time deal, but a serious effort to define cleaning standards, and address areas and sources of contamination and abnormalities.

If you want to know the detailed steps of 5S TPM Implementation, contact me through this blog or my email.

God bless!

AUTONOMOUS MAINTENANCE “Jishu-Hozen” Makina ko Aalagaan ko

MANAGING FOR GLOBAL EXCELLENCE:
AUTONOMOUS MAINTENANCE


DURATION: 2 Days (8 hours/Day)

TARGET AUDIENCE: Engineers/ Supervisors / Managers/ Plant Managers

PRE-REQUISITE: 7 QC Tools, Basic SPC, Introduction to TPM

COURSE DESCRIPTION:

Autonomous Maintenance is one of the major pillars of Total Productive Maintenance (TPM). It focuses on transforming machine operators to take care of their equipment raising their competence to perform activities that prevent forced deterioration of equipment and restores equipment to their desirable form. It also focuses on eliminating minor stoppages, and assists. It also addresses the speed of set-ups. Primary interaction on this pillar is between the operators and technicians. It entails changing mindsets of operators and eliminates boundary between operators and technicians. It is done in simple 7 steps through small group activities that also develop discipline, camaraderie, teamwork, high morale and a sense of accomplishment for all the members of Autonomous Teams.

Autonomous Maintenance can bring about higher machine utilization, thus, higher machine and operator productivity. This Autonomous Maintenance has gained momentum latter part of 1960’s in Japan and was introduced to the Philippines in the middle part of 1990’s.

This course is developed to introduce to all engineers/supervisors/managers/ plant managers, how to implement on a step by step the Autonomous Maintenance. In 2 days, the course will detail the 7 Steps of Autonomous Maintenance Implementation.

The course is also with Japanese origin as it is JIPM has been aligned to our Filipino culture based on the actual hands on experience of the course author. It will be highly interactive. Concept presentations, discussions, and group participation are integral part of the course. Hands on exercise will be a major activity.


COURSE OBJECTIVES:

At the end of the course, the participants should be able to:

• Better understand the Autonomous Maintenance (AM) function and purpose

• Learn and apply the preliminary steps for an AM launch

• Develop the initial skills and knowledge in implementing AM in the factory


COURSE OUTLINE:

 Brief Introduction to TPM- JIPM
 History and Origin
 Basic Terminologies and Definitions

 In-depth Understanding of Autonomous Maintenance
 Basic Composition and Functions
 KPI
 7 Steps
 Exercise and Workshops on each Steps

 Common Issues and Pitfalls of AM

 Relation of AM to other TPM Pillars

 Where and how do we begin?

Introduction to TOTAL PRODUCTIVE MAINTENANCE (TPM)

MANAGING FOR GLOBAL EXCELLENCE:
Introduction to TPM



DURATION: 3 Days (8 hours/Day)

TARGET AUDIENCE: Engineers/ Supervisors / Managers/ Plant Managers

PRE-REQUISITE: 7 QC Tools, Basic SPC

COURSE DESCRIPTION:

Total Productive Maintenance (TPM) is a Japanese approach to Overall Factory Effectiveness (OFE) . It encompasses all the Key Performance Indices of the company specifically on Cost, Productivity, Quality, and People Involvement. It is a comprehensive system that cuts across the entire organization. TPM ensures streamlined, focused and coordinated effort in achieving (OFE). It is simple and step by step and can be easily tracked and monitored to guarantee success. It also develops discipline, camaraderie, teamwork, and a sense of accomplishment for all the members of the organization.

There are many systems corporations can opt for, but TPM is a proven, methodical system applied all over the world on different types of industries. It is successfully implemented initially in Japan and has gained worldwide acceptance even in the USA and in European countries. One American company in the Philippines particularly used TPM as their system enabling them to be best in their class.

This course is developed to introduce to all engineers/supervisors/managers/ plant managers, new and experienced, how to implement a systematic and overall approach to factory improvements. The 3-day course will cover the 8 Pillars of TPM, its functions, how it must be organized and the detailed Steps of TPM Implementation

The course though with Japanese origin has been aligned to our Filipino culture based on the actual hands on experience of the course author. It will be highly interactive and will require an on-line assessment of current improvement systems being used by the factory as well as current issues and KPI’s the factory is monitoring. Concept presentations, discussions, and group participation are integral part of the course. Hands on exercise will be a major activity.


COURSE OBJECTIVES:

At the end of the course, the participants should be able to:

• Better understand the Total Productive Maintenance (TPM)

• Learn and apply the preliminary steps for a TPM Launch

• Develop the initial skills and knowledge in implementing TPM in the factory


COURSE OUTLINE:

 Introduction to TPM- JIPM
 History and Origin
 Basic Terminologies and Definitions

 8 Pillars of TPM
 The 8 Pillars
 Basic Composition and Functions
 KPI each Pillar addresses
 Exercise and Workshops on each Pillars

 12 Steps of TPM Implementation

 Common Pitfalls

 Need for TPM Promotion and Incentive Programs

 Transition Plans- Cross Over to TPM from existing System

 Where and how do we begin?