– as close to the work area as possible – for the right job, Knapp says. The methodology “helps to eliminate some of the Seven Deadly Wastes – Defects, Inventory, Overproduction, Waiting, Motion, Transportation and Overprocessing – especially wasted time, transportation and motion, while making work easier to do.” Developed in Japan by Toyota, 5S workplace organization is a way to reduce waste and optimize productivity by creating a quality work environment that is arranged in a clean, efficient and safe manner and uses visual management to achieve more consistent operational results. A key element of Toyota’s philosophy of Kaizen, a Japanese word meaning continuous improvement, 5S involves five steps, all of which begin with the letter S. Knapp recommends this step-by-step POU process based on the 5S principles: 1. Sort – Determine what is needed and what isn’t. Remove what is not needed from the work area. 2. Simplify – Have a place for everything, taking into account workflow, and be sure everything is in its place. This should be visual and obvious. 3. Systematic Clean – This should be done daily for equipment, tools and the workplace, and needs to include an inspection of these items so any defects can be dealt with. 4. Standardize – Turn the process into a system, document methods, define accountabilities, audit and measure. Simple to use and understand organizational standards must be established in order to enable the fifth S. 5. Sustain – Train workers to be sure they are following the procedures and processes. Work to continually improve those methods using the previous four steps. IN THE SHOWER POU can be applied anywhere that work is regularly done, says Knapp, and uses the shower as an example to demonstrate the concept of Point of Use. “In your shower at home, you most likely have soap, shampoo and maybe some other hair care products. You don’t get out of the shower after getting wet and walk to get shampoo. You keep it right there where you’re going to use it. “You don’t keep multiple bottles of shampoo in the shower, but you might bring in a new bottle once the old one is really low just so you don’t run out mid-shower,” he continues. “POU is that simple.” The hard part, observes Knapp, is determining “how many times can you apply POU at work to keep technicians from ‘getting out while dripping wet’ to go fetch something you already knew they would need.” He cites hand tools as a for instance. Do technicians use all of them all the time? Or, are a few of the tools used over and over again while some get used just once a month or so? Are the ones used all the time stored in the same place – distance from the place of work – as the tools rarely used? “Maybe the common tools should be on a mobile cart or work stand,” suggests Knapp. “That would be application of POU. “Smart technicians already do some of this. They have small carts or even tool bags that go with them to the job, which carry their essential tools – the ones that get used over and over all the time.” EXECUTION To implement Point of Use there are 10 steps, says PPG’s Knapp: | Cover Story Technicians can reduce wasting time “chasing” commonly used tools and parts by crafting and using mobile carts. Photo courtesy of Professional Distributor Magazine VehicleServicePros.com/10621089 Connected By: TruckDown.com REMOVE SOMETHING WHEN LOOKING FOR SERVICE. INTRODUCING MERITOR® SERVICE POINT. When your truck is down, it’s not the time to take chances. You need quality service you can count on – fast. That’s why Meritor Service Point and TruckDown® have teamed up to bring you the fastest and surest way to get the quality Meritor service and parts you need. Just visit TruckDown.com, and you’ll be connected to the leading Meritor-quali ed independent service garages across the United States and Canada. Get ready to experience a whole new level of service. Visit TruckDown.com today to connect with the Meritor-quali ed service locations in your area or learn more about Meritor Service Point at MeritorServicePoint.com. ©2016 Meritor, Inc. All rights reserved. ISSUES can be solved by standardizing work. 14 FLEET MAINTENANCE ❚ APRIL 2016 ❚ VehicleServicePros.com
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