5S / Visual Factory

IPI Vision

A meaningful work opportunity for

every offender

2
 CI

CI - Supporting Tools
Continuous Improvement (CI)
• Standardization
– 5S
– Standard Work
CI – Total Productive Maintenance
Continuous Improvement
• VMM
– Visual management
– CI boards
– Layered process audits
VMM
Just PI – Smart Goals
In
Visual People • Continuous Improvement
Time
Managed Involvement
Metrics – Process Problem Solving
– Kaizen
– VSM
– Go See
Purpose of CI Tools
S • Standardize the system
Standardization
• Return the system to standard
3 • Improve the standard
Why did we do the 5S event?
What was the

FOR

OUR

????
 WE ACCOMPLISHED……
• Discovered roughly 400 square feet of
space that we can now use exclusively
for chemical production!
 CHEMICAL AREA
BEFORE AFTER
 What did we accomplish?
• Discovered roughly 400 square feet of space!
• Redesigned the RAM table area to
eliminate wasted motion.
 Ram table area
BEFORE AFTER
 What did we accomplish?
• Discovered roughly 400 square feet of space!
• Redesigned the RAM table area to eliminate
wasted motion.
• Combined the 2 GUI computers onto 1
desk to free up space and standardize
the location.
 GUI STATION
BEFORE AFTER

X 2!!
 What did we accomplish?
• Discovered roughly 400 square feet of space!
• Redesigned the RAM table area to eliminate
wasted motion.
• Combined the 2 GUI computers onto 1 desk to
free up space and standardize the location.
• Developed a plan to relocate the
apprentice clerk and training materials
to a better location
 CLERK OFFICE
BEFORE AFTER
 What did we accomplish?
• Gained approval to utilize the space in
front of the overhead door for soap
production!
 OVERHEAD DOOR AREA
BEFORE AFTER
 What did we accomplish?
• Gained approval to utilize the space in front of
the overhead door for soap production!
• Reduced the space for the staff desk on
the floor by roughly 50 square feet!
 STAFF SHOP DESK
BEFORE AFTER
 What did we accomplish?
• Gained approval to utilize the space in front of
the overhead door for soap production!
• Reduced the space for the staff desk on the
floor by roughly 50 square feet!
• Relocated a saw to improve safety and
reduce motion!
 TABLE SAW AREA
BEFORE AFTER
 What did we accomplish?
• Gained approval to utilize the space in front of
the overhead door for soap production!
• Reduced the space for the staff desk on the
floor by roughly 50 square feet!
• Relocated a saw to improve safety and reduce
motion!
• Removed 6 trailer loads of non-value
added items from the shop and old
soap!
 What did we accomplish?
• Developed a standard for Floor markings for
all IPI shops!
IPI Floor marking standard
 What did we accomplish?
• Developed a standard for Floor markings for all IPI shops!
• Started applying floor marking tape
Floors
Standard Floor Markings
 What did we accomplish?
• Developed a standard for Floor markings for
all IPI shops!
• Started applying floor marking tape
• Developed a standard for shop signage!
 STANDARD SIGNS

IPI DARK BLUE

WITH WHITE
BOARDERS.
Standard Signs
 What did we accomplish?
• Developed a standard for Floor markings for all IPI
shops!
• Started applying floor marking tape
• Developed a standard for shop signage!
• Established Visual metrics for the team!
 METRICS

Zero Zero DEFECTS 5 DAYS ORDER NO EXTRA STANDARD

RECORDABLES PASSED ON TO DOCK HELP NEEDED WORK WRITTEN
 LEAN THINKING is….
• Understand the differences between value
add and waste.
– What is the customer willing to pay for?
– Understanding what adds value to the product.

IF IT DOESN’T ADD VALUE ITS WASTE!

It might be necessary but it’s still waste.

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 WASTE

What does this monster we call waste look like?

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TIMWOOD = WASTE

Anything that does not add value to the

•Why is Lean important?
product for the customer is waste!

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Transportation WASTE
Transportation

•Why is Lean important?

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 Inventory WASTE

Inventory
•Why is Lean important?

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 Motion WASTE

•Why is Lean important?

Motion

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 Waiting WASTE

•Why is Lean important?

Waiting

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Over Production WASTE

•Why is Lean important?

Over production

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Over Processing WASTE

•Why is Lean important?

Over processing

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 Defect WASTE

•Why is Lean important?

Defects

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 What’s next?
• 5S audit schedule
• 5S task cards SUSTAINMENT MUST DO’s!
• Zone maps
• Install visual metrics board
• COUNTER MEASURE SHEET reviews
 What’s next?
• Floor repairs
• Walls painted
• Finish taping the floors
• Staff desk in office
• Platform for staff desk on floor
• Overhead door removal
• Enclosed dock proposal
 FEEDBACK
• Was it worth the time?

• What went well from your perspective?

• What would you do differently (if anything)

knowing what you know now?
Thank you!

• Great
participation

• Support

• Resources