How to implement effective 6S management at the compressor room site?
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So how can on-site 6S management be implemented in the compressor room? Huatianmou 6S management expert will guide you in exploring: What is 6S management? The main components of 6S management are: sorting (SEIRI), organizing (SEITON), cleaning (SEISO), standardizing (SEIKETSU), discipline (SHITSUKE), and safety (SECURITY). Taking the production workshop as an example, we will discuss 6S management in the compressor room. 1. Sorting: Decide what to keep and what to discard – get rid of items that are not used for a long time, such as those that have not been used for over three years; eliminate everything that can be gotten rid of. 2. Organization: Scientific layout for quick access. Organize the materials and tools used for management and maintenance by first removing any unnecessary or defective spare parts, and then arranging the tools in the warehouse in a way that ensures order, neatness, convenience, and efficiency. Both the placement of materials and tools is managed in a categorized manner; items of the same type are placed together, which not only improves the appearance but also makes it easier to find them when needed. Scientific organization helps save space; especially by placing certain items on higher shelves, this prevents them from taking up valuable space, allowing the area to appear larger. 3. Cleaning: Remove trash to improve the environment. Generally, the areas responsible for maintaining environmental hygiene are divided into three sections: one is the control room, one is inside the factory building, and one is outside the factory building. The cleaning in the duty room mainly involves wiping the floors, including areas such as the bathrooms, electrical rooms, changing rooms, and the duty room itself. Apart from necessary everyday tools like noise-canceling earplugs, flashlights, safety helmets, and duty logs, nothing else is visible on the surface. The floor is covered with tiles and is cleaned regularly. There are mainly two tasks outside the factory building: weed removal in summer and snow removal from the roads in winter. It is very important to remove weeds promptly; otherwise, dead branches and leaves, grass seeds, and cotton fluff will be carried by the wind into the compressor station, increasing the load on the intake filters. 4. Cleaning: Clean the environment thoroughly. The focus of cleaning is on the factory building; for cleaning the building, one aspect to pay attention to is the floors, and the other is the compressors. The factory building mainly requires keeping the floor clean. There is a lot of dust on the floor, so it needs to be cleaned regularly to keep it clean. Apart from the ground, it’s the compressor itself. The cleaning of the compressor itself consists of two parts: internal and external. The external cleaning mainly involves wiping the compressor casing, and this task is carried out regularly. Another task is the cleaning inside the compressor, which is mainly carried out on spare equipment and is also done on a regular basis. To ensure the long-term cleanliness of the environment, we have established systems and plans to carry out cleaning tasks at regular intervals. There are set targets, inspections, records, and corrective actions in place, ensuring that these tasks are carried out on a consistent and standardized basis. 5. Competence: Establish systems and develop good habits. Systems depend on people to be put into practice, and when people’s initiative is brought into play, it can greatly facilitate work. In our work, various systems are established accordingly. In addition to systems such as the production process, information regarding team building, transparency in factory operations, emergency response plans, prevention of occupational diseases, and smoking areas is also displayed publicly on walls. Articles are also frequently published in the group’s internal publications to offer recognition, boost morale, and encourage everyone to follow various systems and procedures voluntarily, thus developing good work habits. 6. Safety: Safe operations with a people-oriented approach. The core goal of 6S management is to ensure safe production. In our daily work, one of the common safety issues is equipment maintenance; the company has strict regulations in this regard, such as requiring the use of safety helmets whenever entering the factory area ； The work uniforms for the entire company are also uniform ； Safety measures must be in place for various maintenance operations; especially for work involving open flames, work at heights, and work in confined spaces, safety measures are essential ； Camera-based security monitoring systems are installed in every corner of the factory, with round-the-clock surveillance.
What was said upstairs are the requirements and standards. Let’s get practical – \"focus on efficiency and ensure practical implementation.\" Usually, it is female workers who operate air compressor stations; \"three women can handle one task,\" and larger air compressor stations have more than just three women. :Lol, in state-owned enterprises and some private companies, many people can get access to the air compressor stations; they more or less all have some kind of connections. :Lol:lol You’re asking for too much; you’re getting impatient. Maybe her husband or some manager will give you a hint in a subtle way. (I’ve really encountered such people – women who constantly use their phones or watch movies; not even the deputy manager can get them to stop). Women care about maintaining their face, so it’s necessary to have more conversations and communication with them. “Clothes, shoes, and children” are all topics they care about. (Toyota has specialists who are dedicated to this task); their talk revolves around the hazards associated with poor cleanliness of tables, floors, and equipment ； When children learn*, it tends to revolve around her work and daily life*. It makes her feel embarrassed; she has to follow the rules to some extent. The young wife taught her how to take care of children. I’m not exaggerating – I recommended an app called “Wukong Literacy”, and my daughter in kindergarten made great progress using it. Now, the job records at the air compressor station are properly numbered across the entire company; the handwriting is neat, and any errors are corrected by carefully scraping them away with a blade. Tackle them one by one; there are always a few who perform relatively well. Once there is evidence, praise them in public, and if necessary, use certain authorities to do so – take the leaders along during inspections and have them give praise through their own words. If a few rules are established, it lays the foundation for creating a good working atmosphere. It would be best to have cases where potential hazards related to \"major equipment\" were identified during cleaning and maintenance processes, with substantial rewards offered for such findings! Give priority to recognizing excellence! Water and oil leakage in air compressor station equipment pose a serious threat to the stable operation of such equipment. Problems are often identified during the 5S process. Here, due to careful inspection during routine checks, we noticed an unexplained increase in the oil level in the centrifuge oil cooler; after shutting down the machine promptly, we found that the tubes were indeed punctured. Both the Equipment Department and the workshop offered substantial rewards, and the individual in question was nominated as the company’s quarterly Star Employee. The internal publications mentioned upstairs, as well as promotion through WeChat official accounts, are all good methods. Women workers should also be actively encouraged to participate in the cultural and sports activities organized by the company (the women workers in our workshop are mostly at the air compressor station). During the Spring Festival team meeting, they deceived people and urged the representatives to go to the workshop. It enhances cohesion; generally, when women agree to take on a task, they tend to strive for perfection more than men, especially in events that are presented to the public. The key is to be able to mobilize. :Lol, I managed to “convince” two female workers from the air compression stations to participate in the speech competition organized by the company. Fortunately, both of them won first place, beating many undergraduates. (One of their speeches is even moving to tears.) Their stories come from the front lines, are more relatable, and make people want to listen. All of the above aims are to create a good working atmosphere. People always have needs; she may not be afraid of having her salary reduced, but she prefers to receive recognition for her work! With cohesion in place, other things become relatively easier; it’s also simpler to meet additional requirements. Due to maintenance work in the air compressor room, oil stains are bound to appear on the floor, and it’s quite frustrating to have to clean it all up thoroughly. They take the initiative to discuss how to divide the tasks and assign responsibilities, to use trisodium phosphate for cleaning... I think taking the initiative is the essence of what Lean advocates.