Step by STep plan drawn for implementing "5S" at work place. Includes detailed audit at each stageFull description
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Description : This is the best book ever written on how to practice at the piano! Most books list what skills are needed (scales, arpeggios, trills, etc.), but not how to acquire them. This book teaches how to s...
'5-S' Road map Who ?
To do What ?
Where?
S0 = Enablers [Motivate people for 5-S implementation] S1 = Seiri [Sort out what is needed and what is not] S2 = Seiton [Do systematic arrangement for all needed S3 = items] Seiso [Ensure spic & span cleanliness with inspection] S4 = Seiketsu [Create a highly standardised workplace] S5 = Shitsuke [Self - discipline at workplace]
When?
Team Leader Team Members P-D-C-A
Jul-07
Plan
S0
Actual
S0
Plan
S0
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
S1
S2
S2
S3
S1
S2
S2
S3
Gemba-1:
Gemba-2:
Actual S0
map Jan-08 S4
Feb-08 S4
Mar-08 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/ More space
EFSHE
Zero waiting
PQCD
1 ] PEEP: Place for everything & everything in its place
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 Once X N/A Weekly X Qtr Qtr 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
Qtr Monthly Fortnight Weekly
Remark
Requisites
Work Area
Classification in work areas
Audit / Visual Inspection of wants / wastes
Scrap Disposal
Listing Wants in an Area after eliminating waste
ACTION PLAN FOR "S1" Seiri Sorting out what is required & dipose unwanted (Aug - Sep 07) Who Status X X X X X X X X X X X X X X X X
Remark
(S1) Waste Identification Checklist Gemba Work Area TM Usage
Condition
Repairable
Process / Equipment / Item in area Freq. Rare Never Good Worst
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 Who Status X X Organising wants in an area in terms of usage / value / importance to process / life cycle X X X X Identifying amenities / infrastructure / tools required for correct organisation (P tags) X X X Organising in compliance with PEEP & X Identifying missing / abnormal item or X structure 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
Thorough cleaning done & scrap disposed safely
All Items / Process / Equipments easly identifiable / accesible / safe
ACTION PLAN FOR "S3" Seiso Thorough Cleaning (Nov - Dec 07) Who
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
0
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
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
0
0
0
0
0
0
1
3
0
4
0
3
0 Score 2
4
0
0 Score 2
1
3
0 Score 2
1
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
Score 2
1
0
4
0
3
0
4
0 = Very Bad Sub Total
SHITSUKE
5S
Check Item Equipments / Process Stock levels Training Support 5-S Billboards
1 = Bad
2 = Avg
3 = Good
Description
4 = Very Good 0
0
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
