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STM Quality Limited

Introduction to 5C

TOTAL QUALITY MANAGEMENT

5C

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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

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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

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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?

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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

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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?

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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

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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

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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

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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!

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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’!