5S MILL AUDITOR TRAINING
BY:MARWANI HIRMI MUDA
1. Complete first 3S by December 2012.
2. Complete 4th S for manufacturing processes by June 2012.
3. 5S audit score of 3.5 by December 2012
MNI 5S Target
S1 Sort out unnecessary itemsS2 OrganiseS3 Cleaning & InspectionS4 Standardization/Visual controlS5 Discipline
5S CONCEPT
Zones 5S Leader Paper Mill (exclude maintenance office) Barry Pulp Mill (include sludge building & Chem. Prep.) Selvam Finishing Marwani Biomass Zainol CHPP Rosli MA RWETP ( includes pump house ) Razab RPW Markus Store (include gas storage & store open yard) Hup Workshop Sanjivi Roll shop ( includes used oil ) Prekash Site and admin ( excludes open yard & Tech. lab ) Bakhtiar Labs ( wet end, Dry end & Tech. Lab) Romizan TNB substation & transformer Wan Sabree Finishing Product warehouse Adnan
StoreWorkshop
Pulp MillPaper Mill
Recovered paper
Warehouse
Biomass Plant
CHPP Plant
ETP
RWTP
Open Space
AdminRoll Shop
Car Park
TNB Substation
Finished Product
warehouse
Finish
ing
Mill Zone
Zones 5S Leader
Paper Mill (exclude maintenance office) Barry
Pulp Mill (include sludge building & Chem. Prep.) Selvam
Finishing Marwani
Biomass Zainol
CHPP Rosli MA
RWETP ( includes pump house ) Razab
RPW Markus
Store (include gas storage & store open yard) Hup
Workshop Sanjivi
Roll shop ( includes used oil ) Prekash
Site and admin ( excludes open yard & Tech. lab ) Bakhtiar
Labs ( wet end, Dry end & Tech. Lab) Romizan
TNB substation & transformer Wan Sabree
Finishing Product warehouse Adnan
Zone and Leader
Scope
1. Covers the entire MNI facilities including off site installations like the river pump house and pipe lines
Duties & Responsibilities
2. Setting of 5S audit standard and format3. Working closely with the Training Sub committee to ensure
sufficiency in competent auditors4. Setting up annual audit calendar5. Conducting regular audit and tracking of the audit results6. Participate in Hong Leong Group inter company cross 5S audit
Mill Scope & Duty
7
Team A Team B
Marwani ( Leader) Markus Buas ( Leader)
Yushak Lamin Mitchelle Ting
Noor Rafidah Mohd Saidi Ali
Chim Moo Shim Ahmad Mazeli
Mohd Fairus Talhah Sivalingam
Mill 5S Audit Team
2011 2012No Activities PIC Status Feb Mac APr Ma
y June July Aug Sept Oct Nov Dec Jan Feb MarAPr Ma
y June
July Aug Sept Oct Nov Dec
1 Mill 5S Committee Set Up AT Completed 23 2 Form Mill 5S Audit Team TKH 30 3 5S audit team training Marwani 1,9 4 3S check sheet and report template Marwani 12 5 5S check sheet Marwani 31 6 5S Score Board Marwani 31 3S Audit 6 Finishing/ Main Lab Team A /B 7 ETP/Bomba pump house/FPW Team A /B 8 TNB sub station & transformer / HV/ CHEM PREP Team A /B
9 RWETP/ Intake / RPW / Sorting Plant Team A /B
10 Admin/Mill wide site / DE,WE Lab/Rollshop/Workshop/Biomass
Team A /B
11 RCF/ CHPP/Maint Off Team A /B 12 PM / Store Team A /B 5S AUDIT (Visual Control) 13 Finishing/ Main Lab Team A /B 14 ETP/Bomba pump house/FPW Team A /B 15 TNB sub station & transformer / HV/ CHEM PREP Team A /B 16 RWETP/ Intake / RPW / Sorting Plant Team A /B 17 Admin/Mill wide site / DE,WE
Lab/Rollshop/Workshop/BiomassTeam A /B
18 RCF/ CHPP/Maint Off Team A /B 19 PM / Store Team A /B Repeat 5S AUDIT (Those below mill score target) 20 Area TBC Team A /B 21 Area TBC Team A /B 22 Area TBC Team A /B 23 Area TBC Team A /B 24 Grand presentation - ETP, TNB Substation,
FPW
25 Grand presentation - Pulp Mill, RPW, Site & admin
26 Grand presentation - Roll shop, Workshop, Biomass
27 Grand presentation - Paper Mill, CHPP, RWTP, Store
Mill 5S Auditor Calander
5S = house keeping only5S Benefits
Heinrich PrincipleHeinrich Principle
Critical Accident1
29
300
Minor Accidents
Factors of Accident( near miss )
BreakdownBreakdown
Eg. Motor
Did not Rotate
Over HeatVibration
Abnormal Sound, etc.
