In my last post, I introduced you to the idea that a 5S project might not be a straightforward enterprise.  You might have to make some adjustments in your approach.  I listed three adjustments I've had to make. 

In this post, I'll review how I applied that thinking to a recent 5S workshop.

In the target area, a polymer was put between two sheets of aluminum and rolled.  There were several sub-sections.  Hardened polymer made the entry end of the machine look like a snow storm.  All space around the machine was taken up with rolls of aluminum, either raw material ready to be run or "partials": rolls of the foil that had not completely run out  but were being kept by the machine "just in case we ran that size again sometime". 

Here's how I applied the "three adjustments":

Adjustment #1:  Ask lots of questions
We spent about 10 minutes of the team answering my questions about which surrounding areas went with the machine and about the flow of material through the area. 

Adjustment #2: Divide and conquer
On the basis of their answers, we focused first on an area where the raw materials for the polymer were stored and measured out.  My questions about flow led us to tackle the material around the machine next.  Lastly, we tackled the machine itself.  We ran out of time before it was completely 5S'd.

Adjustment #3: Tackle a Big Problem
This turned out to be the interesting issue.  Essentially, the area from which rolls were taken from the floor and lifted by crane to the top of the machine was filled with "partials" or rolls that had not been completely run out.  Good raw material to be loaded onto the machine were being stored several yards away and had to be moved to the "staging area" and maneuvered around the partials.

I'm sure you can already see where I'm going with this.

We got rid of the partials to clear the staging area.  We developed a procedure wherein the team would move the next shift's production into the staging area.  We also developed a procedure to use up all the material on a roll whenever possible.  A rack will be built for such partials as must be kept.  (The team realized that, because three different sizes of foil are run on the machine, they would need space for three partial rolls.  They also realized, however, that, if they stuck with their new procedure, no more than  three partials should ever be present.  At the start of our 5S, there were about 25 partial rolls on the floor.)

The area still needs some serious Sweep and Shine especially.  And we didn't have time to implement much Visual Factory at all.  But the team made a big improvement in the operations of that particular line.