The 5S Simulation EventThe intent of the 5S Simulation event is to sequentially define the terminology of 5S one "S" at a time. The event centers on an interactive approach using a menu driven PowerPoint presentation used to describe the logic, the tools and the methods used to implement each "S" intermixed with hands-on participation experimenting with the tools of the "S" and implementing the "S" in the simulated factory or office setting. The goal is to assemble a product before, and again after, the 5S process to demonstrate the improvements possible with an uncluttered and a carefully designed work space optimized for flow.
The 5S Kit contains a large table covering approximately 40"x60" upon which to use markers and tape to create the factory floor layout with aisle ways, doors, and rooms to simulate product flow scenarios. Alternately and office or any other work space could be simulated. Included in the kit are several types of materials to store, transport, and locate items inside the simulated workspace.
The "natural organization" of placing the materials anywhere that feels right becomes the starting point as the participants attempt to efficiently assemble a product. There are both necessary and unnecessary “extra” materials and tools for the Sort process, some of which are in between, i.e. usable but not always necessary to the assembly stage. This leaves the decision with each team to determine what is actually needed or wanted. Thus the use of Red Tags and the Red Tag storage area becomes real as participants make decisions about their work requirements. They can put items in or take them back out if they feel one item is better suited than another as they work - just like the real Red Tag process. The location of shared tools and Shadow Boards is also put to the test as participants must find the ideal location for the needed items. A Brother PT-1090 label maker comes in handy as items are located and identified with their Home Address.
Red Tags, boarder tapes, markers, and laminated place-mats for drawing outlines and other materials provide resources for the team to design their work space using the 5S concepts to improve flow.
The "5S organization" is sequentially implemented and the tools of 5S are practiced at each stage. Once the first 3 steps are implemented, the product is once again assembled only this time with a much noticeable ease in location; just the right materials; and proper tools to do the job.
The final two "S" steps are then explored using the PowerPoint presentation and the sample metrics and weekly monitoring charts used to standardize and sustain the process.
Refer to the 5S Simulation Plan to review a suggested order of the presentation materials and events delivered with this product.The 5S Simulation FAQ Question 1 -- What are the products that come standard with the kit?
Answer 1 -- The 5S Simulation kit includes two sets of materials which can be used to build either the Product A or Product B toys. The standard 5S Package includes the Helicopter and ATV, but can be ordered with any choice of available product kits. For example, the Excavator and SideCar each are performed with just two people (bench #1 and bench #2) The black mats are the “bench” and their purpose is to provide a working surface to contain the screws and small items from rolling onto the floor. Because there are two complete sets of erector materials, you can have two or four participants, two in each “team” working in parallel – which creates a bit of competition and fun. The Excavator and SideCar can be built at the same time - they use tools and like materials in common, but each is a complete set. The 5S Simulation Kit creates a flexible simulation that can accommodate between 2 and 4 participants with hands-on assembly activity, but additional participants can be utilized to perform other 5S activities such as color code design, shadow board creation, and labeling and organizing the product materials. Some facilitators use the same product for both the before and the after build event, and some switch out people such that the first build observers become the second build hands-on people and visa-versa. The first build should be performed with the participants just “dumping” the materials and tools onto the table and organizing them in whatever random way seems suited to them. This is the “natural technique.” The build should require quite a bit of time. Some facilitators time the build and limit it to something like 15 minutes. The product is probably not completed in this time. The second build is after you have created an organized work space, with tools selected and on shadow boards, the excess items “red tagged” and off to the side, and the product materials sorted. The build is then much faster – and usually the product is completed in the allotted time, showing the power of 5S. If the same people will perform both assembly events, then having them build the Excavator first and the SideCar second keeps them from memorizing the assembly process and still shows that a complex assembly can be build in less time when 5S is utilized. If your participants usually work in a mixed-mode product environment, then setting up the factory for both models can also be explored with the additional supplemental kits and you can experiment with those types of organization techniques. Maybe have two competing teams each set up a mixed-mode layout and then tell them which model to build and time them. See which team did the better 5S layout.
Question 2 -- In the main kit I already have a kit bag of materials, 4 black rubber mats and one set of standard process instructions for each product. So could you please advise when I might need to use a supplementary kit?
Answer 2 -- The supplementary kit contains another set of product materials, tools and excess parts along with instruction place-mats and with the "Product A" kit more black rubber bench material. The additional materials add more participants to the hands-on build portion of the event (and some more red-tag items) You only need the supplementary kit when the number of participants becomes larger than can be accommodated by the standard kit, or to provide change-up variety to the events to keep them fresh between training sessions. Supplementary Kits are made from products such as the Boat, the Snowmobile, the ATV, the SideCar, the Helicopter, the Excavator and the RaceCar / Forklift kits. These supplemental kits are available separately under the replenishment supplies tab to expand team size and number of hands-on participants.
Question 3 -- Ref. Slide 38 of facilitator guide. I’m not sure what the final factory layout should be. Should it be set out to assemble both product A and B or just one (the photo on slide 38 suggests a set up for assembling product A only)?
Answer 3 -- The 5S Simulation Kit is designed to be very flexible, but that also makes it a bit vague at first. If you are using 8 to 10 people I would stay with just one of the product models and design the factory layout for optimizing that one model. The “finger fumble” is different for each model and the participants may have a preference for the parts they like to work with.
After you have gone through it once it will make more sense, but remember the goal is not to build the product – it is to understand the value of the 5S principles in organizing the workplace. Some teams have gotten so caught up in the fun of building the models that I had to drag them back to the presentation and discussion of the 5S principles – but as long as you are seeing them think and discuss the difference between natural layouts and 5S layouts then the event will be a success.
Question 4 -- What is the recommended sequence of events using the 5S Game and the 5S Simulation?
Answer 4 -- I usually start with the 5S Games because this gets the participants used to the terms. Then when I go through the presentation, they already have some idea of what the meaning of each principle is about. The practice segments where they create the factory layout on the plastic table cover and design color codes, create shadow boards and sort using red tags links the physical hands on and tactile feel to the words they have heard. Hopefully – by the time they get back to work they have a good idea how to begin applying 5S to their own workplace. See the link to the 5S Plan sheet on the 5S Simulation Event tab.
Question 5 -- I received several tools, some only one piece while others seem to be multiples. Should each participant get their own tool set?
Answer 5 -- Think of how work spaces evolve over time. They collect a random set of items that are needed; some that could be used based on preference, and some that have little or no use. The idea behind SORT is to minimize the clutter to just what is needed. In most cases tools can be shared on a shadow board located between two participants. The tools supplied fall into one of the three categories. It's up to the participant to discover what is necessary. If not certain about a tool, hold it in the Red Tag area until you are sure.