Post on 21-Jan-2016
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© ABSL Power Solutions 2007© STM Quality Limited
STM Quality Limited
Introduction to 5C
TOTAL QUALITY MANAGEMENT
5C
© STM Quality Limited
STM Quality LimitedOBJECTIVE: To raise the level of
understanding on the practical application of 5C within the workplace
Why: In order that employees can apply & transfer that learning into their own areas of responsibility
How: By a practical step-by-step training approach
Application of 5C
© STM Quality Limited
STM Quality Limited
What is 5C?
Structured approach to the application of: - Housekeeping - Associated improvement activitiesIt focuses activities towards: - Improving the workplace: health & safety, quality &
efficiency - How we operate within it - Eliminate waste in all its forms
© STM Quality Limited
STM Quality Limited
Why Apply it?
To create a cleaner, safer & more cost effective company by:
Removing unnecessary items in the workplace
Controlling/labelling stock inventories & essential items
Standardisation in the workplaceIdentification of potential safety
hazards
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STM Quality Limited
Considerations
It requires:A disciplined approach to make it
happenVisual involvement & commitment from
allMaintaining all areas, not just the shop
floorRecognition of a journey, not a race - Not everyone will be committed!
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STM Quality Limited
Considerations
Commitment to 5C:Why will people not be
committed?
What can we do about it?- EDUCATION- INVOLVEMENT- COMMUNICATION
5C
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STM Quality Limited
CLEAR OUT - Remove unnecessary itemsCONFIGURE - Layout - agree storage spacesCLEAN & CHECK - arrange daily cleaning
routinesCONFORMITY - Maintaining a spotless
workplaceCUSTOM & PRACTICE - day to day operation
of the new culture in the workplace
What Are The Elements Of 5C?
© STM Quality Limited
STM Quality Limited
Where Did 5C Come From?
This came from the Japanese who use 5S:CLEAR OUT (Seiri)- Remove unnecessary itemsCONFIGURE (Seiton)- Layout - agree storage
spacesCLEAN & CHECK (Seiso)- arrange daily cleaning
routinesCONFORMITY (Seiketsu)- Maintaining a
spotless workplaceCUSTOM & PRACTICE (Shitsuke)- day to day
operation of the new culture in the workplace
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STM Quality Limited
Where Do You Start?
CLEAR OUT!
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STM Quality Limited
What Are The Elements OF ‘Clear out’?
1. CLEAR OUT - remove unnecessary items
Photograph the area prior to starting
Identify unnecessary items & apply ‘red tag’
Apply tagging rulesDeal with tagged itemsEliminate defective items & dead stock
DateDescriptionLocation
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STM Quality Limited
Red Tag Process
The term ‘unnecessary items’ means: ‘things that are not needed for current production’
As soon as an unnecessary item is found it should be identified with a red tag & moved to the appropriate area
Retain any item to be used within the next month according to the current business requirement - tag everything else
Red tags are to draw attention to items: - that must be actioned upon - which should also remind people of safety & cost
Clarify WHY red tag has been attached & decide on action!
DateDescriptionLocation
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STM Quality Limited
Where now? - Configure
Allocate a place for everythingEnsure all areas are clearly identified e.g.
gangways, work areas, etc.Establish rules to keep everything in placeArrange items for quick access when
required, in the quantity and quality required
Eliminate searching, organise the workplace
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STM Quality Limited
What are the elements of Configure?
2. CONFIGURE - Assigning storage spacesVisual identification within the workplaceStandardisation of storage - KEY - ACCESS TO ANYBODY, IMMEDIATELY
3 POINTS1. Can see2. Can take
out3. Can return
- Where? - What? - How
many?
3 KEYSFix position Fix itemsFix quantity
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STM Quality Limited
But Everywhere’s Dirty!
Dirt can create hazards!
Cleaning can identify problems!
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STM Quality Limited
What are the elements of Clean and Check?
3. CLEAN & CHECK - Consolidate daily cleaning
Decide what to cleanDecide who is in charge of each cleaning
taskDecide on cleaning methodsPrepare cleaning tools & equipmentImplement cleaning
© STM Quality Limited
STM Quality Limited
Maintaining 5C – Monitor and Audit
Example of production workplace Audit Chart
SECTION AUDITED: AUDITOR: ___________________ DATE:______________
NON-CONFORMANCES AND COMMENTS SCORE ACTIONED BY SCORINGGUIDELINES: MAX 10 DATE CRITERIA:
GENERAL CLEANLINESS
LITTER ON FLOOR; ACCESS
TO BINS; BINS OVERFLOWING;
GANGWAYS CLEAR; ETC.
EQUIPMENT STORAGE
TOOLS PUT AWAY; PRESS
TOOLS & JIGS CORRECTLY
STORED; ETC.
COMPONENT CONDITION
CORRECT LABELLING; BINS
OVERFLOWING WITH JOBS;
RUSTY COMPONENTS
MACHINE CLEANLINESS
SLUGS; EXCESSIVE OIL; CUPS
& RUBBISH LEFT ON MACHINES
WORK AREA CLEANLINESS
WORK SURFACES FREE FROM
NEWSPAPERS, WRAPPERS,
CLOTHES ETC.
10- EXCELLENT. NO NON-CONFORMANCES9-8- GOOD BUT MINOR FAULTS WHICH LEAVE ROOM FOR IMPROVEMENT.7-6- AVERAGE-SEVERAL NON-CONFORMANCES5-4- POOR-REQUIRES CORRECTION & RE-AUDITING.3-2- VERY POOR & POSSIBLE SAFETY PROBLEMS. IMMEDIATE ACTION REQUIRED & RE-AUDIT.1-
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STM Quality Limited
Keep It Neat And Tidy
Ensure cleaning procedures are maintainedEnsure everyone is involved & knows how to
maintain standardsRemember SAFETY is the prime concernEnsure improvements are displayed &
everyone knowsDevelop ownership & pride in our workplace
What can be done to prevent accidents & untidiness?
© STM Quality Limited
STM Quality Limited
What are the elements of Conformity?
4. CONFORMITY - Maintain a perfect workplaceMaintain established principlesReview checkpoints
- no unnecessary items - Stocks & tools are accessible - Cleaning being carried out
Develop an organising checklistAgree a frequency of checking, responsibility
& follow up action procedures
© STM Quality Limited
STM Quality Limited
How Can We Improve 5C?
APPLY all 5 steps of 5CMONITOR & review
frequently & consistently
OWN your own workplace
WHEN you make improvements: “SHOUT IT!” - take pride in achievements
DON’T STOP continuous improvement
© STM Quality Limited
STM Quality Limited
What are the elements of Custom and Practice?
5. CUSTOM & PRACTICEVisual controlTake more photographsCreate an auditing mechanism
appropriate to the area being checkedEstablish action/audit patrols - every
area, regularly & publish results
© STM Quality Limited
STM Quality Limited
Maintaining 5C - Don’t wait until it’s too late!
REGULAR CLEANING
ORGANISE & MONITOR
DON’T WAIT UNTIL IT’S TOO LATE!
© STM Quality Limited
STM Quality Limited
Summary ApproachApply 5C in a step-by-step approachEnsure clear communication before starting
activitiesEnsure ownership is established & understoodEnsure involvement of the people in the areaSet standards at each element before progressingRemember 5C is the responsibility of all, not just
the few!
An ongoing improvement activity –
‘a way of life’!