You are quite right Okido the 5S's methodology is pure common sense. Also neatness, cleanliness etc. are natural human traits that some people do and some people don't possess.
Quality Manager
'Hello John, I want to start a project with production to de-clutter the factory and then implement some systems and disciplines to keep everything clean, neat, tidy and in its rightful place.'
Production Manager
'Uh…no time.'
Quality Manager
'What?'
Production Manager
'You know we ain't got time for all that crap Mary, we've got schedules to keep, we're down to the bare bones on capacity and I've got sales screaming in my ear about late shipments.'
Quality Manager
'I understand that John, but if we take a little time out to get ourselves better organised we might actually squeeze a little extra capacity out.'
Production Manager
'What the hell are you talking about while my men are shuffling bits of paper and taking brooms for walks, who's gonna be running my machines?'
Quality Manager
'How long does it take to do a tool change?'
Production Manager
'What's that got to do with it?'
Quality Manager
'Everything, how long does it take to do a tool change?'
Production Manager
'About 6 hours or so.'
Quality Manager
'Have you ever analysed a tool change to see what activities make up the 6 hours.'
Production Manager
'Mary I worked on the shop floor for 14 years, I must have done a zillion tool changes.'
Quality Manager
'I know you can do them in your sleep, but have you ever analysed a tool change to see how much time it takes to do each step - we may be able to reduce it.'
Production Manager
'Oh I get it ‘time and motion' my men are gonna love that. Look Mary we're doing that BS 5750 thing for you and its probably filling all those silly little forms in that takes up most of our time.'
Quality Manager
'How many tool changes do you do a month?'
Production Manager
'About 500.'
Quality Manager
'OK - 500 changes at 6 hours that's 3,000 hours a month. What if I said I could reduce it by a 1,000 to 2,000 hours a month? No extra equipment, no extra staff and nobody will have to work any harder.'
Production Manager
'So who do you think you are now David Blaine?'
Quality Manager
'I'm serious let me look at some tool changes and I'll show you what takes up the 6 hours.'
Production Manager
'The fellas ain't gonna like it.'
Quality Manager
'It's important we do this, I'll talk to them and win them over.'
Production Manager
'1,000 hours?'
Quality Manager
'At least!'
Production Manager
'OK Mary'
And so the 5S's programme begins…
Regards,
Simon