'5-S' Road map - DepartmentTo do Who ? When?

What ? Where? Team Leader Team Members P-D-C-A Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Dec-07

Plan S0 S1 S2 S2 S3

Actual S0

Plan S0 S1 S2 S2 S3

S0

Actual

S0 = Enablers [Motivate people for 5-S

implementation]

Gemba-1:

S1 = Seiri [Sort out

what is needed and what is not]S2 = Seiton

[Do systematic

arrangement for all needed

items]S3 = Seiso [Ensure spic & span

cleanliness with inspection]

Gemba-2:

S4 = Seiketsu [Create a

highly standardised workplace]

S5 = Shitsuke [Self - discipline

at workplace]

'5-S' Road map - DepartmentWhen?

Remarks Why ? MOPJan-08 Feb-08 Mar-08

S4 S4 S5SHE

EFSHE

PQCD

S4 S4 S5PQCD

PQCD

Zero setup PQCDEFSHE

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

Zero defect

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

Zero inventory/

More space

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

Zero waiting

1 ] CLIA: Deploy Clean-Inspect-Lubricate-Adjust 2 ] CPCP

Zero accidents

1 ] SOPs Developed & Displayed 2 ] Establish SDCA

Zero breakdown

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

ACTION PLAN FOR "S0" Enablers

Motivating people for 5S implementation (Jul - Aug 07)

Requisites Who Freq Status Remark

Official information HOD Once Ö

5-S Billboards / Camera TL X

Participation of all TL N/A Ö Gemba identified & teams formed

Effective training TL / TM Weekly X

PQCDEFSHE objectives TL / TM Qtr Ö 5S awareness sessions

1-30-300 principle TL / TM Qtr Ö 5S awareness sessions

Roadmap TL Once Ö Prepared & displayed

5-S as a part of Kaizen roadmap

Progress review TL / Auditor Qtr Ö

Publishing & widely communicating about the progress TM Monthly

Active involvement of the teams TL

Regular meetings TM Fortnight

Developing suggestion schemes TM Weekly

ACTION PLAN FOR "S1" Seiri

Sorting out what is required & dipose unwanted (Aug - Sep 07)

Requisites Area Who Status Remark

Work Area

TM Ö

TM Ö

TM Ö

TM Ö

Classification in work areas

TM X

TM X

TM X

TM X

TL

X

X

X

X

Scrap Disposal

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

Audit / Visual Inspection of wants / wastes

Listing Wants in an Area after eliminating waste

(S1) Waste Identification ChecklistGembaWork AreaTM

Process / Equipment / Item in areaUsage Condition Repairable

Waste

Freq. Rare Never Good Worst Yes No Yes No Yes No

Usage outside area

Better Substitute

avl

(S1) Waste Identification Checklist

Remark

ACTION PLAN FOR "S2" Seiton

Systematic Arrangement of wanted (Oct - Nov 07)

Requisites Area Who Status Remark

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

Organising wants in an area in terms of usage / value / importance to process / life cycle

Identifying amenities / infrastructure / tools required for correct organisation (P tags)

Organising in compliance with PEEP & Identifying missing / abnormal item or structure

(S2) Systematic arrangement checklistGembaWork AreaTM

Process / Equipment / Item in area Usage Value Qty (Nos) Total Pref. No

0

0

0

0

0

0

0

0

0

0

0

0

Critical to process

Item with pref. no "1" should always be the easiest accesible and further on

Scores can be 1/ 3/ 5 for low / Med / High categories repectively & Pref. no will be in descending order of total score

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

ACTION PLAN FOR "S3" Seiso

Systematic Arrangement of wanted (Nov - Dec 07)

Requisites 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

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)

Remark

ACTION PLAN FOR "S4" Seiketsu

Systematic Arrangement of wanted (Jan - Feb 08)

Requisites Area Who Status Remark

TM X

TM X

TM X

TM X

TM X

TM X

TM X

TM X

Daily Inspection / Reporting abnormalities

Action for deviation / 5S awareness session or training

ACTION PLAN FOR "S5" Shitsuke

Systematic Arrangement of wanted (Mar 08)

Requisites Area Who Status Remark

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

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

0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very Good

1S Check Item DescriptionScore

0 1 2 3 4

SE

IRI

Materials / parts Does the inventory or in-process inventory include unneeded mtrl / parts

Machines / Equipment Are there any unused machines or other equipment

Papers / Plastic Mtrl Is there any paper / plastic scrap around

Visual Control Is the waste identified

Sub Total 0 0 0 0 0

2S Check Item DescriptionScore

0 1 2 3 4

SE

ITO

N

Location Indicators Are shelves and other storage areas marked with addresses

Item Indicators Do the shelves have signboards showing which items go where

Qty. Indicators Are Max / Min Inventory levels indicated

Walkway Demarcation Storage areas / Process Area / Units marked

Sub Total 0 0 0 0 0

3S Check Item DescriptionScore

0 1 2 3 4

SE

ISO Floor / Work station Are floors / work station shiny to spot any waste

M/c & Equipments Are they Dust free, running healthy with allowed noise / vibration

Cleaning Stewards Is there a dedicated staff / do they do it voluntarily

Sub Total 0 0 0 0 0

4S Check Item DescriptionScore

0 1 2 3 4

SE

IKT

SU Improvement Idea Is any action plan in place for its deployment

Standard procedure Is the 5S implementation plan documented / published / communicated

Future scope Any continual improvement idea / process / recognition

First 3S Is Seiri / Seiton / Seiso maintained

0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very GoodSub Total 0 0 0 0 0

5S Check Item DescriptionScore

0 1 2 3 4

SH

ITS

UK

E

Equipments / Process Are they easily gettable / managable

Stock levels Is the inventory control adhered to

Training Is Training / 5S awareness in progress

Support Is top management active support available

5-S Billboards Are they updated

Sub Total 0 0 0 0 0

Grand Total 0

0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very Good

SEIRI 0

SEITON 0

0

SEISO 0

SEIKTSU 0

SHITSUKE 0

0

0

0

SEIRI

SEITON

SEISOSEIKTSU

SHITSUKE

0

0.5

1

Audit Result

0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very Good 0

0

0