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The application of Japanese techniques constitutes an excellent benchmarking opportunity for good management practices to improve quality and productivity in American industries.
Lean Manufacturing began its application in the philosophy of quality management in Japanese industries in the 50s, 60s and 70s, originally known as the Toyota Production System (TPS) for being its creators, through the leadership and coordination of Taiichi Ohno, who became a senior executive of the Toyota group.
The techniques used in the TPS management philosophy are different for the management of continuous improvement (Kaizen) of quality and productivity at the site or jobs (Gemba), and throughout the Monodzukuri (Manufacturing) process.
Among the TPS techniques are 5S, Just In Time, Kanban, Jidoka, Poka Yoke, Muda, Andon, Mieruka, Autonomous Maintenance and Visual Control, Quality Control Circles, Basic and Administrative Quality Tools and Planning Cycle Methodology , Do, Check and Action (PDCA).
These techniques are applied not only in the automotive sector but also in different industrial sectors, including service sector organizations.
Lean Manufacturing comprises a set of tools and practices that, when fully and correctly implemented, help improve the performance of the organizational system (Omogbai & Salonitis, 2017).
It is a management model based on producing goods and services adjusted to demand, ensuring the quality of its products, as quickly and at the lowest possible labor cost (Manzano & Gisbert, 2016).
The 5S methodology is part of the techniques of the Production Management System or Lean Manufacturing, each of the techniques are interrelated in the process of continuous improvement, in each of the jobs. The achievement of results depends on the leadership of senior management, and the participation and commitment of the entire human team of the organization.
Order, cleanliness and discipline are an essential part in the implementation of any program of excellence and lean manufacturing.
The application of lean 5S satisfies multiple objectives. Each 'S' has a particular objective such as:
. Remove from the workspace what is useless.
.Organize the workspace effectively.
. Improve the level of cleanliness.
. Prevent dirt and mess.
. Maintain discipline
Practical recommendations to make 5S work:
● A 5S program is not a list of actions that is carried out sporadically, but a systematic activity that must be carried out daily with method, dedication and commitment.
● In this type of project, leadership is crucial and, therefore, requires the firm commitment of management. Leaders must set an example and act in coherence with the deployed strategy.
● This philosophy involves all members of the organization, so it is essential to achieve their participation and take their leading role into account.
● Before starting the project, the people on the team must be informed of its purpose, scope and meaning of each of the stages. It is interesting to graphically document the changes produced and show the before and after photos.
● Begin the deployment of the five stages in a pilot area through a kaizen workshop to achieve an abrupt and highly visible change. And continue the deployment in small areas with the 5 stages completed.
● Include the 5S compliance indicators in the security section of the Short Interval Operational Management (GIC) system for proper monitoring and control.
The 5S allow you to:
● Improve working conditions and staff morale (it is more pleasant to work in a clean and tidy place),
● Reduce time and energy costs,
● Reduce the risks of accident,
● Improves quality, produces fewer defects in both products and services,
● Improve productivity,
● Better meet production and delivery deadlines,
● You have greater control over equipment maintenance.
A comfortable and well-equipped workspace contributes to improving employee productivity. The secret is, to a large extent, in the space itself. For this reason, taking care of aspects such as light or decoration are essential to promote worker productivity.
This technique has many benefits both in industrial plants and in the office, below are the most important points for an office work environment:
The 5s strategy in offices brings visibly important benefits. In addition to contributing to collaborators having organized spaces and desks and, consequently, with a pleasant and light atmosphere; This strategy is very beneficial for optimizing levels around the management indicators of the department and the organization, as well as the vital processes for the company's activity.
By applying the 5s in the office it will be possible to perceive an improvement in the image of the company and its brand; It is useful for making the best impression on both your internal and external customers. Likewise, the negative charge generated in the environment by disorder and disorganization will be easily replaced by a more enjoyable and fluid work environment.
Implementing the 5s project in offices has totally positive consequences in all the vital processes of the organization, making it possible to avoid in a timely manner the execution of erroneous actions and, consequently, the rework that causes so many losses to companies.
With the 5s strategy, it will be possible to meet the deadlines set for each task with greater confidence and commitment; better control the inventory of raw materials and finished products, as well as other processes related to the production and productivity of the organization.
The five S's are a strategy that will allow you to make significant progress as a company, as a team and as a person; The activities carried out under this program are carried out with a higher level of efficiency and quality, within a welcoming, safe and excellence-oriented workspace.
Keys to improve labor productivity:
Workspace lighting
If it is natural, better, although it is necessary to use blinds to avoid annoying reflections on the screen. It is equally important to provide light quality to each job.
Acoustics in workplaces
To increase in a noisy environment a person consumes a lot of energy; for this reason, an ideal work space will be one in which one can isolate oneself acoustically. This is especially delicate in work centers or open coworking spaces.
The office ventilation
It is important to have a ventilation system, since sometimes “too many” people come together in offices.
The temperature in the office
Despite being one of the problems with a difficult solution, it is essential to have an optimal conditioning system for each workspace.
The maintenance of the facilities
It is essential to take care of the facilities and material to avoid accidents or hinder the pace of work.
To reinforce the implementation of the 5s system, it is highly recommended that checklists be defined for each zone and department. These must be based on the principles of the 5s as well as previously defined standards. With these lists or questionnaires we can carry out cross audits, where the qualifications and areas of opportunity to be attacked by each team are obtained.
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