5S consulting company believes that the current work scenes of many printing plants are dirty, chaotic, and poor. The performance is characterized by disordered items, insufficient inventory control ability, poor working environment, and untimely maintenance of production equipment. “5S†management can improve the working environment of the printing company, realize the tool for 3 seconds, and reduce the time for finding and replacing tools. The implementation of "5S" management can maintain the machine in the first time, prevent the machine from running unstable, ensure the stability of the production machine, and ensure the production quality is up to standard. The implementation of “5S†management can also improve on-site management and control capabilities, enabling enterprises to complete production with the lowest production materials in a good production order.
“5S†management was founded in Japan and includes SEIRI, SEITON, SEISO, SEIKETSU, and SHITSUKE.
1. Finishing (SEIRI)
The finishing is not to arrange the existing items neatly and orderly, but to separate the necessities and supplies, and to organize the neat items in order.
The finishing of the printing house can be carried out in the following 3 steps:
1 distinguish between essential materials and non-essential materials. On-site inspection, comprehensive inspection of the workplace, including desktop, wall, under the machine, computer, workshop wiring, around the machine. Pick out the supplies and check whether the equipment and daily necessities are scrapped or idle. See Table 1 for the criteria for its judgment.
2 decisively eliminates no supplies. Find out the necessities and supplies in the production work site, and develop a corresponding treatment plan. See Table 2.
3 Place the necessities. 15 minutes before work every day, the producer should check according to the pre-determined work site requirements. The implementation of the finishing activities can be photographed by camera and video, and the booth can be compared before and after the exhibition, or can be stored in different boxes and marked with labels.
2. Rectification (SEITON)
The implementation of rectification must be carried out after the implementation of the consolidation has achieved a certain effect, and the consolidation is the basis for rectification. The results of the rectification should meet the following four requirements: First, to get the required items immediately. Second, make full use of narrow places. Third, create a safe working environment while improving work efficiency. Fourth, save materials and materials.
The reorganization of the printing house can be carried out in the following three steps:
1 Scientifically arrange the placement position. The placement of material materials is based on the principles of safer and more convenient handling. Items that are frequently used are placed in designated locations, and items that are not commonly used are placed on storage shelves or in warehouses.
Draw work channels and production work areas at the job site. There is a lot of free space at the work site after finishing, and making full use of these spaces is one way to improve efficiency. The work channel must never place items in order to keep the work safe. Items that are often used should be placed close to the workbench, such as scotch tape, printing paper, and paper cutters. The frequency of printing paper replacement is very high, so the paper should be placed close to the printer. Items that are not used in the near future should be placed in a farther position. For example, the ink cartridge of the digital proofer takes two or three weeks to be replaced and can be placed in the storage cabinet. Refer to Table 3 for the specific placement.
2 Divide the details with a paper strip or carton. Place the appropriate label on the appropriate location for the item to find the pick and place.
3 placement method. Items and tools must be placed in fixed locations and areas. The placement can't be changed according to someone's preference, and the fixed placement should suit the habits of most people.
3. Cleaning (SEISO)
Cleaning is done by setting requirements and cleaning the job site. The realization of no garbage, no dirt, maintenance of the precision of the machine repair equipment, early detection of equipment imperfections, reducing the occurrence of faults. Cleaning can be done in three ways: first, clean up the production tools that are usually used, such as office computers. Then clean the equipment used in the production, mainly refers to the daily maintenance of the equipment, this part can be completed with reference to the machine's instructions for use. Finally, the garbage generated during the production process is cleaned, such as the waste paper produced by the paper machine, the waste generated during the printing process, and the packaging box when the material is replaced.
The cleaning of the printing house can be carried out in the following 2 steps:
1 Establish a responsible area and clarify the person in charge. The pre-press production process can separate the pre-press image responsibility area, the digital printing area, the laser photo-recording machine area, and the original inspection area. Printing and finishing can also be divided into different areas according to the machine drawing, and the list of responsible persons should be clearly indicated in the corresponding area.
