Any sensei would tell you to start with 5S before starting your lean conversion process. So, I’m starting my post with 5S. 5S seems to be simplest of things to do but toughest thing to do when the rubber hits the road. It takes a lot of discipline and conviction to keep things clean and in order. I have been doing for long enough to know that it’s easier said than done.
As I tried different ways and failed, I learnt something; we humans are not wired for 5S. Human mind chooses the path of least resistance. If the path of least resistance to throw your tools in a drawer and then hanging it up on a shadow board we will do that. The other thing is a corollary of Parkinsons law. The orginal law says “Work expands to fill time”. Our 5S version of that would “Flat space gathers crap”. Leave a small flat space in the cell, things will find a way to it. This applies to hidden spaces too. The larger your office table the messier it gets. Personally, I found this to be true. I got rid of couple of cabinets, book shelves and document holders from office couple of months ago. Since I do not have any place to hoard my papers, I have been more productive in trying to finish things, instead of letting them wait.
If you really want to make your cells maintain their 5S, design it in such a way where the path of least resistance is where you want your tools to be. Here are some things that we did in one of our kaizens:
1. No more cabinets. Everything inside a cells stays on a open shelf
2. If something needs to stay in a cabinet, use plexiglass cabinets
3. If it’s an assembly cell, have flat space to build the product only. Rest of the tools and jigs should be on holders (It takes a lot of work but worth it)
4. If you have equipments inside the cell, they will have a flat space on top. Build a roof on top of those equipments so that nothing can stay on top
The cell stayed cleaner than most others cell at least until I left that plant. You still need some level discipline to sweep the floors and wipe the equipments every day. The best suggestion that I can offer is to be patient. It takes at least a month to form a habit. Start with one habit at a time. It is easier for you keep track and for the associate to form a habit. There is something that I learnt from my Mom when it’s come to cleanliness. She would yell at me if and when I walk into the house with dirty legs. If you see someone not cleaning, do what my did to me – tough love.
As I tried different ways and failed, I learnt something; we humans are not wired for 5S. Human mind chooses the path of least resistance. If the path of least resistance to throw your tools in a drawer and then hanging it up on a shadow board we will do that. The other thing is a corollary of Parkinsons law. The orginal law says “Work expands to fill time”. Our 5S version of that would “Flat space gathers crap”. Leave a small flat space in the cell, things will find a way to it. This applies to hidden spaces too. The larger your office table the messier it gets. Personally, I found this to be true. I got rid of couple of cabinets, book shelves and document holders from office couple of months ago. Since I do not have any place to hoard my papers, I have been more productive in trying to finish things, instead of letting them wait.
If you really want to make your cells maintain their 5S, design it in such a way where the path of least resistance is where you want your tools to be. Here are some things that we did in one of our kaizens:
1. No more cabinets. Everything inside a cells stays on a open shelf
2. If something needs to stay in a cabinet, use plexiglass cabinets
3. If it’s an assembly cell, have flat space to build the product only. Rest of the tools and jigs should be on holders (It takes a lot of work but worth it)
4. If you have equipments inside the cell, they will have a flat space on top. Build a roof on top of those equipments so that nothing can stay on top
The cell stayed cleaner than most others cell at least until I left that plant. You still need some level discipline to sweep the floors and wipe the equipments every day. The best suggestion that I can offer is to be patient. It takes at least a month to form a habit. Start with one habit at a time. It is easier for you keep track and for the associate to form a habit. There is something that I learnt from my Mom when it’s come to cleanliness. She would yell at me if and when I walk into the house with dirty legs. If you see someone not cleaning, do what my did to me – tough love.