Lean and Environment Toolkit Training Modules: Lean and Environment Toolkit Training Modules Version 1.0 – January 2006 Next Page
Lean and Environment Toolkit Training Module 5: Lean and Environment Toolkit Training Module 5 6S (5S+Safety) Previous Page Next Page
Purpose of This Training Module: Purpose of This Training Module Learn why Environment, Health, and Safety (EHS) should be an integral part of 6S implementation
Learn how to identify EHS issues during the Sort process – the first pillar of 6S
Learn how to incorporate EHS into 6S inspections and audits of the Shine and Sustain pillars
What is 6S?: 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
More on 6S
The Six Pillars of 6S: 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 More on each Pillar
Relationship of the 6S Pillars: Relationship of the 6S Pillars
Why Should EHS be an Integral Part of 6S?: 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
TO CONSIDER: 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? Previous Page
Tools for Incorporating EHS into 6S: Tools for Incorporating EHS into 6S
Use yellow-tagging to identify EHS issues during the Sort process
Expand 6S inspections of the Shine pillar to include EHS issues
Expand 6S audits performed as part of the Sustain pillar to include EHS issues
Identify additional ways to implement EHS within 6S
Use Yellow Tagging to Identify EHS Issues during the Sort Process: 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
What is Yellow-Tagging?: 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
Designed to supplement red-tagging with key differences including the scope of projects, criteria used, and options for disposal or reuse
The Four Steps of Yellow-Tagging: 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
Step 1: Identify Yellow-Tag Targets…: Step 1: Identify Yellow-Tag Targets… Two types of targets should be identified:
The physical areas where tagging will take place
The specific types of items that will be evaluated
Potential items to consider yellow-tagging include:
EHS hazards in the workplace
Chemicals and other hazardous materials
Environmental wastes
…and Criteria: …and Criteria After choosing targets, criteria for evaluating yellow-tagged items needs to be agreed upon. This could include:
The risk of an item
The availability of alternatives
Opportunities for improved environmental performance
Step 2: Make and Attach Yellow Tags: Step 2: Make and Attach Yellow Tags Could be as simple as yellow sticky notes stating the reason for the yellow tag
Could also contain standard data that your company uses for tracking materials
Key is to include data that will allow your company to evaluate performance improvements from 6S and that will support your company’s overall materials tracking system
An Example of a Yellow Tag: An Example of a Yellow Tag
Step 3: Evaluate and Address Yellow-Tagged Items: Step 3: Evaluate and Address Yellow-Tagged Items If you find an EHS issue during yellow-tagging, ask “why” five times to identify the root cause of it
Then ask “how” to address the root cause
If an item is both unnecessary (red-tagged) and hazardous (yellow-tagged), follow appropriate procedures for disposal of hazardous wastes
If items are yellow tagged but not a red tagged (i.e.necessary but hazardous), find out if you can avoid the need to use those materials or if there is a less toxic alternative Ask “Why” 5 Times
Step 4: Document and Share the Results: Step 4: Document and Share the Results Document necessary information from the yellow-tagging process in a log book or other system
Track the improvements and savings that have resulted from yellow-tagging
Share your results with others to show what you have achieved and to generate ideas for future improvements
TO CONSIDER: TO CONSIDER
Name three types of items and three locations that you could target for yellow-tagging at your company.
What criteria would you use for identifying EHS issues with yellow tags?