Dirty (Sand, Cutting chips etc.)
High HumidityOil Mist
Heavy Load, etc.
Prev
entiv
e M
aint
enan
ce
Improvement ( Countermeasure ) focus not only on the problems,but also inclusive the contributing factors.
Indi
vidu
al Im
prov
emen
t
5S. A
uton
omou
s M
aint
enan
ce
Bre
akdo
wn
Mai
nten
ance
Meaning, Definition and Purpose of 5S
Meaning of 5S
GOODARRANGEMENT
( SEIRI )
GOOD ORDER( SEITON )
CLEANING
( SEISO )
NEATNESS
(SEIKETSU)
DISCIPLINE
(SHITSUKE)
Definition
Separate necessary& Unnecessary
Things
Determine a Layout Enabling Ready Use of Necessary Things at the Necessary Time
Clean it by Removing Dirt, Stain and Foreign Substances
Ensure the 3S above(Maintain Neatness in
Terms of Hygieneand Environmental
Contamination)
Encourage Obedience to
the Rules
Definition
Separate necessary& Unnecessary
Things
Determine a Layout Enabling Ready Use of Necessary Things at the Necessary Time
Clean it by Removing Dirt, Stain and Foreign Substances
Ensure the 3S above(Maintain Neatness in
Terms of Hygieneand Environmental
Contamination)
Encourage Obedience to
the Rules
Example of EffectExample of Effect
Reduced inventoryReduced inventory
Efficient use of limited spaceEfficient use of limited space
Prevention of missing things Prevention of missing things
Prevention of leakage of air and oilPrevention of leakage of air and oil
Prevention of searching for last itemsPrevention of searching for last items
Elimination of unstable stateElimination of unstable state
Maintenance,improvement of capacity of facilitiesMaintenance,improvement of capacity of facilities
Important points of facilities can be cleaned and inspected
Important points of facilities can be cleaned and inspected
Improved environment of work shopImproved environment of work shop
Elimination of causes of accidentElimination of causes of accident
Reduced carelessnessReduced carelessness
Observation of rulesObservation of rules
Achievement of better human relationsAchievement of better human relations
Purpose
CostReduction
CostReduction
ImprovedEfficiency
ImprovedEfficiency
ImprovedQuality
ImprovedQuality
ReducedBreakdown
ReducedBreakdown
ImprovedSpirit of
Challenge
ImprovedSpirit of
Challenge
Assurance of Safe-ty and Prevention of Environmental
Problems
Assurance of Safe-ty and Prevention of Environmental
Problems
Purpose
CostReduction
CostReduction
ImprovedEfficiency
ImprovedEfficiency
ImprovedQuality
ImprovedQuality
ReducedBreakdown
ReducedBreakdown
ImprovedSpirit of
Challenge
ImprovedSpirit of
Challenge
Assurance of Safe-ty and Prevention of Environmental
Problems
Assurance of Safe-ty and Prevention of Environmental
Problems
Purpose
CostReduction
CostReduction
ImprovedEfficiency
ImprovedEfficiency
ImprovedQuality
ImprovedQuality
ReducedBreakdown
ReducedBreakdown
ImprovedSpirit of
Challenge
ImprovedSpirit of
Challenge
Assurance of Safe-ty and Prevention of Environmental
Problems
Assurance of Safe-ty and Prevention of Environmental
Problems
Aims Typical Activities
1. Throw out the things you do not need.2. Deal with the causes of dirt and leaks.3. Housecleaning.4. Treat defects and breakage.5. Inspect covers and troughs to prevent leak age and scatter.
