Lean Six Sigma - Revision history

Marcin: /* Visual Workshop and Organization Master List */

2026-03-01T23:19:39Z

Visual Workshop and Organization Master List

← Older revision		Revision as of 23:19, 1 March 2026
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	= Visual Workshop and Organization Master List =		= Visual Workshop and Organization Master List =
			Source - [https://chatgpt.com/share/69a4c950-b7a4-8010-a3ca-94126496535c]
	== 1. Visual Control Foundations ==		== 1. Visual Control Foundations ==
	=== Workspace Zoning ===		=== Workspace Zoning ===

Marcin: /* Core Visual Workshop Costs: 5S + Flow + Safety + Boards */

2026-03-01T23:17:22Z

Core Visual Workshop Costs: 5S + Flow + Safety + Boards

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Marcin: /* Core Visual Foundation: 5S + Flow + Safety + Boards */

2026-03-01T23:13:26Z

Core Visual Foundation: 5S + Flow + Safety + Boards

← Older revision		Revision as of 23:13, 1 March 2026
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	\|}		\|}

	= Core Visual ~~Foundation~~: 5S + Flow + Safety + Boards =		= Core Visual Workshop Costs: 5S + Flow + Safety + Boards =

	== Scope (Included Systems) ==		== Scope (Included Systems) ==

Marcin: /* Visual Workshop Implementation Cost */

2026-03-01T23:13:02Z

Visual Workshop Implementation Cost

← Older revision		Revision as of 23:13, 1 March 2026
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	\|}		\|}

	~~=Visual Workshop Implementation Cost=~~
	= Core Visual Foundation: 5S + Flow + Safety + Boards =		= Core Visual Foundation: 5S + Flow + Safety + Boards =

Marcin: /* Visual Workshop Implementation Template */

2026-03-01T23:12:44Z

Visual Workshop Implementation Template

← Older revision		Revision as of 23:12, 1 March 2026
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	\| $20–$200		\| $20–$200
	\|}		\|}

			=Visual Workshop Implementation Cost=
			= Core Visual Foundation: 5S + Flow + Safety + Boards =

			== Scope (Included Systems) ==
			* Floor zoning
			* Shadow boards
			* Labeling system
			* Min/Max + Kanban (consumables control)
			* Cleaning stations
			* FIFO lanes
			* WIP limits
			* Status boards (work tracking)
			* Safety visuals
			* Audit boards (5S + safety + quality)
			* Escalation ladder (who to call / when)
			* KPI wall (SQDCM or similar)
			* Skill matrix (training + qualification visibility)
			* Defect board (quality at the source)
			* PM board (preventive maintenance visibility)

			== Estimated Material Cost ==
			* $4,000 – $12,000 (typical)

			== Cost Coverage (Typical Spend Categories) ==
			* Tape/paint (floor lines, zone markings, arrows)
			* Label printer + supplies (labels, label stock, laminating)
			* Boards (whiteboards, magnetic boards, bulletin boards)
			* Bins/racks (point-of-use storage, staging racks)
			* Dividers/foam (drawer organization, tool shadowing)
			* Signage (PPE, hazards, exits, instructions)
			* Lighting upgrades (basic task lighting where needed)
			* Basic maintenance tools (PM consumables, tags, holders)

			== Labor Effort ==
			* 200–400 internal hours over 4–8 weeks (typical)

			== Baseline Standard ==
			This is the baseline for a serious professional shop:
			* Clear zones, labeled storage, and point-of-use organization
			* Visible workflow status and WIP control
			* Visible safety and quality standards at the workstation
			* Regular audits with ownership and follow-up
			* Metrics and escalation pathways posted and used

Marcin: /* Gemba Walk */

2026-03-01T23:08:02Z

Gemba Walk

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Marcin at 23:01, 1 March 2026

2026-03-01T23:01:51Z

← Older revision		Revision as of 23:01, 1 March 2026
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			=About=

	https://en.wikipedia.org/wiki/Lean_Six_Sigma (LSS)		https://en.wikipedia.org/wiki/Lean_Six_Sigma (LSS)

Marcin: /* Visual Workshop */

2026-03-01T23:01:39Z

Visual Workshop

← Older revision		Revision as of 23:01, 1 March 2026
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	\|}		\|}

	~~=Visual Workshop=~~
	= Visual Workshop and Organization Master List =		= Visual Workshop and Organization Master List =