2 Establish a sound responsibility sharing area and cleaning standards. From daily cleaning to weekly cleaning, the contents of the cleaning should be divided into five parts. Image production area, digital proofing area, laser phototype area, printing area, post-press processing area. The daily cleaning of each part is mainly to remove the garbage of the day, and the ground is kept clean and free of debris. The air should be fresh and the temperature and humidity adjusted to moderate. Check the working machine before going to work every day to prevent accidents. The implementation method of cleaning is that the relevant leaders check the cleaning situation once a week. Or use occasional spot checks, paying special attention to the cleanliness of the corners and the cleaning of office equipment. If you find a problem, find the person responsible and improve it according to your responsibilities.
4. Cleaning (SEIKETSU)
Cleanliness is a management at a glance, standardized management. Create a comfortable working environment, and continuously organize and rectify to maintain or guarantee safety and health.
5. literacy (SHITSUKE)
Literacy refers to the cultivation of good habits and the creation of a regular working environment. Create a good workplace, cultivate a variety of good manners, and develop a habit of obeying collective decisions.
The implementation of literacy requires companies to provide some opportunities for employees to give full play to their individual initiative. The reason why literacy is the core of “5S†management is that because of self-cultivation, we can spontaneously improve our work ability, subjectively and willing to continuously improve the production process and ensure the smooth progress of all work. The purpose of literacy management is to improve the ability of employees to improve their work habits. In the printing factory, you can operate from the following three aspects:
1 Prepare the “Workbookâ€, from the process flow to the production mode, job process, job responsibilities, to standardize the employee's work steps and processes. Write a Handbook of Frequently Asked Questions to develop the ability of employees to discover and solve problems. Encourage employees to record problems encountered during the work process so that they can learn and improve in the future.
2 Enterprises attach importance to training, let employees love learning, mobilize employees to learn enthusiasm, and make the company become a learning and innovative enterprise.
3 Cultivate employees to consciously formulate work plans, self-monitoring good habits, change work from passive to active, and develop a good habit of self-consciousness.
Precautions for implementing 5S management
(1) Grasp the implementation points: First, the correct value consciousness. This is the first step of the 5S activity. The criteria for distinguishing between on-site items and the unwanted items is the use value rather than the original purchase value; don't mean it is thrown away; changing the position may have a greater use. The second is the correct method. Three fixed: fixed point, constant volume, quantitative, (three points: partition, sub-frame, layering) + three elements: location, method, representation + technology: process science, logistics convenient. The third is to clarify the post responsibility system. The fourth is the institutionalization of assessment. Fifth, the behavior is long-term.
(2) Defining the division of work on the site 5S. The role of management: training support, let all employees know what is 5S, understand the importance of 5S; resource support, let all employees have the time to carry out 5S activities daily and set up 5S group; participate in support, actively participate in 5S activities, timely Respond to the red list and recognize the efforts of the staff.
The role of employees: learning 5S knowledge; actively participate in the implementation of 5S and provide advice; develop a sense of 5S honor; establish a self-management concept.
(3) 5S propulsion process - PDCA cycle. First, the key to achieving a virtuous cycle is in stage A. The second is to complete a loop and finally have a closed loop.
(4) Evaluation of “5S†activities. First, a scoring standard table is prepared, including an office scoring standard table and an on-site scoring standard table. In the assessment, the shortcomings are used to record the description, and then the methods of the defective items, code names and deductible points are checked, so that the reviewers do not have to look for the check items and waste time. The frequency of the start of the score should be more dense, once a day or once a day, once a month to summarize, and to give praise and correction.
(5) Evaluation and rewards and punishments. The scoring committee shall submit the score form to the executive department on the day of the evaluation, and the executive department shall make statistics and publish the results in the announcement column the next day. The reward and punishment activities will be conducted in units of “monthsâ€. The top two will be awarded to the pennants and bonuses. For those who are lagging behind, they can be fined appropriately, but this is only a form and not a final purpose.
Application of 5S activities in the production site
1. Establish and improve the management organization of 5S activities, and define their responsibilities and working standards from top to bottom. Establish a management network system to meet the actual needs of production. The center is responsible for professional management of 5S activities, conducting macro control, inspection, and guiding the production site work of the two teams, conducting inspections and assessments; the workshop is responsible for office and production. On-site inspection and rectification work; the team and individuals are responsible for the cleaning and cleaning of their respective office and production sites.