Name three improvements or savings that would result from a yellow-tagging activity at your company. Previous Page
Tools for Incorporating EHS into 6S: Tools for Incorporating EHS into 6S Use yellow-tagging to identify EHS issues during the Sort process
Expand 6S inspections of the Shine pillar to include EHS issues
Expand 6S audits performed as part of the Sustain pillar to include EHS issues
Identify additional ways to implement EHS within 6S
2. Expand 6S Inspections of the Shine Pillar to Include EHS Issues : 2. 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
Particularly useful for the 10 Common Manufacturing Processes with Environmental Opportunities
10 Common Processes
Tools for Incorporating EHS into 6S: Tools for Incorporating EHS into 6S Use yellow-tagging to identify EHS issues during the Sort process
Expand 6S inspections of the Shine pillar to include EHS issues
Expand 6S audits performed as part of the Sustain pillar to include EHS issues
Identify additional ways to implement EHS within 6S
3. Expand 6S Audits Performed as Part of the Sustain Pillar to Include EHS Issues: 3. 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
Key Questions
Example 6S Audit Checklist with EHS Items: Example 6S Audit Checklist with EHS Items Click here for the full example checklist: http://www.epa.gov/lean/toolkit/app-e.htm
Tools for Incorporating EHS into 6S: Tools for Incorporating EHS into 6S Use yellow-tagging to identify EHS issues during the Sort process
Expand 6S inspections of the Shine pillar to include EHS issues
Expand 6S audits performed as part of the Sustain pillar to include EHS issues
Identify additional ways to implement EHS within 6S
4. Identify Additional Ways to Implement EHS within 6S: 4. 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 example:
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
TO CONSIDER: TO CONSIDER
How well do 6S inspections and audits assess EHS activities and performance in your company?
What approach might be most appropriate for incorporating EHS considerations into 6S assessment tools in your company?
Previous Page Previous Page Next Page
Reflections on Integrating EHS and 6S: 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 also 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
Reflections on Integrating EHS and 6S, Continued: Reflections on Integrating EHS and 6S, Continued
What did you learn from this training module that was particularly useful?
Do you need any more information to understand how to incorporate EHS into 6S?
Would any other tools be helpful?
EPA Lean and Environment Toolkit Training Modules: EPA Lean and Environment Toolkit Training Modules For more information about EPA’s Lean and Environment Toolkit Training Modules, visit: www.epa.gov/lean
EPA is interested in learning from organizations’ experiences with lean and environment, and welcomes your comments on this training module
Please contact EPA by using the form found at http://www.epa.gov/lean/auxfiles/contact.htm
Previous Page
More on 6S: More on 6S Based upon the five pillars (5S) of the visual workplace in the Toyota Production System
“Cleans up” and organizes the workplace basically in its existing configuration
Typically the starting point for shop-floor transformation
Provides a methodology for organizing, cleaning, developing, and sustaining a productive work environment
Encourages workers to improve the physical setting of their work and teaches them to reduce waste, unplanned downtime, and in-process inventory Back to Main Presentation Next Page
6S References: 6S References Hirano, Hiroyuki. 5 Pillars of the Visual Workplace. Portland, OR: Productivity Press, 1995.
Peterson, Jim, Roland Smith, Ph.D. The 5S Pocket Guide. Portland, OR: Productivity Press,1998.
Productivity Press Development Team. 5S for Operators: 5 Pillars of the Visual Workplace. Portland, OR: Productivity Press, 1996.
Productivity Press Development Team. 5S for Safety Implementation Toolkit: Creating Safe Conditions Using the 5S System. Portland, OR: Productivity Press, 2000.
Productivity Press Development Team. 5S for Safety: New Eyes for the Shop Floor. Portland, OR: Productivity Press, 1999. Back to Main Presentation Previous Page
Pillar 1: Sort (Get rid of it): Pillar 1: Sort (Get rid of it) Focuses on eliminating unnecessary items from the workplace that are not needed for current production operations
Uses visual methods such as red-tagging to identify these unneeded items
Involves evaluating the necessity of each item in a work area and dealing with it appropriately
Can help to reclaim valuable floor space and eliminate such things as broken tools, scrap, and excess raw material Next Page Back to Main Presentation
Pillar 2: Set in Order (Organize): Pillar 2: Set in Order (Organize) Focuses on creating efficient and effective storage methods
Arranges items so that they are easy to use
Labels them so that they are easy to find and put away
Can only be implemented once the first pillar, Sort, has cleared the work area of unneeded items
Strategies include:
Affixing labels and placards to designate proper storage locations
Outlining work areas and locations
Installing modular shelving and cabinets Next Page Previous Page Back to Main Presentation
Pillar 3: Shine (Clean and solve): Pillar 3: Shine (Clean and solve) Focuses on thoroughly cleaning the work area
Daily follow-up cleaning is necessary to sustain improvements
Enables workers to notice malfunctions in equipment such as leaks, vibrations, breakages, and misalignments that could lead to loss of production
