5S Training at TTGB
Bosch Thermotechnology Ltd. Bosch Group
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training
Why
is 5S important?
What
are your expectations?
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training
5S Philosophy
The concept of 5S was developed in Japan in the early 1980s as the five
principles to a total quality environment.
5S originates from the Japanese:
Seiri or organisation
Seiton or neatness
Seiso or cleanliness
Seiketsu or standardise
Shitsuke or discipline
This has been adapted into English terms.
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
How other companies used 5S?
Video
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
The 5S Pillars
2nd S: Set in order
Define a location for every item needed in relation to the best
flow organisation
Visually identify all locations (mark, label)
3rd S: Shine and keep clean
4th S: Standardise
5th S: Sustain:
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Consolidate
and sustain
1st S: Sort out
Eliminate what is unneeded and decide what is needed
Keep only what is strictly necessary
Start
5S Training at TTGB
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
The 5S Pillars
2nd S: Set in order
Define a location for every item needed in relation to the best flow
organisation
Visually identify all locations (mark, label)
3rd S: Shine and keep clean
Shine and keep the workplace and equipment clean
Develop regular cleaning and inspection programs for shared
areas
4th S: Standardise
Create a visually managed workplace
Define operating procedures shared by everyone in the team
Define visual standards for safety conditions, process control and
operating procedures
5th S: Sustain:
Maintain what has been decided
Continuously look for improvement as a team
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Consolidate
and sustain
1st S: Sort out
Eliminate what is unneeded and decide what is needed
Keep only what is strictly necessary
Start
5S Training at TTGB
What 5S is NOT?
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training
What 5S is NOT? - Chaos on the roads
Thermotechnology
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
What is 5S? - A tool to simplify your life
Thermotechnology
10
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
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5S Training
Kitchen chaos?
Thermotechnology
11
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
5S Simplify your life
Thermotechnology
12
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
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5S Training at TTGB
5S exercise (Time Game)
Sort
Set in order
Shine
Standardise
Sustain
Thermotechnology
13
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
What IS 5S?
From Shed to Supermarket Culture
Closed
Private
Individual
Open
Public
Team
Thermotechnology
14
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5S Training at TTGB
5S is the basis for
Efficiency
Robust processes
Team work
Continuous
improvement
Thermotechnology
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5S Training at TTGB
Who do you think works more efficiently?
What information is going in, what is coming out?
Minimum input
Maximum output
Thermotechnology
16
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
5S Exercise (Discussion)
What are the potential barriers that we might be confronted with?
What can we do to reduce these barriers?
Thermotechnology
17
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
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5S Training at TTGB
Our 5S Guidelines for the office
1. Sort
Clear floors
No boxes on the floor
No boxes or other equipment under the
desks
No cables
Coats belong on coat hanger or
wardrobe
Free window sills (exception plants)
No material on top of cupboards
2. Set in order
Everything clearly labelled and
responsible assigned
Cupboards
Folders
Trays
Boards
3. Shine
Clear desk after work
Energy efficient mind set
Switch off PC and all electrical
equipment
Last one switches lights off
4. Standardise
Team: Once a month on Friday afternoon
for 2hrs
Individual:
5 min every day
Put everything back into its place after
usage
All boards to standard
Title
Responsibility for regular update
5. Sustain
Display and update 5S team board
Audit sheet
Responsible person
5S PDCA Chart
Pictures of hotspot area and its
improvement
5S Rules
Thermotechnology
18
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5S Training at TTGB
Champions Role
Actively challenge 5S in the offices
Drive standards for offices
Audit the area
(self audit and others)
Exchange experiences
Share knowledge
Run follow up meetings in the
departments
(support from TTGB/CIP if
required)
Thermotechnology
19
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training
More information WoP/CIP Intranet
Thermotechnology
21
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editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
Example Drawer and Cupboard Identification
Thermotechnology
22
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5S Training at TTGB
Example Workstation organisation
Thermotechnology
23
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Training at TTGB
Example board identification and general
information
Thermotechnology
24
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Champions Meeting Kick off, 20.04.07
1st S = Sort out what needs to happen?
Phase 1:
Eliminate what is unneeded and decide what is needed
Create red tag holding area for unneeded items
Ask other departments whether they could use your unneeded items (e.g:
desk, PCs, telephones, chairs etc)
Review after a set period of time
Ask cleaners to dispose unneeded items
Manager to decide on disposal of equipment
List all bigger and more expensive (>50)
Manager to sign off list
Check every 3 months for unneeded items
Phase 2:
Clean up drives
Thermotechnology
25
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Champions Meeting Kick off, 20.04.07
2nd = Set in order what needs to happen?
Phase 1
Label your cupboards
Label folders
Label Trays (In, Out, in progress)
Boards
5S
Sort, Set in order, Shine, Standardise, Sustain
Thermotechnology
26
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Champions Meeting Kick off, 20.04.07
2nd = Set in order what needs to happen?
Phase 2
Organise files
Thermotechnology
27
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Champions Meeting Kick off, 20.04.07
3rd S = Shine What needs to happen?
Shine and keep the workplace and equipment clean
Develop regular cleaning and inspection programs for shared areas
Thermotechnology
28
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
5S Champions Meeting Kick off, 20.04.07
4th S Standardise What needs to happen?
5S Audit sheet (OFFICE)
Section:
SORT - Eliminate what is unneeded and decide
what is needed
for every item needed
SET-IN-ORDER - Define a specific location
Audit
No excess pieces of equipment, reference
materials, boxes or other stuff on or under desks.
1.3 Visual control
All personnel items and equipment stored at one
designated area.
1.4 Disposal
There is a red tag holding area. All items are clearly
defined with responsibility, date of sorting and date
of disposal.