2. Carry out extensive and in-depth work of ideological education for employees, and turn 5S activities into conscious actions of employees. This is the core of 5S activities. This work is gradually deepening and is gradual. The responsibility and quality of employees have a process from quantitative to qualitative.
3. Improve and establish the working standards for office space, production site and equipment management. This is the premise for 5S activities. Only when the employees are clear about how to do it and why they have done so can we ensure that the 5S activities are carried out in an orderly manner. We must set standards for the management, finishing, and cleaning of the site as part of the operating standards.
4. Incorporate 5S activities into the post responsibility system, strictly check and evaluate, and link with the scores. This is an important guarantee that 5S activities can be adhered to for a long time.
5, through the PDCA cycle, continuously improve the 5S level, that is, through the inspection to continuously find problems, propose improvement measures and plans, continue to solve problems, improve in persistence, and persist in improvement. This is the basis for preventing the “slope†of 5S activities.
How to carry out 5S management
1. Establish a dedicated promotion organization
Set up a dedicated on-site 5S promotion team, each department must send at least one responsible person to join
The team is responsible for the on-site 5S-driven planning, and communicates with the company's departments in a timely manner to gradually improve the 5S management.
2. Promote a standardized way of working
(1) Emphasis on system management. That is to emphasize what time, place, person, what to do, how much to do, how much.
(2) For the purpose of quality management. That is to take the customer as the center, leadership leadership, full participation, but also pay attention to process control and management.
3. Mobilize the enthusiasm of employees and create a good working environment
Create a good working environment, establish a fair and reasonable employee incentive system, mobilize the enthusiasm of employees, and actively cooperate with the promotion of on-site 5S, so that employees can form a concept of being a member of the promotion team, which can greatly accelerate the on-site 5S Promotion speed.
4. Pay attention to the use of the links of the five activities, and gradually promote
Finishing is the premise of rectification, rectification is the consolidation of consolidation, cleaning is the effect of sorting and rectification, and through cleaning to continue to maintain and consolidate the previous achievements, through continuous publicity and implementation, summary and improvement, make it rise to one The habit, that is, self-cultivation, enables the enterprise to form an overall improvement atmosphere and enter a benign cycle.
5S consulting company believes that the current work scenes of many printing plants are dirty, chaotic, and poor. The performance is characterized by disordered items, insufficient inventory control ability, poor working environment, and untimely maintenance of production equipment. “5S†management can improve the working environment of the printing company, realize the tool for 3 seconds, and reduce the time for finding and replacing tools. The implementation of "5S" management can maintain the machine in the first time, prevent the machine from running unstable, ensure the stability of the production machine, and ensure the production quality is up to standard. The implementation of “5S†management can also improve on-site management and control capabilities, enabling enterprises to complete production with the lowest production materials in a good production order.
“5S†management was founded in Japan and includes SEIRI, SEITON, SEISO, SEIKETSU, and SHITSUKE.
1. Finishing (SEIRI)
The finishing is not to arrange the existing items neatly and orderly, but to separate the necessities and supplies, and to organize the neat items in order.
The finishing of the printing house can be carried out in the following 3 steps:
1 distinguish between essential materials and non-essential materials. On-site inspection, comprehensive inspection of the workplace, including desktop, wall, under the machine, computer, workshop wiring, around the machine. Pick out the supplies and check whether the equipment and daily necessities are scrapped or idle. See Table 1 for the criteria for its judgment.
2 decisively eliminates no supplies. Find out the necessities and supplies in the production work site, and develop a corresponding treatment plan. See Table 2.
3 Place the necessities. 15 minutes before work every day, the producer should check according to the pre-determined work site requirements. The implementation of the finishing activities can be photographed by camera and video, and the booth can be compared before and after the exhibition, or can be stored in different boxes and marked with labels.
2. Rectification (SEITON)
The implementation of rectification must be carried out after the implementation of the consolidation has achieved a certain effect, and the consolidation is the basis for rectification. The results of the rectification should meet the following four requirements: First, to get the required items immediately. Second, make full use of narrow places. Third, create a safe working environment while improving work efficiency. Fourth, save materials and materials.
The reorganization of the printing house can be carried out in the following three steps:
1 Scientifically arrange the placement position. The placement of material materials is based on the principles of safer and more convenient handling. Items that are frequently used are placed in designated locations, and items that are not commonly used are placed on storage shelves or in warehouses.
