Environmental Studies.pdf

Environmental Studies UNI122 Learning Outcomes By the end of this unit students will be able to:  Implement waste minimization techniques in the engineering workplace.  Make improvements to workplace organization using a workplace scan.  Employ methods of visual management in th...

Environmental Studies UNI122 Learning Outcomes By the end of this unit students will be able to:  Implement waste minimization techniques in the engineering workplace.  Make improvements to workplace organization using a workplace scan.  Employ methods of visual management in the engineering workplace. Lean Six Sigma Approach Lean Six Sigma Approach a team-focused managerial approach that seeks to improve performance by eliminating resource waste and defects, as well as deviations from standards. What are 5 steps for Six Sigma? What are 5 steps for Six Sigma? 1- Define the problem. Craft a problem statement, goal statement, project charter, customer requirement, and process map. What are 5 steps for Six Sigma? 2- Measure the current process. Collect data on current performance and issues. Verify that the data is reliable, and update the project charter as needed. What are 5 steps for Six Sigma? 3- Analyze the cause of issues. Examine the process and data that was collected, display the data, investigate and confirm what’s causing the issues, and continue updating the project charter as needed. What are 5 steps for Six Sigma? 4- Improve the process. Decide on solutions to fix issues and create process maps for those new solutions. Take steps to implement the new fixes and continue to measure improvement. What are 5 steps for Six Sigma? 5- Control. Refine the new process, continue monitoring, and use findings elsewhere in the business, if possible. 5S Technique WHAT ARE THE 5 BENEFITS OF A 5S SYSTEM? WHAT ARE THE 5 BENEFITS OF A 5S SYSTEM? Creating space within your facility by removing unnecessary tools and equipment WHAT ARE THE 5 BENEFITS OF A 5S SYSTEM? Reducing downtime and improving quality by consistently maintaining equipment WHAT ARE THE 5 BENEFITS OF A 5S SYSTEM? Reducing waste from unnecessary motion by organizing the workspace WHAT ARE THE 5 BENEFITS OF A 5S SYSTEM? Engaging operators by granting them more responsibility for their work environment WHAT ARE THE 5 BENEFITS OF A 5S SYSTEM? Creating a safer work environment by ensuring it is clean and well-maintained 1- SORT What Is Sort? The Sort step separates items in your workspace that you know you need from items that you do not or may not need. Move the latter to a “red tag” holding area. Why Do You Need Sort? Sort enables you to have a more productive workspace by removing unneeded clutter (and eliminating distractions). It also is a first step towards opening up space that can be used for other things. Sort Items needed in this work area. These are items you know that you regularly use in the context of this work area and thus will stay in this work area. Items needed in another work area. These are typically misplaced items. If an item is used in another work area, “sort” it into that area by delivering it to the team member responsible for that work area. Items you may need. For items you are unsure about, use the 5S “red tag” system. Mark such items with red tags, which at a minimum, should include the name of who tagged the item, why it is thought to no longer be needed, a proposed review date, and the name of the manager who must approve of disposal. Move the item to a red tag holding area, which should be organized by review month to make it easy to manage the area. Items you do not need. These are items that you are 100% confident are not needed. They should be immediately discarded, recycled, or donated, or sold if in good condition. Examples on SORT Remove waste from your workspace. Discard broken or old parts using 5S red tags. Responsibly recycle materials and papers. Separate everyday tools from special-case tools. Avoid overfilling your workspace with excess materials. Create an overflow area outside of the workspace for duplicate materials, tools, and parts. Straighten (set to order) What Is Straighten? The Straighten step thoroughly organizes the items that remain after sorting, making frequently used items easily accessible and providing every item a clear and easy-to- find home. Why Do You Need to Straighten? Straighten enables every item to have a specific home where it can be easily found and to which it can be easily returned. It reduces the waste from excess motion, as items are placed in more ergonomic locations. It is also the second step on the path to opening up space that can be used strategically toward the goal of improving production. Straighten Provide easy access to frequently used items. The key to reducing waste from excess motion is to place frequently used items within easy reach. Group like items. Group the remaining items into logical categories and brainstorm the best way to organize and store each of these categories. Utilize visual designs. For each group, decide on the best way to make it clear when an item is missing or misplaced. A classic example is creating a shadow board for tools. Use containers. If it is appropriate for the type of item, consider organizing it within a container. Unleash the labeler. If an item is too big to put into a container, consider giving it a frame and putting a label on the item in addition to the frame. Be agile. Your initial straighten pass will likely deliver a significant improvement - but you are also likely to overlook some potential improvements. Plan a 5S team meeting with a focus on straightening at the one and two week points, and brainstorm further improvements as part of your initial implementation. Examples on STRAIGHTEN Give every item a distinct “home.” Use color as a way of organizing and creating meaning. Integrate shadow boards and other visual indicators into the plant floor. Dedicate a surface or area entirely to shadow boxes and tool storage. Dedicate another surface or area entirely to working. Shine What Is Shine? The Shine step elevates the work area by ensuring thoroughly cleaned and inspected tools, equipment, and other items. It also can include routine maintenance on equipment, Why Do You Need to Shine? Shine creates a work environment that engages and empowers operators by giving them more responsibility and agency over their work area. It also helps them to identify problems before they interfere with production. For example, in a clean work environment, it is much easier to spot emerging issues such as fluid leaks, material spills, metal shavings from unexpected wear, hairline cracks in mechanisms, etc. SHINE Grab the metaphorical spray bottle. Using appropriate cleaners and cleaning tools, make the work area sparkle. With every sweep, mop, brush, wipe, wash, and wax, strive to return your workspace to its former glory. Be Miyagi. Find the source. The guiding principle of this 5S step is “clean to understand”. If there are any signs of leaks, spills, or unexpected debris, strive to understand the source. It is likely an early warning of a future problem. Inspect. After cleaning each item, take a moment to look it over and examine its condition. Does it need updating, maintenance, or repair? Examples of Shine Wipe down equipment. Examine the wear of your tools. Disassemble larger objects to inspect the state of their parts. Investigate a recurring unclean spot or mess. Make sure to follow proper cleaning procedures to prevent damage to equipment. Standardize What Is Standardize? The Standardize step is a bridge between the first three 5S steps (Sort, Straighten, Shine) and the last step (Sustain). In this step, your goal is to capture best practices for 5S as standardized work for your team. Why Do You Need to Standardize? Standardize makes 5S repeatable. It transforms 5S from a one-off project to a reproducible set of activities. Standardize Document in pairs. Have one team member walk through each 5S task as another team member documents it to ensure nothing important is missed. Capture the essence. We are huge proponents of simplicity (and agile). Capture the essence of each task and no more. Otherwise, your documentation will be difficult to maintain. Prefer checklists. Checklists feel easy. Short checklists feel even easier. A great format is providing a name for each task that serves as a quick reminder and a more detailed description for training. Organize to simplify. Organize your checklists by role, by shift, and by frequency (daily, weekly, monthly). This will make the 5S process much less intimidating to your team. Examples on Standardize Write down your 5S practices. Create “implementation” checklists and “audit” checklists. Create “kits” that contain the materials needed to perform a specific task. Use photos and other simple visuals as part of your training materials. Build a schedule for tasks.