Who
Frequency
When
Equipment required
Signed Clean / Inspect schedule
Mon
Tue
Wed
Thu
Fri
Mon
Tue
Wed
Thu
Fri
Mon
Tue
Displays on
walls
Who
Frequency
When
Equipment required
3.2
There is a schedule for cleaning. The system is
displayed and a cleaning sheet has been filled out
when, who and what was cleaned.
3.3 Floor
The floor is clean and clear.
3.4 Desk
The desks are clean and tidy.
3.5 Equipment
All equipment on the desk is clean (PC, keyboard,
telephone, mouse, personnel area)
4.1 Display of 5S
There is a designated display area for 5S activities.
4.2 Signage
There is signage for fire exit points, rules of
evacuation, assembly point.
4.3 Display targets
Departmental Cockpit Charts and PDCA Charts if
applicable are displayed clearly.
4.4 Energy usage
All electrical equipment are switched off after work.
(PC, monitor, printer). This habit is visualised in the
office.
4.5
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
There are rules about cleaning and tidiness in the
office. The rules are displayed.
Cleaning
responsibilities
The general environment is in good condition,
including colour, air, lighting, etc.
Feeling of
cleanliness
5.1 Display of 5S
The 5S display is updated.
5.2 5S Measure
5S audit measure is displayed in departmental
cockpit chart or any other measurement tool if
applicable.
Responsible:
TTGB/CIP
I3.1 Maturity Model Assessment Score
4
4
3
PDCA
3
2
2
1
1
Data as of date: 02.02.07
Comment:
Signed Clean / Inspect schedule
Jan
after
Heading of boards and responsibility are assigned.
3.1 Rules
2005
No.
Monthly: Area to Shine / Inspect
before
2.3 Visual control
Division TTGB objective:
Audit result of Policy Deployment awareness in %
Plant objective:
Achieve Maturity Level 4
Department target:
Achieve Maturity Level 4 by End 2007 by promoting and
communication Policy Deployment
Actions
Respon-cible
Contribution
to target
10%
Create template for PD quartlery Audit
- Assess tempalte with Ian (basis MML, ISO2001)
- Create audit plan (when, who)
- design auditors training
BA,
IC, AG
Design and give PDCA training
- How to set actions and to fill out form
Design handbook section for use of BSC & PDCA
BA
30%
BA
10%
Hotspot
Documents &
Equipment
Title:
Cleaning Sheet
Weekly: Area to Shine / Inspect
Date
OBSERVATION
100%
Display boards are up-to-date, tidy, well balanced
and well structured.
Displays on
walls
Plant: WoP & CyP
Date
Score:
50% 75%
25%
Labelling of cupboards and equipment allows
immediate identification. e.g. responsibility, title, &
content
Folders, trays and equipment on desk and in
cupboards are clearly identified, e.g. responsibility,
title, year, content
All personnel items and equipment are clearly
defined and labelled. Everything is stored in a fixed
place.
Department and There is a who's who board. The department as
such is identified, e.g. signage on doors outside the
2.4 manager
department and at manager doors.
identification
2.2
2.5
efficiency in mind
SHINE - Keep the workplace clean with energy
Workplace Organisation
Area:
Inspect and Shine Schedule
Auditor:
0%
0%
1.2 Desks
BBT UK THERMOTECHNOLOGY Ltd.
5S
Champion:
Score:
No irrelevant reference materials in and on top of
cupboards, such as documents, boxes, equipment,
etc.
2.1 Cupboards
workplace
STANDARDISE - Create a visually managed
Previous Mark
EVALUATION CRITERIA
1.1 Cupboards
1.5
further improvements
SUSTAIN - Sustain 5S attitude and make
Champion
No. CHECK ITEM
Criteria of measurement
Rules, Protocol
5S
Design Communication Tools for PD
BA
5%
Implement Communication Tools for PD
BA
20%
Train and support use of BSC
BA
20%
Improve visualisation at CyP
- create action plan
BA
5%
2006
2005
Jan
Feb
2006
Jan
Mar
Feb
Apr
Mar
May
Apr
Jun
May
Jul
Aug
2007
Jun
Jul
Sep
Aug
Oct
Sep
Oct
Nov
Nov
Dec
Dec
2008
2008
2009
2010
2009
2010
Status Effect-ness
Dec
1
Sum of expected contribution
Current forecast
10
11
12
100%
Actual
Target (Plan)
Legend
Target:
Scheduling
End:
Postponed:
green: as planned
Start :
Actual:
Current forecast:
0
4
Fullfilment of actions:
yellow: difference, not critical
red: out of plan, critical
Effectiveness of actions
as planned or better:
slightly below plan:
well below plan
J
K
L
Biggest improvement
Congratulation
Peter Sample
Index:
5S Audit Sheet
Cleaning Sheet
5S PDCA
Hotspot: Good vs Bad
5S area winner
5S Rules
Thermotechnology
29
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Index:
5S Audit Sheet
Cleaning Sheet
5S PDCA
Hotspot: Good vs
Bad
5S area winner
5S Rules,
Protocol
5S Champions Meeting Kick off, 20.04.07
4th S Standardise What needs to happen?
Milkrun system for paper
One department to organise
refill of paper to reduce
departmental stock
Storage system
Defined minimum and
maximum amount of
stationary
General storage for overload
on stationary
Ensure standard pens, office
equipment used
2 boxes A4
required, MKT
1. Drop request card at
order centre
Order 40
envelopes, code
XZA, MKT
3. Refill stock for
department
Order 5 folders,
code SDF, MKT
Thermotechnology
30
2. Order new paper,
stationary
Internal | WoP/CIP | 26/11/2010 | Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
