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1、5S活动培训教材活动培训教材1The 7 types of wasting 生产现场浪费的七种形式Wasting by1、Overproduction 过量生产的浪费2、Waiting time 等待的浪费3、Transport 搬运的浪费4、Work process 工作过程中的浪费5、High stock 大量库存的浪费6、Movement 移动时间的浪费7、Production errors 不良品的浪费21、Wasting by overproduction 过度生产的浪费 Accumulation of finished goods 成品的积压 Overproduction can
2、cause or intensify other types of wasting 过度生产会导致加大其他形式的浪费 Installation of standardized buffers 标准预留量的设定 Do not produce more than demanded 不要超过生产指令的要求产量32、Wasting by waiting time 等待的浪费 Employees without work / Low performance of employees 无事可做的员工 / 效率低的员工 Employees do only monitor processes 员工只做监督过程
3、工作 Delayed material supply 原料供应不及时 Visualize wasting through one piece flow 通过单件流将浪费改进 Cycle time production 生产周期化43、Wasting by transport 运输过程中的浪费 Time-consuming loading, unloading and repacking of parts 时间花费在装载、卸载和重新包装上 Needless transports, long distances 没有必要的搬运，长距离 Tools are not stored in one sin
4、gle space 工具不是放在一个单独的位置里Installation of u-shaped production lines, one piece flow 安装”U”型生产线，形成单件流Flow production 生产流程化Logisticians 定置管理54、Wasting by the work process 工作流程上的浪费Different work steps of employees员工不同的工作节拍Non-value adding process无价值的工序When machining parts employees use their hands to hold
5、 them当加工零件时，员工用手工操作Reduce unproductive movements减少无产能的移动Optimize clamping devices优化夹具Develop error prevention mechanisms机械化生产65、Wasting by high stock 大量库存的浪费 High stock volume / high costs of storage 大量库存 / 高价值库存 Parts are incomplete / Date on label is overdue 零件不全 / 不能保证先进先出 Reduce set-up time (SME
6、D) 快速换模改进理念 Reduce lot sizes 减少大量的中间缓冲空间 KANBAN control / Supermarket principle 实现看板管理 / 超市原则76、Wasting by movement 移动时间的浪费 Difficult access 复杂的工序 Multi-handling 多次操作 Employees have to stoop, stretch, turn around, etc. 员工需要弯腰、伸长、转身等Strictly follow best point principles 严格遵守最优原则Optimized clamping and
7、 holding devices 优化工具Standardized work flow 工作流程标准化87、Wasting by production errors 生产中产生的失误损失 Production of reject parts 不合格品 Rejected parts enter the following work step 不合格品进入下面的工作环节 Repairs, customer complaints 修理，客户投诉Check parts with special instruments(100% control) 特殊或专用检具检验部件Develop error pre
8、vention mechanisms (Poka-Yoke) 推广防错技术Standardize workflow 标准化工作流程”Master” the process 控制工作流程9The Method 5S 5S方法The 5 points of 5S are the basis of our work 5个基本要求整理Seiri整顿Seiton素养Shitsuke清洁Seiketsu清扫SeisoClearing out 整理Remove needless things at the workplace and its surroundings将工作场所和周围无用的物品清理掉Get o
9、rder整顿Keep needed material in order and ready to use保证有用的材料有序摆放，随时备用Clean up清扫Keep machines, equipment etc. clean保持机器、仪器等清洁Standardization清扫标准化Define standards on the basis of the improved condition以改善工作环境为基础制定标准Discipline素养Keep defined standards and constantly improve themMake an audit坚持制定的标准并不断完善需
10、检查Implement the method when designing and optimizing new waste-free workplaces and to prepare for the workshop当涉及和优化新的无序工作区域和新车间作准备时，照此方式执行101112131415The method 5SGoals of the 5S method 5S方法的目标 Clean and safe workplaces 清洁、安全的工作场所 Wasting by - search process 消除寻找产生的浪费 - equipment preparation 消除仪器准备
11、产生的浪费 - tool preparation 消除工具准备产生的浪费 - ways 消除工作方法中产生的浪费 - utilization of too many tools, etc. 消除过多工具使用产生的浪费 is eliminated Fast and early elimination of leakages and problems through fast identification 通过快速识别，更快更早地消除漏洞和问题 Improvement of workplace ergonomics 工作场所工效的提高 Minimization of - waiting time
12、使等待时间最短 - movement of pieces 使搬运部件时间最短使 - storage 使库存时间最短 - transport complexity 使复杂的运送时间最短16Examples for 5S 5S实例 Practical implementation of the 5S method 5S方法的实际执行方法的实际执行17Best point workplace design 工作场所的最佳设计At a best point workplace you may: use both hands 用双手 not walk 不过多走动 not stretch 不用伸手够东西
13、not lean forward 不用探身过去 not search things 不需找东西 not turn around 不用转身You are not supposed to adapt your work movement to the workplace. The workplace may be adapted to your work movement.你不要让工作移动来适应工作环境，而是应该让我们的工作环境来适应工作需要。1819Agenda for assembly cell AS单元工作流程1.Training about waste, 5S, Bestpoint 关于浪费、5S、要点的培训2.Check current situation 查看现场情况3.S1 Seiri - Sort out 整理4.S2 Seiton - Get order 整顿5.S3 Seiso Clean up 清扫2021
