PART 4

5S

How to Audit and Guide SUPER

5S Activities

The Structure of Part 4: Twelve Focal Points Super 5S Auditors Should Examine Rules for Participation in Super 5S Inter-Departmental Competitions (four pages) A Super 5S Evaluation Form for Factory / Operation Site A Super 5S Evaluation Forms for Office A Super 5S Evaluation Summary 5S Guidance Stickers (here is a need for Seiri, Seiton or Seiso) 5S Guidance Stickers (here is an excellent example of 5S practice) Ten Useful Hints for Winning Super 5S Competitions Passport to Successful 5S - pages 1 and 4 Passport to Successful 5S - pages 2 and 3

72

Twelve Focal Points Super 5S Auditors Should Examine

G G G G G G G G G G G G

Do the CEO and managers support Super 5S program? Are people proud of their workplaces? Are workplaces clean and organized? Are workplaces safe for people to work in? Are machines and equipment clean and well maintained? Are items easy to retrieve? Are machines and tools conveniently located? Are inventories stored for FIFO retrieval? Are products free from dust? Do people clean daily without prompting? Are the uniforms worn by people clean and tidy? Is a good image of the enterprise reflected in its people?

A 5S audit is conducted according to the method of Super 5S interdepartmental competitions. Auditors evaluate and record each department s level of 5S practice according to its achievement in the six major objectives of Super 5S program: Productivity, Quality, Cost, Delivery, Safety and Morale. Auditors may use the Super 5S evaluation forms (for factory / operation sites and offices). The method for filling out the Super 5S evaluation forms is described in the rules for participating in Super 5S inter-departmental competitions.

73

Rules for Participating in Super 5S Inter-Departmental Competitions - 1

1. Objectives Proposed competitions are aimed at improving the organization s total productivity through everyone s participation in the Super 5S program. Qualification for Participation Any department which is implementing 5S on a certain level is eligible for participation. 3. Competition Period Each competition will be organized for a period of 6 months, two times a year on a continuing basis. 4. Auditing Team An auditing team appointed by the Super 5S Steering Committee will visit each competing department and evaluate its Super 5S activities at the end of each competition period. 5. Super 5S Evaluation Forms One of the following Super 5S Evaluation Forms will be used by the auditors according to the function of the participating departments:

SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE

DEPARTMENT:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

ITEM materials / parts work-in-process finished products defective / rejects machines / equipment wiring / piping dies / tools / jigs spare parts / lubricants containers / pallets racks / shelves / cabinets carts / wagons / forklifts lifts / conveyers / cranes desks / tables / chairs forms / files / records floors / passages / stairways walls / windows / ceiling lighting / ventilation working wears / shoes safety devices fire extinguishers / fire exits cleaning tools / waste baskets canteens / toilets / lockers external areas / gardens security guards / car parks NO. OF ITEMS EVALUATED (b):

SUPER 5S PRACTICE IDENTIFIED:

FOCUS are they conveniently located and labeled for easy retrieval? are they conveniently located for easy handling? are they conveniently located and labeled for easy retrieval? are they clearly labeled for separation from good items? are they clean, safe, well-maintained and convenient to operate? are they laid out in a tidy, safe and convenient manner? are they conveniently labeled and placed at designated locations? are they conveniently labeled and placed at designated locations? are they clean and conveniently placed at designated locations? are they dust-free, tidy and conveniently labeled for items stored? are they well-maintained and placed at designated locations? are they clean, tidy, safe and well-maintained? are they clean and organized inside and outside? are they up-to-date, easy to retrieve and at convenient locations? are they dust-free, tidy, safe and well-maintained? are they dust-free, tidy, safe and well-maintained? are they adequate for efficient operation? are they clean and do they present a good image? are they conveniently located for use and well-maintained? are they adequate and cleaned regularly? are they clean, tidy and well-maintained? are they clean, tidy and well-maintained? are they clean, tidy, safe and do they present a good image? are they clean, tidy, safe and do they present a good image? TOTAL SCORE (a) ADJUSTED SCORE = (a) / (b) x 10 BONUS SCORE FOR SUPER 5S PRACTICE FINAL SCORE COMMENTS FOR IMPROVEMENT:

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

SCORE 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

20 15 10 5 0

AUDITOR:

DATE:

74

Rules for Participating in Super 5S Inter-Departmental Competitions - 2

(a) Super 5S Evaluation Form - Factory / Operation Site (b) Super 5S Evaluation Form - Office 6. Evaluation 1) Two Aspects of the Evaluation Evaluation scores will be recorded by each auditor in two aspects of Super 5S activities for each participating department: (a) Scores on the 5S Level Achieved (b) Scores on the Super 5S Practice Identified 2) Evaluation on the 5S Level Achieved Each auditor is expected to mark his score on each itemized question listed on the form and enter the added total score in the space TOTAL SCORE (a). ADJUSTED SCORE (maximum 100) will be obtained by the the following formula: ADJUSTED SCORE = TOTAL SCORE (a) / NO. OF ITEMS EVALUATED (b) x 10

SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE

DEPARTMENT:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

ITEM materials / parts work-in-process finished products defective / rejects machines / equipment wiring / piping dies / tools / jigs spare parts / lubricants containers / pallets racks / shelves / cabinets carts / wagons / forklifts lifts / conveyers / cranes desks / tables / chairs forms / files / records floors / passages / stairways walls / windows / ceiling lighting / ventilation working wears / shoes safety devices fire extinguishers / fire exits cleaning tools / waste baskets canteens / toilets / lockers external areas / gardens security guards / car parks NO. OF ITEMS EVALUATED (b):

SUPER 5S PRACTICE IDENTIFIED:

FOCUS are they conveniently located and labeled for easy retrieval? are they conveniently located for easy handling? are they conveniently located and labeled for easy retrieval? are they clearly labeled for separation from good items? are they clean, safe, well-maintained and convenient to operate? are they laid out in a tidy, safe and convenient manner? are they conveniently labeled and placed at designated locations? are they conveniently labeled and placed at designated locations? are they clean and conveniently placed at designated locations? are they dust-free, tidy and conveniently labeled for items stored? are they well-maintained and placed at designated locations? are they clean, tidy, safe and well-maintained? are they clean and organized inside and outside? are they up-to-date, easy to retrieve and at convenient locations? are they dust-free, tidy, safe and well-maintained? are they dust-free, tidy, safe and well-maintained? are they adequate for efficient operation? are they clean and do they present a good image? are they conveniently located for use and well-maintained? are they adequate and cleaned regularly? are they clean, tidy and well-maintained? are they clean, tidy and well-maintained? are they clean, tidy, safe and do they present a good image? are they clean, tidy, safe and do they present a good image? TOTAL SCORE (a) ADJUSTED SCORE = (a) / (b) x 10 BONUS SCORE FOR SUPER 5S PRACTICE FINAL SCORE COMMENTS FOR IMPROVEMENT:

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

SCORE 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

20 15 10 5 0

AUDITOR:

DATE:

75

Rules for Participating in Super 5S Inter-Departmental Competitions - 3

3) Evaluation of the Super 5S Practice Identified Each auditor is also expected to look for Super 5S practice(s) implemented in each department, and give an additional score to such good practice(s) according to it(s) value(s) in the space BONUS SCORE FOR SUPER 5S PRACTICE(S) provided on the form (maximum 20). 4) Final Score The ADJUSTED SCORE (for 5S level achieved) and the BONUS SCORE FOR SUPER 5S PRACTICE(S) are totaled and become the FINAL SCORE (maximum 120). 5) Auditor s Explanation on Super 5S Practice(s) Identified Each auditor should explain his reason(s) for awarding a BONUS SCORE in the space SUPER 5S PRACTICE(S) IDENTIFIED. 6) Auditor s Comments for Future Improvement Each auditor is advised to state his comments for future improvement suggested in the space COMMENTS FOR IMPROVEMENT.

SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE

DEPARTMENT:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

ITEM materials / parts work-in-process finished products defective / rejects machines / equipment wiring / piping dies / tools / jigs spare parts / lubricants containers / pallets racks / shelves / cabinets carts / wagons / forklifts lifts / conveyers / cranes desks / tables / chairs forms / files / records floors / passages / stairways walls / windows / ceiling lighting / ventilation working wears / shoes safety devices fire extinguishers / fire exits cleaning tools / waste baskets canteens / toilets / lockers external areas / gardens security guards / car parks NO. OF ITEMS EVALUATED (b):

SUPER 5S PRACTICE IDENTIFIED:

FOCUS are they conveniently located and labeled for easy retrieval? are they conveniently located for easy handling? are they conveniently located and labeled for easy retrieval? are they clearly labeled for separation from good items? are they clean, safe, well-maintained and convenient to operate? are they laid out in a tidy, safe and convenient manner? are they conveniently labeled and placed at designated locations? are they conveniently labeled and placed at designated locations? are they clean and conveniently placed at designated locations? are they dust-free, tidy and conveniently labeled for items stored? are they well-maintained and placed at designated locations? are they clean, tidy, safe and well-maintained? are they clean and organized inside and outside? are they up-to-date, easy to retrieve and at convenient locations? are they dust-free, tidy, safe and well-maintained? are they dust-free, tidy, safe and well-maintained? are they adequate for efficient operation? are they clean and do they present a good image? are they conveniently located for use and well-maintained? are they adequate and cleaned regularly? are they clean, tidy and well-maintained? are they clean, tidy and well-maintained? are they clean, tidy, safe and do they present a good image? are they clean, tidy, safe and do they present a good image? TOTAL SCORE (a) ADJUSTED SCORE = (a) / (b) x 10 BONUS SCORE FOR SUPER 5S PRACTICE FINAL SCORE COMMENTS FOR IMPROVEMENT:

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

SCORE 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

20 15 10 5 0

AUDITOR:

DATE:

76

Rules for Participating in Super 5S Inter-Departmental Competitions - 4

7. Awarding With better results and psychological effects in mind, the implementing organization should work out an awarding method that can encourage, but not discourage, the participating colleagues and departments toward intended objectives.

Congratulations!
PRODUCTIVITY AWARD FOR BEST WINNER 1997

IN 5S INTER-DEPARTMENTAL COMPETITION

IMPROVE YOUR PRODUCTIVITY THROUGH 5S ACTIVITIES

77

SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE

DEPARTMENT:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

ITEM materials / parts work-in-process finished products defective / rejects machines / equipment wiring / piping dies / tools / jigs spare parts / lubricants containers / pallets racks / shelves / cabinets carts / wagons / forklifts lifts / conveyers / cranes desks / tables / chairs forms / files / records floors / passages / stairways walls / windows / ceiling lighting / ventilation working wears / shoes safety devices fire extinguishers / fire exits cleaning tools / waste baskets canteens / toilets / lockers external areas / gardens security guards / car parks NO. OF ITEMS EVALUATED (b):

SUPER 5S PRACTICE IDENTIFIED:

FOCUS are they conveniently located and labeled for easy retrieval? are they conveniently located for easy handling? are they conveniently located and labeled for easy retrieval? are they clearly labeled for separation from good items? are they clean, safe, well-maintained and convenient to operate? are they laid out in a tidy, safe and convenient manner? are they conveniently labeled and placed at designated locations? are they conveniently labeled and placed at designated locations? are they clean and conveniently placed at designated locations? are they dust-free, tidy and conveniently labeled for items stored? are they well-maintained and placed at designated locations? are they clean, tidy, safe and well-maintained? are they clean and organized inside and outside? are they up-to-date, easy to retrieve and at convenient locations? are they dust-free, tidy, safe and well-maintained? are they dust-free, tidy, safe and well-maintained? are they adequate for efficient operation? are they clean and do they present a good image? are they conveniently located for use and well-maintained? are they adequate and cleaned regularly? are they clean, tidy and well-maintained? are they clean, tidy and well-maintained? are they clean, tidy, safe and do they present a good image? are they clean, tidy, safe and do they present a good image? TOTAL SCORE (a) ADJUSTED SCORE = (a) / (b) x 10 BONUS SCORE FOR SUPER 5S PRACTICE FINAL SCORE COMMENTS FOR IMPROVEMENT:

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

SCORE 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

20 15 10 5 0

AUDITOR:

DATE:

Enlarge this form to A4 size.