1.Everything has a clearly designated place. 2. Thirty-second storage and retrieval. 3. Filing standards. 4. Zoning and placement marks. 5. Eliminate lids and locks. 6. First in, First Out
6. Clean the grounds.7. Organize the warehouse.8. Eliminate grime and burrs.9. Eliminate oil pans.
7. Neat notice boards. 8. Easy-to-read notices. 9. Straight lines and right angles. 10. Functional placement for
materials, parts, carts, shelves, tools, equipment and everything else.
1. Quick 5S drills.2. Individual responsibility.3. Make cleaning and inspection easier.4. Sparkling clean campaigns.
5. Everybody is a janitor (priority 5S).
6. Perform cleaning inspections and correct minor problems.
7. Clean even the places most people do not notice.
Organization (Seiri): Stratification management and dealing with the causes.
Neatness (Seiton):Functional storage and eliminating the need to look for things.
Cleaning (Seiso):Cleaning as inspection and degrees of cleanliness.
Preparedness Towards 5S
1. Okay marks.
2. Danger zones marked
on meters.
3. Thermal labels.
4. Directional markings.
5. Belt-size labels.
6. Open-and-shut
directional labels.
7. Voltage labels.
8. Color-coded pipes.
9. Oil labels.10. Warning colors.11. Fire extinguisher signs.12. . Responsibility labels.13. 5S calendars.14. Wire management.15. Inspection marks.16. Precision-maintenance
labels.
17. Limit labels.
18. Color coding.
19. Preventing noise
and vibration.
1. All-together cleaning.
2. Exercise time.
3. Pick-up practice.
4. Wear your safety
shoes.
5. Public-space
management.
6. Practice dealing with emergencies.
7. Individual responsibility.
8. Telephone and communication
practice.
9. 5S manuals.
10. Seeing is believing.
Standardization (Seiketsu): Visual management and 5S standardization.
Discipline (Shitsuke):Habit formation and a disciplined workplace.
Visual ControlAims Typical Activities
5S Awareness Training
Drawing up aMaster plan,Setting up Target
Forming up5S Teams
Carry out 5SStep by Step
5S Audit using 25 point Check sheet
5S Competition(Gold,Silver,Bronze metal)
Fixed Positionphotograph
Five Steps
To Shaping UpThe Shop Floor 5S
Visual Control
The first 3 ’S’
The 4th ‘S’
Identify area ofImprovement“Show Room Concept “
Red tag CampaignRed EagleSaman System
5S Implementation
Initial phase of 5S activityHLYM 25 point check sheet
No Check Point
1. 5s Promotion system
2. Cleaning ( score unit : each facility )
3. Dirt source
4. Portions difficult to be cleaned.
5. Take out & put back in 30 seconds ( File , Jig & tool measurement tool, parts etc.)
6. Measures for safety ( for facilities )
7. visual control 1 - indicating the direction of flow ( pipe lined materials)
