5S in the Foam Plant

A few years ago, Commodore undertook an initiative to implement 5S in both of our divisions.  Looking back on the process, it is interesting to see how the changes that 5S brought have become routine here at Commodore.

5S, for those not familiar, is a method of workplace organization.  Originating in Japan, each of the five S’s relate to a part of the organization process.  Here is a brief summary of the 5S’s:

• Sort:  Removing all nonessential items from the work place.
• Straighten:  Arranging all tools and equipment in a manner that promotes work flow.
• Shine:  Keeping the workplace clean; and more importantly, putting things back in designated places so they can be found when needed.
• Standardize:  Consistent work practices; operating in a consistent fashion.
• Sustain:  Maintaining focus on the previous four S’s.  

While we use 5S here at Commodore Technology, our sister company, Commodore Plastics, has benefitted greatly from the use of 5S.  Most noticeably, we have had measureable improvements in downtime reduction, and the cleanliness of the plant is outstanding.

One key area where 5S was first implemented was the foam roll storage area.  Before 5S, foam rolls were set in the warehouse for aging in whatever order they were produced.  While this would not be a problem if all of the rolls were the same, our multiple sheet types meant that it could become very difficult to locate the correct rolls for any given thermoformer run.  Today there is a system in place that keeps the foam in a dedicated space (sort) where it is arranged by sheet type (straighten).  Maintaining the warehouse in an orderly fashion (shine) and always following the procedures for storing the foam (standardize) means no more downtime while our operators are waiting for the correct material.  As this system has become a normal part of our routine, we are aware of the need to keep at it (sustain).

Although implementing 5S can be challenging, in some ways the most difficult part of the 5S method is sustain.  Human nature tends towards reverting back to old methods and practices.  One useful tool that is a part of our routine is the 5S Checklist.  Performing daily and weekly audits using checklists ensures that all of the elements of 5S are being consistently applied.  Here is a copy of the daily checklist for the foam warehouse:

As you can see, there are numerous items that get reviewed each day.  Thanks to the checklist, any deviation from the 5S standards can be quickly identified and corrected.  Problems are documented, and over time we can see if there is a particular issue that needs futher evaluation or a change in procedure.  Another aspect of the 5S and the use of the audit checklist is that we can score the performance of the plant personnel against the 5S standard.  We have not only created a cleaner, safer, and more productive work environment, but we have the tools to measure our employees' performance against the standard.

In a future post I will discuss some details about how we use the 5S performance data as a part of our employee incentive program.  In the meantime, let us know if we can help you in any way, whether with your 5S initative, or any other aspect of your plant operation.