Workshop presentation on Shop Floor Organization for furniture manufacturers. April 24, 2012

1. EFFECTIVE SHOP FLOOR ORGANIZATION
FOR MICRO & SMALL
FURNITURE MANUFACTURERS

2. Today you will learn:
3 . How to organize your production space
4 . Plan a better work flow
5 . About the Factories act
6 . How to keep a safe work environment
7 . How maintenance of equipment can help you

3. Agenda Start End Time
Module 1 Operations Organization
Registration & introduction 9:00 9:30 0.50 hr.
a. Effective shop floor organization for small facilities: 2.5 hrs.
Effective layout options for small facilities 9:30 10:00 0.75 hr
Process Flow & Shop Floor Organization 10:00 11:00 1.00 hr
Coffee Break 11:00 11:15 0.25 hr
Space Utilization for efficiency including 5-S methodology 11:15 11:45 0.50 hr.
b. Safety for small furniture manufacturers: 3.5 hrs
Introduction to the Factories Act and OSHA Stds. 11:45 12:15 0.50 hr
Lunch 12:15 1:15 1.00 hr
Basic Equipment maintenance tips 1:15 1:45 0.50 hr.
Preventing Electrical Hazards 1:45 2:15 0.5 hr
Impact of lighting and ventilation on safety 2:15 2:45 0.5 hr
Wrap up and close 2:45 3:00 0.25hr
Total Workshop time 6.0 hrs.

4. EFFECTIVE SHOP FLOOR ORGANIZATION

5. WHAT HAPPENS IF YOUR SHOP FLOOR
IS NOT ORGANIZED?

6. • You spend more time looking for things
• It is difficult to know how much waste you have
• It is hard to move around
• It is harder to produce quality work
• You can lose things and not know
• Space is wasted
• Everything is confusing

7. HOW CAN YOU SOLVE THESE
PROBLEMS?

8. 1. Proper LAYOUT of production space
Why do you need a proper layout?
The objective of facility layout id to locate people,
machines and processes in a logical, time-saving and
money-saving manner that meets anticipated production
levels

9. 1. Proper LAYOUT of production space
Some goals to achieve through layout design
2. Maximize the use of machine tools
3. Minimize labour requirements
4. Provide a smooth flow of materials and products
5. Minimize health hazards
6. Minimize material handling effort
7. Maximize the use of available space
8. Provide maximum flexibility to avoid “hiccups” in operations
9. Maximize output

10. Materials in Materials in
Process
Product or line
TYPES OF LAYOUT
Finished product Finished product

11. Product or Line Layout:
Focus is on sequence of production or assembly of
products
Ideal for Mass Manufacturing situations
Workstation sequence is fixed and does allow changes to
production
Not flexible to product changes

12. Process Layout:
Group machines that perform similar or related functions
together or close to each other, such as saws.
It allows flexibility in making several types of products at
the same time
It requires careful production planning and material
handling to avoid bottlenecks and delays in production

13. Process Layout:
Exercise:
a. Name the different functions needed to make a side table:
_____________________________
_____________________________
_____________________________
_____________________________

14. Process Layout:
Exercise:
b. Do a rough sketch to show how the materials flow from machine
to machine:
Assume you have:
Table saw Jigsaw (or handsaw)
Miter saw Belt sander
Router Clamps (for Shop note)
Other hand tools

15. Process Layout:

16. “5-S”

17. Putting the “5-S” system in place to clean up & manage
your shop floor

18. What is “5-S”?
The Five S program focuses on having visual order,
organization, cleanliness and standardization.
The results you can expect from a Five S program are:
improved profitability, efficiency, service and safety.
The 5-S concept originated in Toyota, Japan.
- Factories in Japan are reputed for their
cleanliness and orderliness.
- This is due to their ability to instill a sense of
responsibility and discipline into their workers,
particularly at the plant (shop-floor) level.

19. S ort
S et in Order
S hine
S tandardize
S ustain

21. Some benefits of “5-S”?
• Improves safety / Reduces accidents
• Reduces downtime
• Enhances operational control of processes
• Creates a healthier corporate climate
• Improves product quality
• Improves efficiency and productivity
• Improves delivery times and assists in reducing
costs
• Creates a positive work environment
• Improves customer perceptions

22. SORT
Sorting is the first step in cleaning up your floor. It helps
to identify things which are no longer necessary in the
space.
Separate according to:
•What Is Needed
•Needed Later
•Not Needed
Discard What Is Not Needed
Separate Needed Items By Frequency of use

23. SORT
Name 5 things in your work area which aren’t necessary.
When you return, make it a duty to remove them!

24. SORT
For items which are needed – identify where they
should go.
For items non needed – remove them from the floor
and into the garbage!

