Inspired to clean and organize the shop, I spent a day and half last weekend in 5S mode. During this I found 5 jigs and fixtures projects I wanted to complete. 4 out of 5 are done; the 5th awaits some t-track. While I am excited about some new gadgets, I am really happy to work in a better organized shop.
I found more drill bits than I ever thought I had, stored in 3 different locations.
There was lots of extra sandpaper and the best of all… a new Dewalt orbital sander that I had forgotten during our move last year.
Since being indoctrinated into Lean management I have to admit (reluctantly for a natural born pack-rat) that the 5S methodology does work. At least the first four S’ are easy. The fifth, sustainment is a little more challenging to make a habit. For now I refer to an Americanized version…(It’s sad to realize that a management philosophy built on standards can have so many variations!)
In the picture below is the result of the first of 5S’ last weekend, Sorting. The pile in front is donations to local charities. The one in the back is stuff to be relocated out of my way. For the most part, yard maintenance supplies that should be in the shed with the other stuff. Fundamentally, sorting is strictly about determining what needs to be in the workspace and what does not. When in doubt, throw it out!
It’s outta here!
The second S and the before and after picture below is what really makes the effort worthwhile. Sweep is not really about cleaning as much as it is organizing. The object is to find a designated location for everything. Giving each item a home and using it religiously prevents the need to ever go searching again.
Before
I’ve hated looking at this mess for 18 months.
The time finally came!
After
The third of 5S’ is Scrub. Scrub is about cleaning and also about maintenance. Making sure tools and equipment are kept clean helps ensure long life by reducing wear and tear. As an example; on bearings and bushings that may accumulate sawdust.
The forth of 5S’ is more valuable to a multi-person shop. Standardization is about setting and following rules using the first three of the 5S’. Each person works to the same standard of organization and cleanliness. This teamwork approach improves morale by ensuring each person works to support the efficiency of all.
The fifth and most difficult S is sustainment. This is where most fail. Just like a new year’s resolution, it is easy to say you’re committed but another thing to live up to it. I have found that my commitment is directly proportional to the amount of energy I invest in establishing a new habit. If I go to the effort to build a new rack specifically to store sheets of sandpaper, I am more likely to put the sandpaper there. The same applies to spices in the kitchen, toiletries in the bathroom; and office supplies at work. Try it.
…..coming next….
….jigs-n-fixtures….
