por We explain what Seiketsu is, its characteristics, benefits, how to implement it and we give several examples.
what is the Seiketsu?
He Seiketsu (standardization) It is the fourth stage of the Japanese 5S method for lean manufacturing. Its objective is to establish standards in the work methodologies related to the first three 5S stages (Seiri, Seiton and Seiso) and in operations in general.
In the methods, tools and processes that must be shared with other people, it is necessary to renounce personal tendencies. This responds to the need to act in favor of helping each other to understand things, thus sharing a common vision.
In this way, all employees will know how to organize and maintain their workplace in an efficient and safe way, with clear instructions that are well understood by all.
Without standardized work, you will never be able to continually improve processes or find out where errors are occurring.
In order for a standardized system to be understood by all, staff must be trained and even subjected to periodic testing to ensure that they understand it properly. The design of the system should facilitate its learning.
Seiketsu Characteristics
It’s a state
Seiketsu does not refer to an activity, but to a state or condition. It consists of building a solid set of procedures to maintain the first 3S.
However, the true purpose of Seiketsu is not just to standardize what has been done in the first three stages of 5S, but to achieve standardized work, ensuring that the most efficient ways of doing things are done in a repeatable way, by instructions. documented work procedures (standard operating procedures).
Seiketsu is also about the visual concept: everyone should be able to distinguish normal and abnormal conditions at a glance.
Standardization
Standardization makes abnormalities and unusual situations stand out. If a group of cleaning machines is placed in an orderly row, with a place for each, then it will be noted if one is missing.
Similarly, if all inspected parts have a tag placed in a standard and visible location, it can be easily detected when one is missing to be inspected. Color tags also allow you to highlight items that have failed inspection.
Labeling, color coding, and other visual tools, along with written procedures, are all part of the standardization process.
There are many possibilities for creativity in standardization: use positioning markers, transparent protective covers that provide visibility, liquid crystals and other electronic codes that change with changing conditions, arrows to show routes, etc.
Benefits of Seiketsu
Reduce training time
Similar situations are similarly documented, basic tasks are done in each workgroup, and experienced coworkers can explain things to newcomers.
Reduce or eliminate confusion
Each worker clearly knows their tasks and responsibilities
How to implement Seiketsu?
– The roles and responsibilities of all personnel must be documented and clear. Management must provide sufficient time for staff to develop and implement the changes.
– Staff must be willing to accept changes and help implement them. For staff to adopt standard processes, everyone in the company must be informed.
– The more group discussion meetings you have when you are implementing and documenting what the standard is or what the standard should be, the more likely it is to maintain it successfully.
– The three previous stages of 5S should be standardized, making sure that cleaning becomes part of the routine process. This must be done by providing time, equipment and documented instructions to staff.
– Color code the different areas, functions, etc., to make things clear, with common codes throughout the company.
– Ways must be found to extend the use of standard colors and images to convey important information quickly and consistently. The main benefit with this is increased safety in the workplace.
– Have standard ways of storing tools and equipment in their cells so anyone in the company knows where to look for things. Have specific areas and color codes for documentation so that they are common across all areas.
– Have operators document the workflow. These documents will guarantee consistency between work shifts and different operators.
– By having the operators themselves define and write the instructions, any problems with them are avoided, either because they do not understand the work instructions or because they do not agree with the methods described. In addition, they are more motivated by having more control over their own working methods.
examples
Use of standardized signs
All “Exit” signs look the same, but are different from “Entry” signs or “Restroom” signs, to make the message easy to understand quickly.
Some of this has been incorporated into society: a red circle with a diagonal stripe to indicate “don’t come in here” or “don’t do this”, or labels with a skull and crossbones for poisons.
Workplace cleaning
Each worker should have a set of daily cleaning tasks, such as:
– Clean the tools before storing them in their respective shelves.
– Sweep a designated area of the floor.
– Clean and inspect the machinery used during that shift.
– Store the elements of the workplace properly: for example, placing the lids on the containers.
– Turn off or unplug power tools, as necessary.
– Clean dust from work surfaces.
– Visually check that everything is in place.
This set of actions should not add more than five minutes to each worker’s set of daily routine tasks. The key is for this to become routine.
In order for management to enforce standards, they must be documented. Pictures of the tidy workplace should suffice.
use of colors
The use of colored stickers can be established to be visibly affixed to products checked by quality insurers on a production line, to indicate their particular quality status. For example:
Red Label
The product does not meet quality specifications. It must be discarded.
yellow label
Product under observation. Additional testing or rework required.
green label
Quality approved product.
The ideal is to make the use of these labels part of daily life in all work areas.
Colors can also be used on people, with different colors on helmets, badges, shirts, etc., to indicate the function or hierarchical position of the worker.
This, for example, will make it easy to see where electricians are working. It also makes it clear when someone is doing a job for which they are not qualified.