Facilitator’s Guide - Amazon Web Services

5S Workplace Productivity

Facilitator's Guide

Straighten

This important step is far more than "lining things up in straight rows." By the end of this module you'll understand why. A step by step guide to presenting Gemba Academy's 5S course to lean learners in all positions. This guide includes key points, discussion items, quiz questions and answers, and helpful tips. Using Gemba Academy's online learning content, any facilitator can use this guide to get teams of people started with 5S.

June 2017

Straighten

Preparation and Lesson Plan

Use this page to prepare for each training session.

Resources

? Gemba Academy videos ? Online quizzes ? Red tagging templates ? Audit templates

Prepare for a Successful Training Session

? Watch videos and complete quizzes on your own at least one day before the training session. ? Read this guide thoroughly and become familiar with the course content before presenting to

others. ? Prepare a suitable training room for your participants. ? Prepare a computer with internet access and a projector or large screen. Test all equipment

before the training session. ? Have your Gemba Academy username and password ready.

U:_______________ P:_______________

? Choose your quiz style. The most popular option is to use the online interactive quiz, answering questions as a group with open discussion. Another option is to print the PDF version and have participants complete the quizzes individually.

Training Session Outline

? Step 1: Introduce the session topic and content to the participants.

? Step 2: Play a video. ? Step 3: Lead a group discussion using this

guide. Review key points, ask prepared questions and have participants fill in the blanks in their workbooks. ? Step 4: Take the quiz and review responses. ? Step 5: Apply what has been learned in your workplace.

Choose Your Quiz Style

When questions come up, encourage other participants to answer. Responding to questions with "What does the team think?"

goes a long way to build engagement.

Helpful Tip

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Step 1: Session Overview

? Introduce the training topic. This module explains what Straighten is, why it's important, the three-step process to Straighten, and the Three F standards.

? Explain what to expect during this session. In this session, we will: ? Watch "Straighten" (12:00) ? Discuss what we learned from the video using the workbook ? Review the content with a quiz and talk about the results ? Watch "FedEx Office Straightening - Desk" and "Closet"

? Before you begin... ? Review the progress your participants have made on their 5S area. How did they Red Tag the area? What are they planning to do with their Red Tagged items? ? Ask your participants what they think "Straighten" means. Discuss their definitions.

Step 2: Play "Straighten" Video

Pause the video at 9:18. See how many point-of-use items you can find, and discuss how the set-up at this particular machine might be improved.

Step 3: Review Key Points

What is Straighten?

? Straighten means to arrange all necessary items to maximize the economy of movement, or to place the things we use the most close by in a clearly labeled and designated place.

? When we Straighten, we need to ask "what's the right place for the items we use most?" ? A key mantra of Straighten is "a place for everything, and everything in its place."

Why is Straighten Important?

? Straightening alleviates and in some cases eliminates the frustration caused by searching for items in a disorganized workplace.

? Straightening also reduces inventory: Straightened items don't get lost, since they all have a place, and corporations don't have to keep buying extra supplies.

? Straighten is also at the core of several Lean and business principles, such as safety, ergonomics, quality, inventory control, productivity, standard work, the visual workplace, and employee morale.

The Three-Step Process to Straighten

1. Understand the current situation. ? Analyze how people do the work, how long it takes them, and what they use to do it.

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? Study both veteran and new workers to see if there are any differences. ? Look at the distance they travel to their tools and supplies, the frequency certain tools or

supplies are used, and the time required to get and put away items. ? Observation must be done at the gemba, or the place the work is done. 2. Decide where things belong based on this understanding. ? Ask "what's the most natural place for that item that creates the smoothest flow possible?" ? Label things clearly and identify boundaries, using either paint or tape to denote boundary

lines. ? Use "Point-of-use" storage; having materials located close to the process where they will be

used will make things safer and more efficient. 3. Determine how they should be stored.

? Just because things are easy to locate doesn't mean they're easy to retrieve: items stacked on the floor, for example, are easy to find but difficult to obtain.

? Simple racking goes a long way to keeping things organized. ? "Shadow boards" make it easy to identify when tools or parts are missing, as well as allow

people to quickly retrieve items. ? Adding wheels to storage units can also make storage units much easier to move efficiently.

The "Three F" Standards

? Proper storage takes three things starting with "F" into consideration. ? FIXED Location: everything should have a dedicated location and not "wander". ? FIXED Item: a place for everything, and everything in its place. ? FIXED Quantity: only a pre-determined amount of items can be stored; no mound-hills are

allowed.

Step 4: Quiz

1. The Straighten step simply means to arrange things in neat rows. True False

2. A good definition of Straighten is, "a place for everything, and everything ___________." on shelves in its place where no one can see it in drawers

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3. What are some of the reasons we do the straighten step? Select all that apply. Removes frustration of searching Increases cost Can reduce inventory Makes things easy to find and return

4. List these Straighten steps in the correct order. _2_ Decide where things belong _3_ Decide how things should be stored _1_ Understand the current situation.

5. "Materials, tools, and parts located close to the process they will be used" best describes what principle?

Pull Point of Use Jidoka One Piece Flow

6. Labels, shadow boards, and painted boundary lines are all excellent tools and techniques used during the straighten step.

True False

7. Which is not one of the "Three F Standards" used to describe proper storage techniques. FIXED Authority FIXED Quantity FIXED Location FIXED Item

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