Draw work channels and production work areas at the job site. There is a lot of free space at the work site after finishing, and making full use of these spaces is one way to improve efficiency. The work channel must never place items in order to keep the work safe. Items that are often used should be placed close to the workbench, such as scotch tape, printing paper, and paper cutters. The frequency of printing paper replacement is very high, so the paper should be placed close to the printer. Items that are not used in the near future should be placed in a farther position. For example, the ink cartridge of the digital proofer takes two or three weeks to be replaced and can be placed in the storage cabinet. Refer to Table 3 for the specific placement.
2 Divide the details with a paper strip or carton. Place the appropriate label on the appropriate location for the item to find the pick and place.
3 placement method. Items and tools must be placed in fixed locations and areas. The placement can't be changed according to someone's preference, and the fixed placement should suit the habits of most people.
3. Cleaning (SEISO)
Cleaning is done by setting requirements and cleaning the job site. The realization of no garbage, no dirt, maintenance of the precision of the machine repair equipment, early detection of equipment imperfections, reducing the occurrence of faults. Cleaning can be done in three ways: first, clean up the production tools that are usually used, such as office computers. Then clean the equipment used in the production, mainly refers to the daily maintenance of the equipment, this part can be completed with reference to the machine's instructions for use. Finally, the garbage generated during the production process is cleaned, such as the waste paper produced by the paper machine, the waste generated during the printing process, and the packaging box when the material is replaced.
The cleaning of the printing house can be carried out in the following 2 steps:
1 Establish a responsible area and clarify the person in charge. The pre-press production process can separate the pre-press image responsibility area, the digital printing area, the laser photo-recording machine area, and the original inspection area. Printing and finishing can also be divided into different areas according to the machine drawing, and the list of responsible persons should be clearly indicated in the corresponding area.
2 Establish a sound responsibility sharing area and cleaning standards. From daily cleaning to weekly cleaning, the contents of the cleaning should be divided into five parts. Image production area, digital proofing area, laser phototype area, printing area, post-press processing area. The daily cleaning of each part is mainly to remove the garbage of the day, and the ground is kept clean and free of debris. The air should be fresh and the temperature and humidity adjusted to moderate. Check the working machine before going to work every day to prevent accidents. The implementation method of cleaning is that the relevant leaders check the cleaning situation once a week. Or use occasional spot checks, paying special attention to the cleanliness of the corners and the cleaning of office equipment. If you find a problem, find the person responsible and improve it according to your responsibilities.
4. Cleaning (SEIKETSU)
Cleanliness is a management at a glance, standardized management. Create a comfortable working environment, and continuously organize and rectify to maintain or guarantee safety and health.
5. literacy (SHITSUKE)
Literacy refers to the cultivation of good habits and the creation of a regular working environment. Create a good workplace, cultivate a variety of good manners, and develop a habit of obeying collective decisions.
The implementation of literacy requires companies to provide some opportunities for employees to give full play to their individual initiative. The reason why literacy is the core of “5S†management is that because of self-cultivation, we can spontaneously improve our work ability, subjectively and willing to continuously improve the production process and ensure the smooth progress of all work. The purpose of literacy management is to improve the ability of employees to improve their work habits. In the printing factory, you can operate from the following three aspects:
1 Prepare the “Workbookâ€, from the process flow to the production mode, job process, job responsibilities, to standardize the employee's work steps and processes. Write a Handbook of Frequently Asked Questions to develop the ability of employees to discover and solve problems. Encourage employees to record problems encountered during the work process so that they can learn and improve in the future.
2 Enterprises attach importance to training, let employees love learning, mobilize employees to learn enthusiasm, and make the company become a learning and innovative enterprise.
3 Cultivate employees to consciously formulate work plans, self-monitoring good habits, change work from passive to active, and develop a good habit of self-consciousness.
Precautions for implementing 5S management
(1) Grasp the implementation points: First, the correct value consciousness. This is the first step of the 5S activity. The criteria for distinguishing between on-site items and the unwanted items is the use value rather than the original purchase value; don't mean it is thrown away; changing the position may have a greater use. The second is the correct method. Three fixed: fixed point, constant volume, quantitative, (three points: partition, sub-frame, layering) + three elements: location, method, representation + technology: process science, logistics convenient. The third is to clarify the post responsibility system. The fourth is the institutionalization of assessment. Fifth, the behavior is long-term.
