6S is a standard in many facilities. This standard spawns from the Lean Manufacturing and Six Sigma standards of 5S. Of course, it adds one more characteristic to it: the sixth S, Safety. Back in 2006, I achieved a Green Belt in Six Sigma and Safety was mentioned a good amount as a driver for several of the processes. The fact Safety was not one of the fives shows two things, I’m getting older and getting closer to that age where I have been out of school longer than I was in; and Safety is and should be a top priority, maybe it always should have been.
In case you have never been introduced to Lean Manufacturing or Six Sigma, this principle focuses on a single piece flow and optimizing a work process to minimize the amount of time it takes. This increases efficiency in the manufacturing process and ultimately puts money back into the bottom line of the business.
The first S is Sort, you should remove anything that is not needed for the production process, this could be additional tooling or resources that are not needed for the specific work station or task. This prevents any kind of clutter or confusion on what is needed.
The second S is Set In Order, just like the photo above, every tool and bin should have it’s place at the work station. This helps operators find what they need when they need it. The outlines also give a visual indicator to any tool or device that may be missing and or in use. Again, it helps with the operators time efficiency and reduces risk of leaving a tool in a process.
Third is SHINE, every aspect of a work area should be cleaned up, sometimes this needs to be done throughout the shift and other times just at the end of the shift to put everything back in place and prepare for the next operator or day. When I worked in retail I would hear managers tell people, “You have time to lean, you have time to clean.” and while it isn’t the best approach, it is a true statement. This does contribute to keeping production running at high efficiency, being able to spot leaks or wear issues on equipment that aren’t caked in chips, grease, and used fluids. It can also aid with safety by preventing slips or falls from a leak or debris building up from a process.
Fourth, Standardize, this means all work areas should look the same, maybe not the exact same tools, or process, but any operator should be able to walk into a work station, read the documentation, and be able to function sufficiently. This also helps to keep the old ways of tribal knowledge from happening which will prevent changes and adjustments from not being documented and will help to reduce learning curves when changes happen.
Fifth, Sustain, this is one of the hardest. This means the standards that have been set in place are kept. Repetition is key in a scenario where 5S or 6S are being implemented and even where they have been set in place for a while. Revisiting the standards and ensuring they are aligned to production and operator needs is always good.
Sixth, Safety, this should always be at the forefront of any process. Being able to keep operators safe during a work day is always a high priority and one of the many ways to do that is to use the other five Ss to make sure that they can efficiently and safely work throughout their day.
Whether it is replacing open pipe blowoffs with engineered nozzles, cross drilled blowguns with Safety Air Guns, installing Line Vacs to help evacuate trim or debris, Super Air Amplifiers to cool down a part before it is being handled. I’ve even helped customers with custom length air hoses to ensure their operators can’t reach the air hose into a process too far in order to ensure operator safety. EXAIR is always focused on safety and ensuring our products help increase process efficiency. If you want to see how we can help you and your team, contact an Application Engineer today.
Brian Farno, MBA – CCASS Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF
