15S

5S Basics

5S5S

25S

8 WASTES8 WASTES• DDefect / Correction• OOverproduction• WWaiting• NNot utilizing employee talents• TTransportation / material movement• IInventory• MMotion• EExcessive processing

35S

PPBPPB(Monthly)(Monthly)

COBCOB(Daily)(Daily)

Visual Factory-Information Visual Factory-Information Gathering/OrganizationGathering/Organization

PABPAB(Hourly)(Hourly)

Information CenterInformation Center(Plant-wide Reporting)(Plant-wide Reporting)

FromEach Department

Department ReportingDepartment Reporting

PABPAB = Process Analysis BoardCOBCOB = Certified Operation BoardPPBPPB = Process Performance Board

45S

SortSort

StraightenStraighten

ShineShine

StandardizeStandardize

SustainSustain

55S

65S

75S

85S

95S

105S

There are basically three different types of workplaces...

115S

125S

135S

145S

155S

165S

175S

1S

4S

3S

2S

5S

Sort

Straighten

Shine

Standardize

Sustain

185S

195S

205S

1SSort

• Segregate What Is Needed, Needed Later, and Not Needed• Discard What Is Not Needed•Segregate Needed Items By Frequency of Use

215S

Where to PerformWhere to Perform

225S

235S

245S

C E N G-

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X X X

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File completed Tag at ____________

5S -

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Item Name &/or Description:

Department: Value per Item:

Classification: 1.              Raw Material2.              Work-in-Process3.              Component4.              Finished Product

5.              Machine / Equipment6.              Mold / Jig7.              Tool / Fitting8.              Other______________

Reason: 1.              Unnecessary2.              Defective3.              Leftover Material

4.              Unknown5.              Other______________

Action: 1.              Eliminate2.              Return3.              Move to Red Tag Storage 4.              Other_______________

Completed:   

Tag Attached:

Year_____ Month_____ Day____

Action Taken:

Year_____ Month_____ Day_____

255S

Sort

265S

275S

285S

295S

2S

Straighten

305S

315S

Small Crescent Wrench

Small Claw Hammer

Flat Tip Screwdriver

Large Crescent Wrench

Large Claw Hammer

325S

335S

345S

355S

Stage 1Stage 1 Stage 2Stage 2 Stage 3Stage 3 Stage 4Stage 4

365S

375S

Before

After

385S

Before

After

395S

Before

After

405S

Before

After

415S

425S

3S

Shine

435S

Why Shine?

445S

455S

465S

475S

Shine Targets

485S

495S

5S Assessment

Score Sheet

5S Observed Condition Improvement Action

0

Storage of cleaning equipment: All cleaning equipment stored in a neat manner; handy and readily available when needed

0

Items on floor: Work-in-process, tools and any other material are not left to sit directly on the floor. Large items such as tote boxes are positioned on the floor in clearly marked area, identified by painted or taped lines.

0

Storage and arrangement:: Boxes, containers, and materials are always stored neat and at correct work angles convenient to the operators where appropriate. When items are stacked evenly or in a manner that would not cause them to toppling over. Storage areas are provided for all necessary items at POUS (Point-Of-Use Storage). No items are placed on top of machines, cabinets, and equipment. Unidentified items can not lean against walls or columns.

0

Operating equipment/machinery: Each piece of equipment/machinery has guards and deflectors that prevent debris from falling uncontained to the floor.

0Document storage: Only documents necessary to the operation are stored at the workstations and are stored in a neat and orderly manner.

0Tool and gauges arrangement: Tools, gages and fixtures are arranged neatly and stored, kept clean and free of any risk of damage.

0

Workbench and desk control: Kept free of objects including records and documents (unless in use). Tools and fixtures are clean and placed in their proper location.

0

Information boards: PPB, COBs, and PABs are arranged in a neat and orderly manner. No outdated, torn, or soiled documents are displayed

0

Emergency access: Fire hoses and emergency equipment are unobstructed and stored in a prominent easy-to-locate area with proper identification. E-Stop switches and breakers are marked or color-coded for immediate visibility.

0

Aisle ways marking: Aisles and walkways are clearly marked and can be identified at a glance; lines are straight and at right angles where appropriate with no chipped, worn floor marking.

0

Equipment maintenance: Controls of machines are properly labeled. Critical points for daily maintenance checks are clearly marked. Equipment check sheets are clean, neatly displayed and completed daily.

0

Tool and gauges convenience: Tools, gages and fixtures are arranged so they can be easily accessed when needed. 0Shelves and benches arrangement: Arranged, divided and clearly labeled it is obvious where things are stored; status and condition is recorded

0

Equipment cleanliness: All machines and equipment are kept clean by routine daily care. 0Floor cleaning: All floors are clean and free of debris, oil and dirt. Cleaning of floors is done routinely -- daily at a minimum—posted schedule.

05S control and maintenance: There is a disciplined system of control and it is maintained at the highest possible level. It is the responsibility of every one to maintain this system and environment. Documentation exist indicating cleaning responsibility for each team member in the work area.

0

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·  Remove unneeded equipment, tools, furniture, etc. ·  Provide information on department PPB·  Review excess inventory, supplies, parts, or materials ·  Identify existence of safety hazards (water, oil, chemical, machines, extension cords, etc.)

{Enter Location here}Location Being Audited: (place cursor in red corner for INSTRUCTIONS)

To-Do Items

Remove unnecessary items. All items not required for performing operations are removed from the work area. Only tools and products are present at workstation

·  All team members have had 5S training·  Daily 5S actions performed·  Place all personal belongings stored in a neatly maintained location ·  Job aids are current and readily accessible·  Routine 5S Implementation Audit is performed until sustained

Aisle ways maintenance: Aisles are always free of materials and obstructions; nothing is placed on the lines and objects are always placed at right angles to the aisles where appropriate.

0.00Legend: <2 (RED) 2 to 4.75 >4.75 (GREEN)

Equipment painting: All machines and equipment are neatly painted; equipment cleaning schedule developed and posted for each major piece of equipment.S

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Document control: All documents are labeled clearly as to content and responsibility for control and revision. Obsolete

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·  Floors, walls, stairs, and surfaces are free of dirt, oil and grease·  Equipment is kept clean and free of dirt, oil, and grease·  Cleaning materials are easily accessible·  Lines, labels, signs, etc. are clean and not damaged·  No other cleaning problems (of any kind) are present

0

0

0

·  Correct location for items are identified·  Items are placed in their correct locations·  Aisle ways, workstations, equipment locations are indicated·  Items are put away immediately after use·  Inventory or WIP height and quantity limits are obvious

·  Necessary information is visible·  All standards are known and visible·  Checklists exist for all cleaning and TPM maintenance jobs·  All quantities and limits are easily recognizable·  All necessary items can be located in 30 seconds

5S Implementation Audit Score =

505S

515S

525S

It is important that It is important that we establish the we establish the

first 3S before we first 3S before we progress to the progress to the

next 2S.next 2S.

535S

545S

4SStandardize

555S

565S

575S

585S

5SSustain

595S

605S

January 2007 June 2007

615S

625S

635S

?

645S

655S

Now, what would you do?

665S

675S

685S

695S

705S

RememberRemember55 SS

1S

4S

3S

2S

5S

Sort

Straighten

Shine

Standardize

Sustain

715S