(2) Defining the division of work on the site 5S. The role of management: training support, let all employees know what is 5S, understand the importance of 5S; resource support, let all employees have the time to carry out 5S activities daily and set up 5S group; participate in support, actively participate in 5S activities, timely Respond to the red list and recognize the efforts of the staff.
The role of employees: learning 5S knowledge; actively participate in the implementation of 5S and provide advice; develop a sense of 5S honor; establish a self-management concept.
(3) 5S propulsion process - PDCA cycle. First, the key to achieving a virtuous cycle is in stage A. The second is to complete a loop and finally have a closed loop.
(4) Evaluation of “5S†activities. First, a scoring standard table is prepared, including an office scoring standard table and an on-site scoring standard table. In the assessment, the shortcomings are used to record the description, and then the methods of the defective items, code names and deductible points are checked, so that the reviewers do not have to look for the check items and waste time. The frequency of the start of the score should be more dense, once a day or once a day, once a month to summarize, and to give praise and correction.
(5) Evaluation and rewards and punishments. The scoring committee shall submit the score form to the executive department on the day of the evaluation, and the executive department shall make statistics and publish the results in the announcement column the next day. The reward and punishment activities will be conducted in units of “monthsâ€. The top two will be awarded to the pennants and bonuses. For those who are lagging behind, they can be fined appropriately, but this is only a form and not a final purpose.
Application of 5S activities in the production site
1. Establish and improve the management organization of 5S activities, and define their responsibilities and working standards from top to bottom. Establish a management network system to meet the actual needs of production. The center is responsible for professional management of 5S activities, conducting macro control, inspection, and guiding the production site work of the two teams, conducting inspections and assessments; the workshop is responsible for office and production. On-site inspection and rectification work; the team and individuals are responsible for the cleaning and cleaning of their respective office and production sites.
2. Carry out extensive and in-depth work of ideological education for employees, and turn 5S activities into conscious actions of employees. This is the core of 5S activities. This work is gradually deepening and is gradual. The responsibility and quality of employees have a process from quantitative to qualitative.
3. Improve and establish the working standards for office space, production site and equipment management. This is the premise for 5S activities. Only when the employees are clear about how to do it and why they have done so can we ensure that the 5S activities are carried out in an orderly manner. We must set standards for the management, finishing, and cleaning of the site as part of the operating standards.
4. Incorporate 5S activities into the post responsibility system, strictly check and evaluate, and link with the scores. This is an important guarantee that 5S activities can be adhered to for a long time.
5, through the PDCA cycle, continuously improve the 5S level, that is, through the inspection to continuously find problems, propose improvement measures and plans, continue to solve problems, improve in persistence, and persist in improvement. This is the basis for preventing the “slope†of 5S activities.
How to carry out 5S management
1. Establish a dedicated promotion organization
Set up a dedicated on-site 5S promotion team, each department must send at least one responsible person to join
The team is responsible for the on-site 5S-driven planning, and communicates with the company's departments in a timely manner to gradually improve the 5S management.
2. Promote a standardized way of working
(1) Emphasis on system management. That is to emphasize what time, place, person, what to do, how much to do, how much.
(2) For the purpose of quality management. That is to take the customer as the center, leadership leadership, full participation, but also pay attention to process control and management.
3. Mobilize the enthusiasm of employees and create a good working environment
Create a good working environment, establish a fair and reasonable employee incentive system, mobilize the enthusiasm of employees, and actively cooperate with the promotion of on-site 5S, so that employees can form a concept of being a member of the promotion team, which can greatly accelerate the on-site 5S Promotion speed.
4. Pay attention to the use of the links of the five activities, and gradually promote
Finishing is the premise of rectification, rectification is the consolidation of consolidation, cleaning is the effect of sorting and rectification, and through cleaning to continue to maintain and consolidate the previous achievements, through continuous publicity and implementation, summary and improvement, make it rise to one The habit, that is, self-cultivation, enables the enterprise to form an overall improvement atmosphere and enter a benign cycle.
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