78

SUPER 5S EVALUATION FORM - OFFICE

DEPARTMENT:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

ITEM desks / tables / chairs cabinets / shelves documents / files forms / office supplies telephones facsimiles typewriters / word-processors computers / monitors printers copying machines electric wiring lighting / ventilation floors / walls / windows / ceiling fire extinguishers emergency exits safety devices working clothes / shoes waste baskets

FOCUS are they tidy and conveniently organized? are they clean and labeled for the easy retrieval of things needed? are they clean and systematically organized? are they tidy and conveniently stored for retrieval? are they clean and well-maintained? are they clean and well-maintained? are they clean and well-maintained? are they clean and well-maintained? are they clean and well-maintained? are they clean and well-maintained? Is it tidy, safe and conveniently laid out for operation? are they adequate for efficient operation? are they dust-free and well-maintained? are they adequate and well-maintained? are they adequate and clear of obstacles in case of emergencies? are they adequate and well-maintained? are they clean and do they present a good image? are clean and well-maintained?

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

SCORE 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4 8 6 4

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

NO. OF ITEMS EVALUATED (b):

SUPER 5S PRACTICE IDENTIFIED:

TOTAL SCORE (a) ADJUSTED SCORE = (a) / (b) x 10 BONUS SCORE FOR SUPER 5S PRACTICE FINAL SCORE COMMENTS FOR IMPROVEMENT:

20 15 10 5 0

AUDITOR:

DATE:

Enlarge this form to A4 size.

79

SUPER 5S EVALUATION SUMMARY

ORGANIZATION:

DATE:

DEPARTMENT

DATE OF AUDIT

ADJUSTED PT.

SUPER 5S PT.

TOTAL PT.

RANKING

AUDITOR

Enlarge this form to A4 size.

80

Here is a need for

Here is a need for

Here is a need for

Here is a need for

SEIRI
Here is a need for

SEITON
Here is a need for

SEITON
Here is a need for

SEISO
Here is a need for

SEIRI
Here is a need for

SEITON
Here is a need for

SEITON
Here is a need for

SEISO
Here is a need for

SEIRI
Here is a need for

SEITON
Here is a need for

SEITON
Here is a need for

SEISO
Here is a need for

SEIRI
Here is a need for

SEITON
Here is a need for

SEITON
Here is a need for

SEISO
Here is a need for

SEIRI

SEITON

SEITON

SEISO

Three kinds of stickers in different colors for SEIRI (red), SEITON (blue) and SEISO (green) are used respectively by the 5S auditor for corrective actions as illustrated below:

Here is a need for

K.T. SEITON 6/16/97

6/16/97

When the auditor identifies a place in need of 5S Kaizen, paste an applicable sticker to the specific location for action by the individual or group in charge. In these examples, stickers for SEITON are applied.

6/16/97

81

Here is an Excellent Example of

Here is an Excellent Example of

Here is an Excellent Example of

5S

Practice

5S

Practice

5S

Practice

Here is an Excellent Example of

Here is an Excellent Example of

Here is an Excellent Example of

5S

Practice

5S

Practice

5S

Practice

Here is an Excellent Example of

Here is an Excellent Example of

Here is an Excellent Example of

5S

Practice

5S

Practice

5S

Practice

The sticker for congratulation is used by the 5S auditor when he identifies a Super5S practice as shown below:

here is an Excellent Example of

5S

Practice
K.T. 6/16/97

82

Ten Useful Hints for Winning Super 5S Competitions

G G G G G G G G

Two heads are better than one - try brainstorming. Look for inconvenient areas to improve. Look for disorganized areas to improve. Look for unsafe areas to improve. Look for dirty or untidy areas to improve. Look for seven categories of waste to eliminate. Clean the surface of machines extensively. Pay more attention to common areas including canteens, toilets, gardens, external passages and car parks. Show evidence that more colleagues are involved in Super 5S activities. Make your Super 5S practices more visible.

Seven Categories of Waste: 1) Waste arising from overproduction 2) Waste arising from defects 3) Waste arising from waiting time / delays 4) Waste arising from the accumulation of work-in-process 5) Waste arising from transport 6) Waste arising from process 7) Waste arising from unnecessary motions or actions If you make a thorough analysis into the origin of these categories of waste and practice Super 5S so as to eliminate this waste, you will reduce costs and improve productivity.

