Precast Inc. - July/August 2008 - (Page 41) Employees are typically assigned responsibility for portions of the work area sometimes referred to as zones. One person is given a zone to maintain, and he is responsible for keeping that area free of clutter, organized and clean. If the area does not pass inspection, he is held accountable for taking action to correct the situation. This results in a sense of ownership and pride in the work area. Also under the standardization tool, controls are put in place to create a visual workplace. This is a workplace using colors, signs, symbols and other visual indicators to reduce the possibility of errors within the process. Visual workplace is frequently used in safety programs by painting lines to indicate clear passageways. Warning signs with clear visual indicators where a dangerous situation exists alert the employees to this hazard. Visual tools also identify lockout conditions, spills, confined spaces, personal protective equipment requirements and many other safety conditions. With most visual tools, words do not need to be on the sign to communicate the message. As the culture changes and the new work procedures become a habit, the plant is transitioning into the sustain phase. During an OSHA audit, the audit sheets are analyzed to determine if the processes are being followed. If there are nonconformances found during the audit, then the process must be evaluated and changed if necessary. To effectively continue the habits of sort, set in order and shine, there must be a perceived benefit for maintaining the habits. The reward must be greater for doing things right than for failing to sustain the practice of 5S. For any change to be effective, the pain of “same” must be greater than the pain of “change.” The last element of 5S+1 is safety. If we become proficient at the first five S’s, then the final S, safety, will be improved. An evaluation of the OSHA Standards finds that many of them already embody the concepts of 5S. The General Duty Clause requires an employer to provide a workplace that is free of recognized hazards. Clutter in the work area is a hazard that can be eliminated. Putting tools away eliminates potential trip hazards. Clean work areas help to eliminate slip and fall hazards. The 5S+1 process is a system that is relatively easy to use in the workplace. It eliminates clutter and standardizes the way processes are done. When successfully implemented, the principles of 5S lead to improved safety. Hazards such as tripping over clutter or slipping on spills are greatly reduced. The workplace uses better visual communication in the form of signs or symbols. This makes it easy for anyone to spot abnormalities at a glance. At a time when bottom line results are the focus of so many companies, this is a system that is not costly to implement. And yet, the results of improved flow, higher productivity and fewer accidents result in a higher profit margin, a healthier bottom line and improved employee morale. Meanwhile, the home improvement show on TV is over and the garage is a mess. It’s time to organize it and be free of the clutter for a stress-free life. Sam Lines and Chuck Overbay are employed by Concrete Sealants Inc. in New Carlisle, Ohio. They are co-champions of the Lean Manufacturing initiative at Concrete Sealants. JULY/AUGUST 2008 | WWW.PRECAST.ORG 41 NPCA photo http://www.precast.org
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