8. Visual control 2 - Valve open-shut indication.
9. Visual control 3 - Maintaining wire ropes
10. Visual control 4- Indications of the extinguishers
11. Visual control 5- Thermo label
12. Visual control 6- G (good) marks (for fastening -up)
No Check Point
13. Visual control 7- Cooling fan (tape, windmill) etc.
14. Visual control 8- Check mark ( for daily check )
15. Visual control 9- Indication of the rotating direction
16. Visual control 10 - Indication of belt size & number
17. Visual control 11. 15 -block ( line ) & floor
18. Visual control 12 - Meter Control zone
19. Visual control 13 -Measuring Instrument
20. Visual control 14 - Three- piece set.
21. Visual control 16 - Cleaning tool
22. Visual control 17 - Oil substation
23. Visual control 18 - Electric distribution board
24. Visual control 19 - Air
25. Visual control 20 - Lighting equipment
Level 0 : Red Tag campaign
5S committees have been formed and actively promoting 5S at the shop floor (according to zone)
All possible (at each zone)-cleaning points -Dirt sources-Difficult cleaning points-Tools/ files Retrieval -Safety points have been identified and abnormalities can be detected easily
Initial Phase of 5S ActivityNo Check Point
1. 5s Promotion system
2. Cleaning ( score unit : each facility )
3. Dirt source
4. Portions difficult to be cleaned.
5. Take out & put back in 30 seconds ( File , Jig & tool measurement tool, parts etc.)
6. Measures for safety ( for facilities )
7. visual control 1 - indicating the direction of flow ( pipe lined materials)
8. Visual control 2 - Valve open-shut indication.
9. Visual control 3 - Maintaining wire ropes
10. Visual control 4- Indications of the extinguishers
11. Visual control 5- Thermo label
12. Visual control 6- G (good) marks (for fastening -up)
No Check Point
13. Visual control 7- Cooling fan (tape, windmill) etc.
14. Visual control 8- Check mark ( for daily check )
15. Visual control 9- Indication of the rotating direction
16. Visual control 10 - Indication of belt size & number
17. Visual control 11. 15 -block ( line ) & floor
18. Visual control 12 - Meter Control zone
19. Visual control 13 -Measuring Instrument
20. Visual control 14 - Three- piece set.
21. Visual control 16 - Cleaning tool
22. Visual control 17 - Oil substation
23. Visual control 18 - Electric distribution board
24. Visual control 19 - Air
25. Visual control 20 - Lighting equipment
All critical inspection areas must have proper visual control and Inspection checklists are prepared accordingly.
Workers are carrying out the 5SInspection everyday (5min beforeand after starting work)
HLMG 5S Council members Audit in action HLMG 5S Council members Audit in action
Audit Findings & Areas for ImprovementGeneral
Wiring
Structural
Safety
Audit Findings & Areas for Improvement
Fire extinguishers
Visual Control
Electrical distribution board
Audit Findings & Areas for Improvement
Wire ropes, Oil sub station, Motor belts , spare parts … cleaning tools
Visual Control
Audit Findings & Areas for Improvement
requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1
18 Drawings/ catalogs / posters N
19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1
25 5S work routine improvement system 1
Average 2.21
requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1
18 Drawings/ catalogs / posters N
19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1
25 5S work routine improvement system 1
Average 2.21
Floor Wiring
Common Used items
Desks & Chairs
Audit Findings & Areas for Improvement
requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1
18 Drawings/ catalogs / posters N
19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1
25 5S work routine improvement system 1
Average 2.21
requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1
18 Drawings/ catalogs / posters N
19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1
25 5S work routine improvement system 1
Average 2.21
Ceiling
Walls, curtains or shades
Stationery
Audit Findings & Areas for Improvement
requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1
18 Drawings/ catalogs / posters N
19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1
25 5S work routine improvement system 1
Average 2.21
requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1
18 Drawings/ catalogs / posters N
19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1
25 5S work routine improvement system 1
Average 2.21
Common filing & cabinets
Individual Drawers Storing of samples
Audit Findings & Areas for Improvement
Noteworthy EffortsNoteworthy efforts Noteworthy efforts
Beginning of 5S promotion
5S Deployment started
Good 5S initiatives (Standardizations are required)
Noteworthy efforts Noteworthy efforts
Conducive Office environment
Neat arrangement of file & Centralized storage of Stationery
Promote Go Green
Initial 5S cleaning and sorting were observed
Noteworthy Efforts
Discussion : Audit Preparation & Procedure
BEFORE AUDIT:
1. Scope of audit2. Zone/Area layout3. Check sheet4. Camera, 5. notebook
.
