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A safe and well-organised Workplace : The MODULAR 5S programme

Dr.  J. R. Thomas  Associates uniquely deliver 5 S training in a series of  progressive modules.

Introducing 5S in a modular way allows companies to manage their 5S programme in a way that suits their exact needs.

The timing of the next phase in the programme will be dependent on completion of actions identified in the previous module, thus allowing companies to progress at a rate that suits them.

Significantly, not everyone needs to be put through all the modules.

Standard training packages for all operators for example could mean commitment to just 2 of the initial modules. 

On the other hand, highly skilled individuals and initiative leaders could be put through all of the modules.

In this way :

COMPANIES CAN DESIGN AN UNIQUE 5S TRAINING PROGRAMME THAT MEETS THEIR EXACT NEEDS AND PROGRESS AT A PACE THAT SUITS THEIR SITUATION.

5S Before and after 1

 Modules are structured as follows :

  • Module 1 : Developing a safe workplace.
  • Module 2 : Organisation and Optimisation of the workplace.
  • Module 3 : Advanced asset care: “In-your-face Engineering”.
  • Module 4 : Quality through robust Visual management systems.
  • Module 5 : Developing safe and optimised working procedures.

A summary of the key objectives and outcomes from each module can be obtained by clicking on the following link :

5S taster

 Just one action plan throughout!

Another unique feature of this programme will be the continuation of an action plan throughout the programme.

The prioritised action plan developed in the first module to improve safety standards in the target area will be continually developed and enhanced by ideas generated during each  subsequent module.

Excellence model

In this way, a consistent improvement document is constantly updated with new ideas and managed by the team from start to finish.

 How will we provide this service ?

In addition to traditional face-to-face training courses and on-site mentoring, Dr. John R. Thomas Associates are able to provide this training using modern state-of-the-art communication methods tailored to the customer’s exact needs and at a pace that resources allow.

These can take the form of  :

  •  Live broadcast sessions.
  •  Webinars.
  •  Group tutorials.
  •  Self-study web packages.
  •  Licenced downloads.

… all tailored to the client’s exact needs and ability to free up people for training.

 

Client feedback on these courses…

From : Mr. Adrian Swindells , Managing Director Abbey Group,  Bedford.

“I have used Dr.John R.Thomas over a number of years as a catalyst for improved and sustained change across the 3 Abbey manufacturing facilities and in the support office functions. World Class manufacturing techniques and analysis have helped to improve the factory operations with safety and bottom line benefits and the world class techniques applied to the office functions have reduced administration time and improved customer service. The wealth of experience and the hands on approach have always ensured the teams are fully engaged.”

Client quote ..

Mr. Ken Wilson Managing Director Euramax Solutions Limited

“As I have moved from business to business I have always used John to introduce 5S and other World Class Manufacturing techniques.   John has the ability to explain the concepts in an easy to understand manner, usually aided with photos and real life examples.  John’s approach is very practical and I have always seen immediate results.  On repeat visits John has always kept himself updated and it’s a real advantage having John’s experience to learn from.   My operations managers usually can’t wait for the next tips and ideas.    For anyone at any level looking for the next efficiency improvement, I would have no hesitation to recommend John”

 

Client quote ..

Mr. Graham Coles, Plant Manager,  D.S. Smith Kettering.

“ Dr John’s programmes are a very easily accepted Paradigm within an engaged workforce, his concept can be tailored to bring out the best in individuals and teams, John always uses techniques to suit his audience”

 

Client quote ..

Mr. Peter White, Managing Director, Ralegh Integrated Solutions :

“Over the years Dr John Thomas has helped us at Ralegh Integrated Solutions to achieve a very high level of Work place organisation through encouraging us to look at what we do, ask if we need to do it and if it could be done better? John has the distinct knack of getting people engaged at any level within the organisation through his obvious knowledge and determined personality”.

 

 

The key objectives and outcomes from each module are :

 

UNIT 1  : 

Developing  a safe  workplace.

Safety management is the one non-contentious factor we can use for driving improvement initiatives: the W.I.F.M. (What’s in it for me!) factor!

bpm

The key outcome of this phase of the programme will be to :

1. Highlight the link between Safety and Performance in the workplace to encourage the attendees to use these concepts to come up with their own prioritised improvement plan.