Marcin: /* 5S Method for Clean Organization */

2026-03-01T22:43:38Z

5S Method for Clean Organization

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Marcin: /* Gemba Walk */

2026-03-01T22:25:28Z

Gemba Walk

← Older revision		Revision as of 22:25, 1 March 2026
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	*Understand problems firsthand		*Understand problems firsthand
	*Support continuous improvement		*Support continuous improvement

			{\| class="wikitable"
			! Section
			! What to observe / ask
			! Evidence to capture
			! Rating (0–2)
			\|-
			\| Walk setup
			\|
			* Purpose/theme for today is clear (Safety / Quality / Flow / 5S / Training)
			* Route and timebox defined (e.g., 20–30 min)
			* Go to point of use (where value is created), not the office
			\|
			* Theme stated
			* Areas visited
			* Time started/ended
			\| 0–2
			\|-
			\| Safety
			\|
			* Any immediate hazards (trip, pinch, electrical, overhead load, PPE gaps)?
			* Are guards, lockout/tagout, and signage in place where needed?
			* Ask: “What safety concern are you most worried about today?”
			\|
			* Hazard list + location
			* Photos of hazards (if allowed)
			* Owner + due date for fixes
			\| 0–2
			\|-
			\| Quality at the source
			\|
			* Is the standard for “good” visible at the workstation (spec, jig, template)?
			* Is first-piece/first-article verification happening?
			* Are defects detected immediately, or discovered later?
			* Ask: “What causes rework here?”
			\|
			* Defect/rework examples
			* Standard references used (doc/photo/jig)
			* Containment actions
			\| 0–2
			\|-
			\| Flow and bottlenecks
			\|
			* Where is work waiting (queues, WIP piles, stalled tasks)?
			* Are downstream steps starved or blocked?
			* Ask: “What is slowing this step down right now?”
			\|
			* Bottleneck step identified
			* WIP counts (rough)
			* Wait reasons
			\| 0–2
			\|-
			\| Standard work adherence
			\|
			* Is there a known best method? Is it being followed?
			* Are deviations visible and explained?
			* Ask: “What part of the standard doesn’t match reality?”
			\|
			* Standard work posted (Y/N)
			* Deviation notes
			* Improvement opportunities
			\| 0–2
			\|-
			\| 5S and visual management
			\|
			* Sort: clutter/red-tag items present?
			* Set in order: tools labeled and in their homes?
			* Shine: clean-to-inspect condition?
			* Standards posted and current?
			* Ask: “Do you spend time searching for tools/materials?”
			\|
			* 5S gaps by S
			* Photos of before/after (if allowed)
			* Time-to-find estimate
			\| 0–2
			\|-
			\| Materials and logistics
			\|
			* Are materials staged at point of use in the right quantity?
			* Are there stockouts or overstock?
			* Are pull signals (Kanban/min-max) in place?
			* Ask: “What materials do you run out of most often?”
			\|
			* Stockout list
			* Overstock list
			* Reorder triggers (Y/N)
			\| 0–2
			\|-
			\| Equipment and uptime
			\|
			* Any downtime, jams, tool failures, or workaround behavior?
			* Is preventive maintenance visible and current?
			* Ask: “What equipment causes the most interruptions?”
			\|
			* Downtime causes
			* Maintenance tags/logs
			* Needed spares/tools
			\| 0–2
			\|-
			\| People, training, and engagement
			\|
			* Are roles clear? Any confusion on handoffs?
			* Training needs visible (new task, new tool, new standard)?
			* Ask: “If you could change one thing today, what would it be?”
			\|
			* Training gaps
			* Suggestions captured
			* Blockers requiring leadership action
			\| 0–2
			\|-
			\| Problem solving and follow-up
			\|
			* Are issues tracked with owners and due dates?
			* Are yesterday’s actions closed or progressing?
			* Ask: “Which open issue is most painful right now?”
			\|
			* Action log entries (owner, due date)
			* Escalations needed
			* Next check-in date
			\| 0–2
			\|-
			\| Closeout
			\|
			* Summarize key observations to the team (no blame)
			* Confirm next steps, owners, dates
			* Thank the operators; confirm how feedback will be used
			\|
			* Top 3 issues
			* Top 3 quick wins
			* Commitments made
			\| 0–2
			\|}
			<small>Scoring suggestion: 0 = not in place / concerning; 1 = partially in place; 2 = consistently in place. Capture 3–5 actionable items per walk and review closure on the next walk.</small>