83

How to do 5S Step by Step

STEP 1 Seiri 1 Seiton 1 Seiso 1 Seiketsu 1 T A R G E T S Shitsuke 1 Keep only necessary items Assign items a place . In each section clean one machine well Create a clean workplace Discard unnecessary items more often A C TI O N S Arrange items by type and size Select a machine and clean it completely Clean one s workplace daily STEP 2 Seiri 2 Seiton 2 Seiso 2 Seiketsu 2 Shitsuke 2 Do not put anything on the floor Make needed items accessible Increase the number of clean machines Create a comfortable workplace Use wagons to transport items Remove obstacles around needed items Use more convenient cleaning tools Set up a cleaning schedule STEP 3 Seiri 3 Seiton 3 Seiso 3 Seiketsu 3 Shitsuke 3 STEP 4 Seiri 4 Seiton 4 Seiso 4 Seiketsu 4 Shitsuke 4

PASSPORT TO SUCCESSFUL 5S

What is 5S?
Seiri: Seiton: Seiso: Sort and discard unnecessary items in the workplace. Arrange necessary items so that they can easily be selected for use. Clean your workplace completely so that there is no dust on the floors, machines or equipment.

Separate work Create more areas from space for passageways effective use Reduce searching time Increase the number of clean machines Create a healthy and safe workplace Draw lines to separate passageways for people Use labels to simplify retrieval Prevent machines from getting dirty Eliminate hazards Reduce walking distances Keep all the machines clean and shiny Create a highly productive workplace Reduce excess inventory Place frequently used items close by Combine cleaning with inspection Introduce creative thinking

Seiketsu: Keep one s workplace productive and comfortable by repeating Seiri-SeitonSeiso. Shitsuke: Train people to follow good work habits.

5S is fundamental to productivity improvement 5S Contributes to PQCDSM

Productivity - increased competitiveness Quality - no defects Cost - no waste Delivery - no delays Safety - no accidents Morale - good teamwork

Copy this on one side of the paper and copy the next page on the reverse side, to make a handy 5S manual.

84

Checklist for Step 3

checkpoints The 5S Activity Bulletin Board is wellorganized and data are updated The locations for materials, components and work-in-process are labeled for easy retrieval Dies, jigs, fixtures and tools are conveniently located so that there is no need to search Bolts, nuts, components and other materials are not kept on the floor Passages and operation areas are clearly indicated and separated by distinct lines Failures found are immediately fixed (uneven floor, projections, machine failures, etc.) Areas difficult to clean are cleaned periodically Without searching tools or documents can be retrieved in less than 30 seconds Rules for 5S practice are implemented and are observed without prompting A 5S patrol is regularly conducted by supervisors for continued improvement
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1

2
score

Checklist for Step 4

checkpoints 1 5S inspections are practiced and recorded at starting and closing times Jigs and tools are easy to return to their designated locations Dirt and stains on machines are removed immediately Things that cause dirt or stains are eliminated Tools and measurement devices are periodically checked and failures are fixed People are active in implementing Kaizen for the improvement of safety, quality and cost Violators of rules are warned by colleagues Components, tools and documents are labeled and easy to retrieve Rules are strictly observed (punctuality, cleaning at the end of the day, etc.) 5S is well maintained and upgraded through creative activities
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1

3
score

10

10

Copy this on the reverse side of a copy of the previous page, to make a handy manual.

85

PART 5 A Collection of Photographs Illustrating SUPER

The Structure of Part 5: Photographs Taken at 4 Model Organizations in Singapore Photographs Taken at 9 Model Organizations in Thailand

5S Practices

HE E E E

5S

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NORMAL

CHECK

STOP

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TOOLS IN USE

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TOOLS AFTER USE

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The End
of the

Presentation
Thank You Very Much for Your Participation
Kazuo Tsuchiya

Postscript Have you decided to implement the program of Super 5S? It is a matter of course that before participating in this program you must prepare elaborate plans (preparations and plans) according to the cycle of management (plan, do and see). At this stage, since seeing is believing, a very effective approach to success would be to visit or organize study tours to model Super 5S companies and exchange information with those involved in implementing Super 5S activities. As I said before, since 1986 I have had the experience of guiding 5S activities in many countries for about ten years. During this time I have tried to improve this book to make it easier for non-Japanese to understand. The title of this book has changed according to these revisions as follows: 1986: How to Implement 5S Activities in Your Organization 1990: Introduction to Advanced 5S Activities 1995: Introduction to Super 5S Engineering 1997: Super 5S is for Everyone The reason I have lately added super is that I intend to make the program surpass the generally understood level of 5S. I want to indicate to those involved in 5S practices the objectives and substance of being more and more creative, being more human and contributing more to productivity.

