Merry Christmas! I know loads of folks won’t see this because of the holidays, but I’m trying to be consistent.
We’ve come a long way in reverse, walking backwards through the 5S’s. Today let’s talk about Set in Order. This comes out of the Japanese Seiton which technically applies more to neatness than order, but the end result is what we’re after. One simple and great example of Seiton is a parking lot. All it is, really, is a bunch of lines painted on the ground but imagine a parking lot with those lines missing. Sure, there are real life examples of this – going to a fair where the parking lot is actually just a field. The parking in that field, however, is managed by some folks with batons or flags guiding cars into lines to park. How would a parking lot operate day after day with no striping and no direction?
There are 3 elements to consider when applying Set in Order – where do things belong, how will they get put away, and how can this be made simple or intuitive – or easy to maintain?
Observe
Start by watching how equipment and material is used in the space. If more than one person is looking for the same tool, another tool will be needed. If a process uses tools and material in a specific sequence, i.e. press on a label using an iron, then flip the garment over to cut loose threads, then pin two parts together with a plastic rivet, the tools – iron, scissors, rivet gun – would line up right to left (product movement from right to left). When watching the process observe where the operator’s hands naturally go. If a tool consistently lands in a specific area, dedicate that area to the tool.
Right place
Are parts, tools, or materials in the right place? Sure, it’s handy to have the entire bin of fasteners nearby, but is that the best use for the space? Maybe the fasteners should come in by a kit – this both reduces extra things in the space AND improves inventory control. Look for places where inventory is being kept and single part flow could replace inventory. More than one part in hand is too much, and in general keeping inventory in situ can lead to loss of inventory control. Some things need to be available immediately, some things should be available “as needed” and might be located farther from the Gemba.
Labels
Everything should be identified and have a home. Each home should also be identified so the new kid on the line can find things and know where they belong. We discuss labelling in depth in the 4th S – Standardize, but in this S you need to know what things need to be labelled. You cannot over-label, the space should be very clear what things belong where both for operation and cleanup. When you are finished with all 5 S’s it should be easy to see what you have on hand AND what is missing.
Your wallet
When thinking about Set in Order, think about how the operators use the space and how to know if everything is where it should be. Think about your wallet. If I asked you to check your wallet your hand would go instinctively to the place where your wallet ALWAYS is. That place may change depending on the pants or purse you have today, but you know exactly where that is and you know immediately if your wallet is absent. You want the same functional location for tools in this space. You want to have things exactly where they should be, and you can tell right away if one of them is missing.
Walk the line
Finally, take the time to walk the line. Does each station have what is needed without having to “borrow” from a neighboring station? Is there a place for work in process to land, and a place for WIP to leave? Watch the operators after everything has been set in place – is everything flowing better, less fumbling and searching? When the team wraps up, does everything go back where it should?
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