25. SORT
Exercise:
List some of the things you can think of in your own
factory that can be thrown away?

26. SORT
Exercise:
List some of the things you can think of in your own
factory that can be thrown away?
Old Tools & machines that will never work again
Scrap lumber and other odd pieces
Old drawings, patterns, etc
Old furniture that have not been worked on in over one
to three months

27. BENEFITS OF SORTING
Keeps the work area clean and clutter free reduces risk
of safety incidents
Creates “extra” work space where necessary items can
be placed
Reduces time spent searching for tools and materials
Removing supplies, materials and paper work not
required to do the work helps improve efficiency

28. Set in Order
Can also be called the STRAIGHTENING OR TIDYING UP
stage.
At this stage you should now ORGANIZE everything.
Arrange items so that they are easy to find and can be
accessed readily.
“A Place for everything and everything in it’s place”

29. Set in Order
Use tags and signs and other labels to identify where
things should be kept.

30. Set in Order
For every item in the workplace we will need to:
Identify it
Allocate a place and store it
Determine how much/how many to store at the work
place

31. Example of area marked out for items

32. Set in Order
• Decide where to keep needed items
– Keep frequently used items at point of use
– Screwdrivers next to screws
• Organize items in a way that makes sense
– Make it easy for anyone to find them, use them and put
them back after use
• Use outlines and labels
– Make it obvious when items are not in their correct place

33. Set in Order
• Decide where to keep needed items
– Locate items according to their frequency of use (higher
frequency = closer to you)
– Store items together if they are used together (i.e. –
ratchets with bolts)
– Store them in the sequence they are used
– Consider tools on retractable cords (overhead)
– Simplify – use one tool for multiple functions

34. Set in Order

35. SOME BENEFITS OF SET IN ORDER
Safety is improved
Clean clutter free floors and aisles
Tools and parts are stored properly so there’s less damage
Less waste of motion – reduced searching for materials, tools
& supplies
Reduced inventory of materials, supplies

36. SHINE
SHINE is all about cleanliness. Clean the workplace
completely so that there is no dust, dirt or garbage on
floor, machine, workbench etc.
Shining results in a cleaner, safer and healthier
workplace.
It helps to maintain the sorting and set in order steps
done before
Shining requires discipline to maintain.
Everyone in the workshop should have the
responsibility to “shine” their work areas daily.

37. SHINE
By constantly cleaning or “shining”, it will make it easier
to inspect equipment and tools often.
When cleaning machines of sawdust, you can see if
parts become loose, wires begin to break, etc.
This gives you a chance to correct any machine defect
before it breaks down
Shining also lifts the morale and pride of persons
working in the space, and will impress your customers a
lot!

38. SHINE
To ensure Shining is done regularly:
Make a roster of who is to do what
Make a schedule of when the place is to be cleaned - for
example: empty bins every evening; sweep the floor
every morning; remove scrap wood once a week, etc.
Keep cleaning equipment (brooms, bins, brushes) in a
easy to reach convenient spot.
Give the responsibility to someone to ensure “Shine” is
done

39. It is important that we
establish the first 3S
before we progress to
the next 2S.

40. STANDARDIZE
Standardizing helps to Maintain a Serene Atmosphere
STANDARDIZE is the means by which we maintain the
first three S’s, namely SORT, SET IN ORDER and SHINE.
- You should maintain high standards of housekeeping
and workplace organization at all times.
Standardizing is about implementing BEST PRACTICES in
the workplace

41. STANDARDIZE
Have a written manual or procedures on who is to do
what, when, how and why is a part of standardization.
Develop a schedule that shows who has what
responsibility.
Responsibilities should be a part of every day work
activity

42. SUSTAIN
SASTAIN is the set of approaches to be used to win hearts
and minds, to make people want to keep applying best
practices in shop organization and housekeeping.
It is having the discipline to maintain the correct
procedures and standards over time
It is creating conditions, or an atmosphere, that encourage
the constant practice of good habits and the elimination of
bad ones

43. RECAP

44. • Sort – to put things in order
– Remove what is not needed & keep what is needed
• Set in order - proper arrangement
– Place things in a way that they are easily accessible
whenever they are needed
• Shine – clean
– Keep things clean & polished; no trash in workplace
• Standardize
– Standardize best practices / processes for cleaning
• Sustain – commitment and self-discipline
– Develop an attitude and culture that follows the other 4S’s

45. BENEFITS
• Reduced set-up times • Less wasted labour
• Reduced cycle times • Better equipment
• Reduce searching time reliability
• Increased floor space • Higher Quality
• Reliable Delivery • Lower cost
• Lower safety
incident/accident rate

46. The End
Jamaica Business Development Corporation.
14 Camp Road, Kingston 4
Tel: 928-5161-5
Or
76 Marcus Garvey Drive, Unit 10A
Kingston 13
Tel: 923-4729