132

How to do 5S Step by Step

STEP 1 Seiri 1 Seiton 1 Seiso 1 Seiketsu 1 T A R G E T S Shitsuke 1 Keep only necessary items Assign items a place . In each section clean one machine well Create a clean workplace Discard unnecessary items more often A C TI O N S Arrange items by type and size Select a machine and clean it completely Clean ones workplace daily STEP 2 Seiri 2 Seiton 2 Seiso 2 Seiketsu 2 Shitsuke 2 Do not put anything on the floor Make needed items accessible Increase the number of clean machines Create a comfortable workplace Use wagons to transport items Remove obstacles around needed items Use more convenient cleaning tools Set up a cleaning schedule STEP 3 Seiri 3 Seiton 3 Seiso 3 Seiketsu 3 Shitsuke 3 STEP 4 Seiri 4 Seiton 4 Seiso 4 Seiketsu 4 Shitsuke 4

PASSPORT TO SUCCESSFUL 5S

What is 5S?
Seiri: Seiton: Seiso: Sort and discard unnecessary items in the workplace. Arrange necessary items so that they can easily be selected for use. Clean your workplace completely so that there is no dust on the floors, machines or equipment.

Separate work Create more space for areas from passageways effective use Reduce searching time Increase the number of clean machines Create a healthy and safe workplace Draw lines to separate passageways for people Use labels to simplify retrieval Prevent machines from getting dirty Eliminate hazards Reduce walking distances Keep all the machines clean and shiny Create a highly productive workplace Reduce excess inventory Place frequently used items close by Combine cleaning with inspection Introduce creative thinking

Seiketsu: Keep ones workplace productive and comfortable by repeating Seiri-SeitonSeiso. Shitsuke: Train people to follow good work habits.

5S is fundamental to productivity improvement 5S Contributes to PQCDSM

Productivity - increased competitiveness Quality - no defects Cost - no waste Delivery - no delays Safety - no accidents Morale - good teamwork

How to do 5S Step by Step

STEP 1 Seiri 1 Seiton 1 Seiso 1 Seiketsu 1 T A R G E T S Shitsuke 1 Keep only necessary items Assign items a place . In each section clean one machine well Create a clean workplace Discard unnecessary items more often A C TI O N S Arrange items by type and size Select a machine and clean it completely Clean ones workplace daily STEP 2 Seiri 2 Seiton 2 Seiso 2 Seiketsu 2 Shitsuke 2 Do not put anything on the floor Make needed items accessible Increase the number of clean machines Create a comfortable workplace Use wagons to transport items Remove obstacles around needed items Use more convenient cleaning tools Set up a cleaning schedule STEP 3 Seiri 3 Seiton 3 Seiso 3 Seiketsu 3 Shitsuke 3 STEP 4 Seiri 4 Seiton 4 Seiso 4 Seiketsu 4 Shitsuke 4

PASSPORT TO SUCCESSFUL 5S

What is 5S?
Seiri: Seiton: Seiso: Sort and discard unnecessary items in the workplace. Arrange necessary items so that they can easily be selected for use. Clean your workplace completely so that there is no dust on the floors, machines or equipment.

Separate work Create more space for areas from passageways effective use Reduce searching time Increase the number of clean machines Create a healthy and safe workplace Draw lines to separate passageways for people Use labels to simplify retrieval Prevent machines from getting dirty Eliminate hazards Reduce walking distances Keep all the machines clean and shiny Create a highly productive workplace Reduce excess inventory Place frequently used items close by Combine cleaning with inspection Introduce creative thinking

Seiketsu: Keep ones workplace productive and comfortable by repeating Seiri-SeitonSeiso. Shitsuke: Train people to follow good work habits.

