5S Implementation Plan at Work Place

'5-S' Road map - Department Who ?

To do What ? S0 = Enablers [Motivate people for 5-S implementation]

Where?

S1 = Seiri [Sort out what is needed and Gemba-1: what is not] S2 = Seiton [Do systematic arrangement for all S3 needed = Seisoitems] [Ensure spic & span cleanliness with inspection] S4 = Seiketsu [Create a highly standardised workplace] S5 = Shitsuke [Self - discipline at workplace]

Gemba-2:

When?

Team Leader Team Members P-D-C-A

Jul-07

Plan

S0

Actual

S0

Plan

S0

Actual S0

Aug-07

Sep-07

Oct-07

Nov-07

Dec-07

S1

S2

S2

S3

S1

S2

S2

S3

Department Jan-08 S4

S4

Feb-08 S4

S4

Mar-08 S5

S5

Remarks

Why ?

MOP

1 ] Demonstrate PQI by doing Kaizens 2 ] Remove 3 D's at Gemba

Zero defect

SHE

1 ] Develop criteria for need/want to release 50% place

Zero inventory/M ore space

EFSHE

1 ] PEEP: Place for everything & everything in its place

Zero waiting

PQCD

1 ] CLIA: Deploy Clean-InspectLubricate-Adjust 2 ] CPCP

Zero accidents

PQCD

1 ] SOPs Developed & Displayed 2 ] Establish SDCA

Zero breakdown

PQCD

1 ] Through continuous education, training, display of results & PDCA improvement cycles

Zero setup PQCDEFSHE

ACTION PLAN FOR "S0" Enablers Motivating people for 5S implementation (Jul - Aug 07) Who Freq Status HOD Once √ TL X TL N/A √ TL / TM Weekly X TL / TM Qtr √ TL / TM Qtr √ TL Once √

Requisites Official information 5-S Billboards / Camera Participation of all Effective training PQCDEFSHE objectives 1-30-300 principle Roadmap 5-S as a part of Kaizen roadmap Progress review Publishing & widely communicating about the progress Active involvement of the teams Regular meetings Developing suggestion schemes

TL / Auditor TM TL TM TM

Qtr Monthly Fortnight Weekly

√

Remark

Gemba identified & teams formed 5S awareness sessions 5S awareness sessions Prepared & displayed

ACTION PLAN FOR "S1" Seiri Sorting out what is required & dipose unwanted (Aug - Sep 07) Requisites Area Who Status TM √ TM √ Work Area TM √ TM √ TM X TM X Classification in work areas TM X TM X X X Audit / Visual Inspection of wants / TL wastes X X TM X TM X Scrap Disposal TM X TM X TM X TM X Listing Wants in an Area after eliminating waste TM X TM X

Remark

(S1) Waste Identification Checklist Gemba Work Area TM Process / Equipment / Item in area

Usage

Condition

Freq. Rare Never Good Worst

Repairable Yes

No

Better Usage Substitute outside area avl Yes

No

Yes

No

Waste

Remark

ACTION PLAN FOR "S2" Seiton Systematic Arrangement of wanted (Oct - Nov 07) Requisites Area Who Status TM X Organising wants in an area in terms of TM X usage / value / importance to process / life TM X cycle TM X TM X TM X Identifying amenities / infrastructure / tools required for correct organisation (P tags) TM X TM X TM X Organising in compliance with PEEP & TM X Identifying missing / abnormal item or TM X structure TM X

Remark

(S2) Systematic arrangement checklist Gemba Work Area TM Process / Equipment / Item in area

Usage

Value

Qty (Nos)

Critical to process

Total 0 0 0 0 0 0 0 0 0 0 0 0

Pref. No

Scores can be 1/ 3/ 5 for low / Med / High categories repectively & Pref. no will be in descending order of total score Item with pref. no "1" should always be the easiest accesible and further on In case of consumables qty. to be re-ordered when inventory level for High / Med or Low value items reaches 25 % / 50 % levels Arrangement to comply PEEP concept so that any missing / misplaced item can be identified by visual inspection List down amenities / tools / structure for correct arrangement. When identified can be purchased or can be picked up from scrap

Requisites External / Internal man power arrangement for through cleaning

Through cleaning done & scrap disposed safely

All Items / Process / Equipments easly identifiable / accesible / safe

ACTION PLAN FOR "S3" Seiso Systematic Arrangement of wanted (Nov - Dec 07) Area Who Status TL / TM X TL / TM X TL / TM X TL / TM X TM X TM X TM X TM X TM X TM X TM X TM X

Remark

Requisites Daily Inspection / Reporting abnormalities

Action for deviation / 5S awareness session or training

ACTION PLAN FOR "S4" Seiketsu Systematic Arrangement of wanted (Jan - Feb 08) Area Who Status TM X TM X TM X TM X TM X TM X TM X TM X

Remark

Requisites Monthly / Qtrly. "5S" audit by Internal / External accesor

Action for deviation / findings / document learnings

5S awareness session / training for continual improvement / Visits

Gains in terms of value, life cycle, availability to be published

ACTION PLAN FOR "S5" Shitsuke Systematic Arrangement of wanted (Mar 08) Area Who Status TL / Auditor X TL / Auditor X TL / Auditor X TL / Auditor X TL / TM X TL / TM X TL / TM X TL / TM X TL / TM X TL / TM X TL / TM X TL / TM X TL X TL X TL X TL X

Remark

0 = Very Bad

SEIRI

1S

SEITON

2S

SEISO

3S

SEIKTSU

4S

Check Item Materials / parts Machines / Equipment Papers / Plastic Mtrl Visual Control

Check Item Location Indicators Item Indicators Qty. Indicators Walkway Demarcation

Check Item Floor / Work station M/c & Equipments Cleaning Stewards

Check Item Improvement Idea Standard procedure Future scope First 3S

1 = Bad

2 = Avg

3 = Good

4 = Very Good

Description

0

Does the inventory or in-process inventory include unneeded mtrl / parts Are there any unused machines or other equipment Is there any paper / plastic scrap around Is the waste identified Sub Total

Description

Is any action plan in place for its deployment Is the 5S implementation plan documented / published / communicated Any continual improvement idea / process / recognition Is Seiri / Seiton / Seiso maintained

3

4

0

0

0

0 Score 2

1

0

3

0

4

0 0

0

Are floors / work station shiny to spot any waste Are they Dust free, running healthy with allowed noise / vibration Is there a dedicated staff / do they do it voluntarily Sub Total

Description

1

0

Are shelves and other storage areas marked with addresses Do the shelves have signboards showing which items go where Are Max / Min Inventory levels indicated Storage areas / Process Area / Units marked Sub Total

Description

Score 2

0

0

Score 2

1

0

0

1

0

0

3

0 Score 2

0

4

0

3

0

0

4

0

0 Sub Total

SHITSUKE

5S

Check Item Equipments / Process Stock levels Training Support 5-S Billboards

0

Description Are they easily gettable / managable Is the inventory control adhered to Is Training / 5S awareness in progress Is top management active support available Are they updated Sub Total Grand Total

0

0

0

0

Score 2

1

3

0

4

0 0

0

0

0 0

0

SEIRI SEITON SEISO SEIKTSU SHITSUKE

0 0 0 0 0

Audit Result SEIRI 1

SEITON

SHITSUKE 0

SEISO

SEIKTSU