AFTER AUDIT:
1. Give comments and findings on the same day
DATE AREA AUDIT
TEAM
No Requirement Score (P) Request Item Tools
1 5S Promotion System 1 An organization chart, action plan & education promotion.
Committee, Action plan, Zoning, Training material
2 5S meeting held periodically, team understand problem MOM, Ownership, Layout with 25 marking
Scope: 3 5S activities implemented on routine basis 5S activities 1. Form commitees 4 Plan for improvement and counter measures. Kaizen improvement 2.Maste r Plan 5 Activities achieved 100% target Control indices/Target
3. Area to tackle defined
4. Job clearly assigned Sub Score
5. Target established 2 Cleaning 1 Cleaning plan, a duties plan and schedule Cleaning schedule
2 The falicities are cleaned On site checked Scope: 3 Additional equipment & devices are cleaned On site checked
1. Equipment clean 4 A check plan drawn up & perodically cleaning is performed Cleaning check sheet
2. Method cleaning. 5 identify potential defects and takes control measures Easy inspection 3. Fast and easy cleaning Sub Score
3 Dirt Source 1 Education is prevailing & sources are identified Dirt source map 2 A map & plan to control available Map and action plan Scope: 3 Over 50% counter measures achieved Dirt source contained 1. Dirt source is isolated 4 Over 80% counter measures achieved Dirt source contained 2. Reduced & eliminated 5 very high improved with cleaning is performed 100% Dirt source isolated 3. Can be removed easily 4. Kaizen to remove dirt Sub Score
3 S Audit Check Sheet
4 Portions difficult to clean 1 Education is prevailing & portions area identified Difficult areas 2 A map & plan to control available Difficult areas cleaning map Scope: 3 Over 50% counter measures achieved 1. Machine's top 4 Over 80% counter measures achieved 2 Machine 's back 5 very high improved with cleaning is performed 100% Facilities covers/ Kaizen
3. Inside machine
4. Under cabinet Sub Score
5. Special cleaning tools
5Take out & put back in 30s 1 Necessary & unnecessary items identified On site checked
2 Storage set in place Location of storage: On site checked Scope: 3 Portios are placed as indicated On site checked 1. Systematic arrangement 4 Improved method for easy retrieval On site checked 2. Easy to identify 5 take out and put back 30s. 30s retrieval system: on site checked
3. Easy retrieval
4. Aware by all & neat Sub Score
6 Measures for safety 1 Safety education is performed, safety policy/check sheet Safety policy, procedures, check sheet 2 Unsafe areas/activities detected with signage Safety signage/ indication Scope: 3 Problems identified with safety counter measures 50% On site: sensor, guides 1. Establish indices/target 4 Problems identified with safety counter measures 100% On site: sensor, guides 2. Identify unsafe area/act 5 High safety awareness with improvement periodically Safety check sheet, safety index/target
3. Permanent measures
4. Signage/ indicator Sub Score 5. PPE regulations
6. Operation standard
GRAND TOTAL SCORE 0
% SCORE 0%
Additional Comment:
3 S Audit Check Sheet
No. Area SCORE 3S AUDIT % S SCORE SCORE 5S AUDIT % S SCORE1 Finishing 2 Main Lab 3 ETP 4 Bomba pump house 5 FPW 6 TNB sub station & transformer / HV 7 CHEM PREP 8 RWETP 9 Intake pump house 10 RPW / Sorting Plant 11 Admin Office 12 Mill wide site 13 DE and WE Lab 14 Rollshop 15 Workshop 16 Biomass 17 Maint Office 18 PM 19 RCF 20 CHPP 21 Store
5S Scoreboard
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