5S is fundamental to productivity improvement 5S Contributes to PQCDSM

Productivity - increased competitiveness Quality - no defects Cost - no waste Delivery - no delays Safety - no accidents Morale - good teamwork

133

Checklist for Step 3

checkpoints The 5S Activity Bulletin Board is wellorganized and data are updated The locations for materials, components and work-in-process are labeled for easy retrieval Dies, jigs, fixtures and tools are conveniently located so that there is no need to search Bolts, nuts, components and other materials are not kept on the floor Passages and operation areas are clearly indicated and separated by distinct lines Failures found are immediately fixed (uneven floor, projections, machine failures, etc.) Areas difficult to clean are cleaned periodically Without searching tools or documents can be retrieved in less than 30 seconds Rules for 5S practice are implemented and are observed without prompting A 5S patrol is regularly conducted by supervisors for continued improvement
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1

2
score

Checklist for Step 4

checkpoints 1 5S inspections are practiced and recorded at starting and closing times Jigs and tools are easy to return to their designated locations Dirt and stains on machines are removed immediately Things that cause dirt or stains are eliminated Tools and measurement devices are periodically checked and failures are fixed People are active in implementing Kaizen for the improvement of safety, quality and cost Violators of rules are warned by colleagues Components, tools and documents are labeled and easy to retrieve Rules are strictly observed (punctuality, cleaning at the end of the day, etc.) 5S is well maintained and upgraded through creative activities
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1

3
score

10

10

Checklist for Step 3

checkpoints The 5S Activity Bulletin Board is wellorganized and data are updated The locations for materials, components and work-in-process are labeled for easy retrieval Dies, jigs, fixtures and tools are conveniently located so that there is no need to search Bolts, nuts, components and other materials are not kept on the floor Passages and operation areas are clearly indicated and separated by distinct lines Failures found are immediately fixed (uneven floor, projections, machine failures, etc.) Areas difficult to clean are cleaned periodically Without searching tools or documents can be retrieved in less than 30 seconds Rules for 5S practice are implemented and are observed without prompting A 5S patrol is regularly conducted by supervisors for continued improvement
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1

2
score

Checklist for Step 4

checkpoints 1 5S inspections are practiced and recorded at starting and closing times Jigs and tools are easy to return to their designated locations Dirt and stains on machines are removed immediately Things that cause dirt or stains are eliminated Tools and measurement devices are periodically checked and failures are fixed People are active in implementing Kaizen for the improvement of safety, quality and cost Violators of rules are warned by colleagues Components, tools and documents are labeled and easy to retrieve Rules are strictly observed (punctuality, cleaning at the end of the day, etc.) 5S is well maintained and upgraded through creative activities
Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1

3
score

10

10

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SUPER 5S PROGRESS CHART FOR TWO-YEAR MASTER IMPLEMENTATION PLAN

STEP

FROM
PENETRATION AND ADVANCEMENT

TO

SUPER S PROGRAMS
Preparations * Understanding philosophy and benefits of Super 5S by CEO * CEO s visit to Super 5S model companies * CEO s commitment to Super 5S implementation * Organize Super 5S Working Committee * Appoint Super 5S facilitators * Train Super 5S facilitators and practitioners CEO s Official Announcement * CEO officially announces implementation of Super 5S for 2 years * CEO explains objectives of Super 5S program to all colleagues * Publicize Super 5S organization and assignments by area * Promote Super 5S with banners, posters and newsletters * Organize basic Super 5S training programs for all colleagues

PHASE MONTH

PREPARATION

MAINTENANCE AND UPGRADING

Big Cleaning by All Colleagues * Organize a full-day of Big Cleaning Day twice a year * Organize small groups who are responsible for assignments in divided areas of the company s premises. * Provide enough cleaning tools and materials * Implement a company-wide big cleaning for one day * Big cleaning includes the elimination of unnecessary items and wastes

Initial Seiri * Establish a Disposal Standard for unnecessary items * Organize a full-day of Seiri activity twice a year * Everyone concentrates to identify and stratify unnecessary items for elimination * Unnecessary items that cost a lot should be evaluated so as to prevent the occurrence of such waste Daily Seiri, Seiton and Seiso * Seiri: Throw away things that are not needed and not being used * Seiton: Improve locations and methods for storing things so that searching time is minimized * Seiso: Set up a daily cleaning schedule for the creation of a healthy and comfortable workplace * Motivate colleagues to come up with creative improvements Periodic Audits on Super 5S * Establish a Super 5S evaluation and incentive plan * Conduct a Super 5S audit regularly by auditors * Organize a Super 5S inter-departmental competition for upgrading * Award groups and individuals for their contributions * Organize study tours to other companies doing Super 5S * Organize Super 5S inter-company competition to sustain the program

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