2. Understand the importance of Auditing and evaluating the Safety standards prevalent in their work area.

3. Provide a ‘car parking’ flip-chart for areas that need to be addressed immediately after the workshop.

As such, the session will be a combination of training using visual images of good and bad practice and practical exercises focusing on the target area (Ideally the attendees own specific work area).

Lean concepts to be trained in this session :

  • Awareness of ongoing safety concerns.
  • Storage and access to firefighting equipment.
  • Access & location of emergency exits.
  • A place for everything – in safety terms.
  • Management of walkways.
  • Awareness and mitigation of trip hazards.
  • Awareness of guarding integrity.
  • Working at height : safe use of steps, gateways and ladders.
  • Safe use of storage racking.
  • Safety lock-off systems.
  • Systems for managing Fork Lift Truck activity.
  • Clear machine instruction labels.
  • Labeling of switches & control panels.
  • Management of First aid equipment.
  • Awareness and contact with 1st Aiders.
  • Management of sharps and spill kits.
  • Awareness of pipe work contents and flow patterns.
  • Management of oil leaks.
  • Environmental control measures.

 

Followed by Group exercise:

Delegates will be divided into groups for an exercise evaluating the current condition of safety systems deployed in their workplace using a simple template the results of which will later be shared with the wider team.

The key outcome of this phase is to get all attendees to develop a prioritised action plan and make measurable and visible changes to the safety standards of the target areas.
The improvements identified will be incorporated into a prioritized Excellence model action plan and will be integrated with the ideas developed during the 5S workplace organization session below.

Throughout this programme only one action plan is developed incorporating all of the improvement ideas from each unit of the training.

In this way the programme can be delivered at a pace that suits the client.

There is no defined timing plan between units – it depends on the resources available to the client to action the improvement ideas.

 

UNIT 2  : 

Organisation and Optimisation of the workplace.

The objective  of this training phase is to get the attendees to develop a prioritised action plan based on optimising the layout, storage systems and organisation of the workplace. At the end of this phase we aim to  realise measurable and visible changes to the look and performance of the target areas.

Lean concepts to be trained in this session…

i. Developing cleaning and checking schedules and the importance of maintaining them.
ii. Designing the optimal layout for the workplace : making the job easier!
iii. Organising the workplace for maximum efficiency : Runners, visitors and strangers.
iv. Developing the most effective storage methodologies.
v. Introducing Kanban systems for both material control and continued supply.
vi. Developing audit systems to ensure standards are maintained.
vii. The use of Excellence models for managing initiatives : Understanding the importance of having clear aims and objectives.

saig21

Throughout this Unit and Unit 1 the teaching resources will rely heavily on using Photographic and Diagrammatic Images: thus re-enforcing the Visual and Kinaesthetic (Learning by doing) learning methods felt to be the most appropriate to this target audience.

Followed by Group exercise:

Delegates will be divided into groups for an exercise evaluating the current condition of systems deployed in their workplace and encouraged to make suggestions on how these could be improved.
Each attendee will be required to carry out (as part of a team) a 5S Workplace organization audit of their own area using a structured template the results of which will later be incorporated into a prioritised Excellence model action plan.

The key outcome of this phase is to get all attendees to develop a prioritised action plan and make measurable and visible changes to the performance of the target areas.
The improvements identified will be incorporated into the action plan developed during the 5 S Safety session above. Throughout this programme only one action plan is developed incorporating all of the improvement ideas from each unit of the training.

saig 22

In this way the programme can be delivered at a pace that suits the client.

There is no defined timing plan between units – it depends on the resources available to the client to action the improvement ideas.

 

UNIT 3  : 

Advanced asset care : In-your face Engineering. 

This course is designed to sit in-between the basic 5S workplace organisation techniques and the more resource-demanding Productive Maintenance approaches.

It is designed to generate low cost/no cost improvement ideas generally based on visual management techniques.