It is a good idea to establish Shine targets, assignments, methods, and tools before beginning the Shine pillar Next Page Previous Page Back to Main Presentation
Pillar 4: Safety (Respect workplace and employee): Pillar 4: Safety (Respect workplace and employee) Focuses on eliminating hazards and creating a safe environment to work
Once the workplace has been organized and cleaned, potential dangers become easier to recognize
A separate “safety sweep” should be performed to identify, label, and deal with hazards
Safety measures can also be implemented in conjunction with strategies in the other five pillars Next Page Previous Page Back to Main Presentation
Pillar 5: Standardize (Make consistent): Pillar 5: Standardize (Make consistent) Used to maintain the first three pillars
Focuses on creating a consistent approach with which tasks and procedures are performed
The first step is to assign 6S job responsibilities and integrate 6S duties into regular work duties using tools such as:
job cycle charts
visual cues (e.g., signs, placards, display scoreboards)
checklists
The next step is prevention of:
accumulation of unneeded items
procedures from breaking down
equipment and materials from getting dirty
Next Page Previous Page Back to Main Presentation
Pillar 6: Sustain (Keep it up): Pillar 6: Sustain (Keep it up) Makes a habit of properly maintaining correct procedures
Often the most difficult pillar to implement and achieve
Sustain focuses on defining a new status quo and standard of workplace organization
Without the Sustain pillar, the achievements of the other pillars will not last long
Tools for sustaining 6S include:
signs and posters
newsletters
pocket manuals
team and management check-ins
performance reviews
department tours Previous Page Back to Main Presentation
Ask “Why” Five Times1: Ask “Why” Five Times1 Why are we using so much water? The parts need to be cleaned before painting.
Why do the parts need to be cleaned? The parts fail quality checks if they aren’t cleaned before being painted.
Why do the parts fail quality checks? The paint doesn’t adhere when part surfaces are not prepared properly.
Why do the surfaces of the part need to be prepared? The surfaces get contaminated with oils used in the previous process.
Why are oils used in the previous process? The oils are used to prevent corrosion during storage.
1Based on an example from Robert B. Pojasek, “Asking ‘Why’ Five Times,” Environmental Quality Management (Autumn 2000): 83. Back to Main Presentation
10 Common Manufacturing Processes with Environmental Opportunities : 10 Common Manufacturing Processes with Environmental Opportunities Metal casting
Chemical and heat treatment of materials
Metal fabrication and machining
Cleaning and surface preparation
Bonding and sealing
Welding
Metal finishing and plating
Painting and coating
Waste management
Chemical and hazardous materials management Back to Main Presentation
Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk: Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk Sort (Get rid of it)
Are potentially risky items and environmental wastes yellow-tagged?
Are all red-tagged items being disposed of properly, including those that must be managed as hazardous or universal wastes? Next Page Back to Main Presentation
Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk: Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk Set in Order (Organize)
Are material containers clean, stored off the floor, closed, properly stacked, and stored/staged in the proper areas?
Are all containers with chemicals or wastes covered or sealed when not in use?
Are all containers with materials, chemicals, and/or wastes properly labeled?
Are initial accumulation points for hazardous waste clean and organized, and do they have effective visual controls? Back to Main Presentation
Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk: Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk Shine (Clean and Solve)
Are any leaks evident from equipment, piping, tanks, exhaust lines, or other areas in the workplace?
Is air quality in the work area good, and free of dust, odors, and fumes? Are ventilation systems clean and unobstructed?
Are all drains in good condition, free flowing, unobstructed and properly labeled?
Are exterior locations near storm water drains and storm water retention areas free from garbage and debris?
Are garbage and recyclables collected and sorted correctly? Are recycling containers and bins free from extraneous materials? Back to Main Presentation
Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk: Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk Safety (Respect workplace and employee)
Are employees using the proper protective equipment when handling chemicals and hazardous waste?
Are lockout and emergency procedures posted and easily accessible? Back to Main Presentation
Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk: Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk Standardize (Make consistent)
Are standard work procedures documented and available for the area?
Are EHS management activities and procedures relevant to the work area integrated into standard work? Back to Main Presentation
Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk: Key 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk Sustain (Keep it up)
Are standard work procedures being followed?
Are workers in the area aware of chemical hazards associated with standard work tasks? Back to Main Presentation Previous Page