Once again, I've let my blog slide a bit.  I do have something of an excuse this time...I've been busy with three clients. 

I've been implementing lean a bit differently  with these clients.  I learned about an approach to 5S called Progressive 5S.  I've always taught that a company should completely 5S an area, then move to the next.  With Progressive 5S, the company gets the entire plant done a stage (or two) at a time. In other words, get the entire plant Sorted and Shined, then move on to getting the entire plant Straightened and implementing visual factory.  I wasn't wild about this approach when I first heard about it, but, after further reflection (and a client who had heard about it and was going to implement it with or without me), I'm persuaded that it overcomes some of the issues I've run into with area-by-area 5S (mainly that a couple of areas get done and then energy fades). 

The steps for Progressive 5S are:

• Sort and Shine - Just what it sounds like throughout the company
• Set in Place - Designate a “home” for every item in the work area
• Sustain - Put it back where it belongs after use
• Simplify - Eliminate non-value-added effort
• Standardize - Expand ownership to everyone to leverage the gains

(Here's a link to a white paper I just found that gives an overview of Progressive 5S.)

And this is just what my one client will be implementing.

I used this model as the basis for another that covers a lean implementation in toto, not just 5S (though, as you'll see, it incorporates it).

Here's my new model.  I call it 10S or 5S X 2 for reasons that will become apparent.

• Strategy and Spread the Word - Planning the implementation and making sure everyone knows what's happening and what their roles are.
• Sort and Shine - Just what it sounds like throughout the company
• Straighten and See - Designate and "home for everything and implement visual controls, hourly charts, and Leader Standard Work.
• Solve and Simplify - Value stream mapping, team problem solving, kaizen events, pull systems....all the advanced stuff.
• Standardize and Sustain - Standard task instructions, TPM, idea systems, innovative HR practices, full implementation of Leader Standard Work.

(I got the term "Leader Standard Work" from the book  Creating a Lean Culture by Daniel Mann.)

OK, I've got to go to a July 4 parade so more about this later.

Happy Independence Day, everyone!