Lean concepts to be trained in this session…

• Marking the proper operating settings and ranges on gauges.
• Effective storage, deployment and management of lubricants.
• Inserting see-through windows on covers of critical equipment to allow their condition to be monitored.
• Marking the proper direction of rotation on motors.
• Labeling replacement belt, filter, and chain sizes.
• Introducing retractable lines to ease access to services.
• Preventing mistakes by effective dial labeling.
• Refusing to tolerate electrical short-cuts.
• Colour-coding set-up and changeover parts for specific jobs.
• Colour-coding pipes and air lines (and their connections) to prevent mistakes from happening.
• Labeling pipes to indicate what they contain and their direction of flow.
• Labeling electrical and electronic wiring and devices to aid trouble-shooting.
• Match-marking nuts and bolts to visually indicate that proper tightness is being maintained.

saig31

Followed by Group exercise:

Delegates will be divided into groups for an exercise evaluating the current condition of Asset care systems deployed in their workplace and encouraged to make suggestions on how these could be improved.
Each attendee will be required to carry out (as part of a team) using a standard Asset care audit template a (accompanied) survey of their area to identify the opportunities that exist. They will then be required to draw up a prioritised action list.
The improvements identified will be incorporated into the Excellence model action plan.

The key outcome of this training is to provide attendees with an understanding that there exists a range of simple, low cost but very powerful tools for getting the best out of their equipment and realising major cost savings and quality/safety gains.

 

UNIT 4  : 

  Introducing robust Visual control systems.

Visual control are means, devices, or mechanisms that are designed to manage or control the operations (processes) so as to make problems, abnormalities, or deviation from standards visible to everyone : thus allowing corrective action to be taken immediately.
Visual control communicates very effectively the information needed for decision making.

Lean  concepts to be trained in these sessions…

• Building effective POKA YOKE mistake proofing systems.

• Introducing visual devices, or mechanisms that are designed to manage or control processes.

• Single point lessons.

• SMART cards with defined settings.

Followed by Group exercise:

Each attendee will be required to carry out as part of a team a (accompanied) survey of their area to identify the opportunities that exist. They will then be required to draw up a prioritised action list.
The improvements identified will be incorporated into the Excellence model action plan

The key objective of this phase is to increase efficiency and effectiveness simply by deliberately making things more visible.

Emphasis is put on incorporating as many photographic instructions as possible into the documents: thus re-enforcing the Visual and Kinaesthetic (Learning by doing) learning methods emphasised in this programme.

When things are visible, they are kept in the conscious mind. It also serves to ensure that everyone has a common viewpoint of what is being displayed.

The key outcome of this phase is to get the attendees to develop highly visible process control systems to enhance customer perception of the product and service being provided.

 

UNIT 5  : Developing agreed, safe and optimised working procedures.

Clear, visual Safe working procedures are the cornerstone of Safe and efficient workplaces since :

  1. They provide an agreed, defined reference standard.
  1. It makes People look at What and Why they do things: perhaps for the first time!
  1. They minimise misunderstanding and miscommunication.
  1. It provides a vehicle for long running disagreements to be aired.
  1. It allows for a line to be drawn in the sand: “this is what is inviolable!”
  1. They provide an excellent training aid.

Getting the Team to develop an Operating procedure can be one of the most valuable and beneficial exercises for ensuring consistent and safe working practices.

 Methodology :

Each attendee will be required to (as part of a team) generate the first draft of a safe working procedure or their process (or review the current document is one already exists).

  • The team then reviews this draft.
  • Any procedure improvements are agreed.
  • Further review until consensus reached.
  • Incorporating as many POKA-YOKE mistake-proofing ideas as possible into current working practices.
  • Any ideas for process improvement are recorded and incorporated into the Excellence model action plan.
  • The tasks are detailed and systematically broken down into their respective component skill sets.

In this way a detailed analysis is undertaken of the tasks required to do a job in the right way.

Emphasis is put on incorporating as many photographic instructions as possible into the documents: thus re-enforcing the Visual and Kinaesthetic (Learning by doing) learning methods emphasised in this programme.

Even if safe working procedures already exist for the operation this is still a valuable exercise because it ensures that every operator has studied and reviewed that document.

Training needs analyses are developed for each skill set.