6S (Workplace Organization)

[Audio] PACTIV EVERGREEN 6S WORKPLACE ORGANIZATION PLAYBOOK PRESENTATION.

[Audio] Purpose and Imprtance What is the purpose of 5S + Safety ( 6S): To spot problems (abnormal condition) quickly and improve operational efficiencies as well as Environmental, Health & Safety. Why is 6S Important? Creates proper environment for standardized work. Encourages visual control & identifies waste. Places high value on EHS. Promotes employee satisfaction. A conditioning discipline for kaizen. Improve SQDCPP performance. Example: "What is 6S? ( pause) 6S is a process for creating and maintaining a organized, clean, high-performance and safe workplace. It is also a conditioning discipline for kaizen. Think about it, how are we going to have the discipline to maintain standard work or deal with oddities if we don't have the discipline to maintain a clean and organized workplace.".

[Audio] What is 6S? 6S is modeled after the 5S process improvement system designed to reduce waste and optimize productivity in the workplace by: - Creating and maintaining organization and orderliness. - Using visual cues to achieve more consistent operational results. - Reducing defects and making accidents less likely. » 6S uses the five pillars of 5S and an added pillar for Safety..

[Audio] The six pillars of 6S Sort (Get rid of it): Separate what is needed in the work area from what is not; eliminate the latter Set in order (Organize): Organize what remains Shine (Clean and Solve): Clean and inspect Safety ( Respect workplace and employees): Create a safe place to work Standardize (Make consistent): Standardize the cleaning, inspection, and safety practices Sustain (Keep it up): Make 6S a way of life.

[Audio] Relationship of the Six Pillars SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN SAFETY.

[Audio] Why Should EHS be an integral Part of 6S? Expanding the scope of 6S to include EHS concerns can help your company to: -Reduce the chance paint, solvent, or other chemicals expire before they can be used -Make defects less likely, so less energy and materials are wasted -Avoid productivity losses from injuries and occupational health hazards by providing clean and accident-free work areas -Meet or exceed your company's environmental performance and waste reduction goals.

[Audio] To Consider Name at least three ways your company could use 6S to improve its environmental performance and reduce wastes. What metrics could you use to track EHS improvements from 6S activities? What ideas do you have for improving your work area?.

[Audio] Sort Perform the Sort function of 6s. -Sort all items in the area and decide what stays and what goes. -Be sure to check with the proper associates before discarding any tools, tooling, cabinets or other potentially valuable items. -Red tag all items that the team believes are trash to allow the proper personnel to disposition or relocate to another area..

[Audio] Sort Continued Use the Red Tag process to tag any items that should be removed from the 5s area to be dispositioned (toss or relocate)..

[Audio] Use Yellow Tagging to Identify EHS Issues during the Sort Process -The objective of the Sort pillar is to identify items that are not needed in the work area and get rid of them -This is done through a process called red-tagging -A yellow-tag strategy can be used at the same time red-tagging takes place to identify any EHS issues.

[Audio] What is Yellow- Tagging? Yellow-tagging is a simple strategy used to: -Identify environmental wastes and items that may be harmful to human health or the environment in the work area. -Evaluate the need for these items • Evaluate potential alternatives for these items. -Address them appropriately. This is a supplement to red-tagging- key differences include the scope of projects, criteria used, and options for disposal or reuse..

[Audio] The Four Steps of Yellow-Tagging Identify yellow-tag targets and criteria. Make and attach yellow tags. Evaluate and take care of yellow-tagged items. Document and share the results..

[Audio] Example of a yellow tag. (drde ae) Itan urrber of Issue Qestim Divisim æspa-sibe: 1. 2. I-Ealth sdety cÜurn Envirmnvntd.

[Audio] Set in order: Perform the SET function of 5S. This is simply to "Set in order" or organize the items saved for the space you are 5S,ing. -Use shadow boards to organize tools or other items. -Use labels to describe the item and its location. "Every item has its place".

[Audio] More set in order examples. Set-in-Order.

[Audio] Shine Perform the Shine function of the 5S. This is simple, you want to clean all aspects of the work area. Go as far as to clean the tools that you put in shadow boards, the floor, cabinets, equipment, everything. The idea here is that a clean area is a safe area. Also, clean equipment is easier to see and troubleshoot. A clean floor removes the potential for slips, trips & falls.

[Audio] Shine continued The requirement is that aisle-ways are clearly marked. You can paint the aisle blue w/yellow lines (see below) but this is not required. If you already have painted aisles then just maintain them. If you do not, then you can use other means to clearly mark them. Do what makes sense for your facility..

[Audio] Vision How much lower would your energy bill be if your plant was kept this clean and free of debris and dust? How much more productive would your team be if they were allowed to invest the time and energy to 5S their work area and maintain this work environment? How much would your safety performance improve and cost decrease if your plant looked closer to this and all the pictures reviewed in this presentation?.

[Audio] Let's expand 6S Inspections of the Shine Pillar to Include EHS Issues -Shine activities include daily cleaning and inspection by workers in their work area. -Involve EHS personnel in developing specific inspection checklist items for each work area. - Questions should integrate EHS management procedures and waste identification opportunities into daily inspections..

[Audio] Standardize Create daily standard work using the SWIS format to describe the steps required to the keep the area cleaned and organized by the personnel responsible for the area. Develop SWIS (standard work instructions) documents. Hang laminated signs showing photos of how the space is expected to be left each day. Develop check sheets for the operators and Supervision to do daily inspections of the work space to assure compliance..

[Audio] Sustain Sustainment involves a Total Organizational effort to move from where we were, to where we want to be! To sustain we must train, teach and expect the new way of 5s to be our new normal. "Inspect what you expect" Be sure to Audit the process and hold associates accountable for sustainment of the new norm. Continue to look for ways to further improve the 5s area with more sorting, setting, shining and standardization to assure growth and sustainment..

[Audio] 6S Area Auditing: Use the std. 6S Audit Standard Work (see supporting material) Add layered auditing to your Leader Std Work for your Supervisor's, Unit Managers and Plant Managers Post in the area for the owners of the work space and all other to see the results. (include photos if possible)..

[Audio] Expand 6S Audits Performed as Part of the Sustain Pillar to Include EHS Issues Sustain activities include weekly or other periodic audits to assess progress with 6S implementation Involve EHS personnel in creating plant-wide inspection and audit questions and checklists Questions should ensure that environmental wastes and risk are routinely identified, properly managed, and eliminated where possible Questions can also be used to train 6S inspectors and auditors, or to provide background for a broader rating category.

[Audio] Here's a example 6S Audit Checklist with EHS Items..

[Audio] Identify Additional Ways to Implement EHS within 6S There are many small things you can do to incorporate EHS in the 6S process. Here are just a few examples: -Use low-toxic paint in white or a light color - this can help save lighting and energy costs. -Use different colored containers for hazardous waste, recycling, and other non-hazardous wastes. - Mark aerosol cans with colored dots to indicate where to dispose them. -Use environmentally friendly cleaning supplies..

[Audio] Reflections on Integrating EHS and 6S The 6S pillars work together to increase productivity, reduce defects, make accidents less likely, save time, and reduce costs. When expanded to include EHS issues, they can help reduce hazards and improve environmental performance. By explicitly incorporating EHS issues into all six pillars during 6S inspections, you can eliminate more waste and risk at your company creating a safer and more efficient workplace. Thank you for attending this presentation!.

Appendix.

Details of blue / yellow aisle way – Bedford Park1.

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