Safety – 5S Implementation Guide

5S Implementation Guide The scope, size and timeliness of completing the 5S event must will be impacted by the availability of dedicated resources who are capable of actively participating in the event. Note: Some sites do not have enough dedicated resources to complete a 5S event within a brief period of time (similar to a kaizen activity), under these circumstances each of the 5S can be completed separately over a planned time frame. 2. A visual display board should be established in a centralized location within the work area in order to provide a location for pictures and other standard work documentation.

Management Responsibility Management must provide the following: The area where the 5S activity will take place, The 5S team lead and support personnel who will participate in the event, Note: The event can be accomplished by personnel who work outside the area where the event is taking place but team selection should primarily be comprised of personnel from within the impacted area to assure direction and ownership. Necessary resources including: Available time and materials to perform the activities Concise directions regarding dispositioning of tagged items

Identify workers, processes, and functions of the area. Area Preparation Identify workers, processes, and functions of the area. Target Area Name: 2. Define the boundaries of the target area and tape it off. 3. State the primary purpose of the target area. Criteria Who When Status Draw area map (event scope) Identify all necessary equipment, tools and materials Identify unnecessary equipment, tools and materials Yellow tag unnecessary items

5S Action Checklist Sort Straighten Shine Standardize Sustain Distinguish between what is needed and not needed BEFORE AFTER Unneeded equipment, tools, furniture, etc. are present Unneeded items are on walls, bulletin boards, etc. Items are in aisles, stairways, corners, etc. Unneeded inventory, supplies, parts, or materials are present Safety hazards (debris, water, oil, chemical, machines) exist Sort Correct places for items are not obvious Items are not in their correct places Aisles, workstations, equipment locations are not identified Items are not put away immediately after use Height and quantity limits are not obvious A place for everything and everything in its place Straighten Cleaning, and looking for ways to keep it clean and organized Floors, walls, stairs, and surfaces are not free of dirt, oil, and grease Equipment is not kept clean and free of dirt, oil, and grease Cleaning materials are not easily accessible Lines, labels, signs, etc. are not clean and unbroken Other cleaning problems of any kind exist Shine Systematically maintain and monitor the first three S’s Necessary information is not visible All standards are not known and visible Standard Work doesn’t exist for all cleaning and maintenance jobs All quantities and limits are not easily recognizable Items cannot be located in 5 seconds Standardize Area workers have not had 5-S training 5-S is not performed routinely Personal belongings are not stowed neatly Standard Work is not available or up-to-date Daily 5-S audits are not performed Stick to the rules Sustain Note: Check all that apply, plan countermeasures.

Sort Guidelines The team lead should work with management to develop a work schedule to complete the Sort process in a expeditious manner. If necessary management should provide 5S training to new team members. Management will provide guidance and materials to support the following: Focused area where the event will occur Expected outcomes including allotted time to conduct the activity Directions (criteria) and materials to sort, tag and disposition equipment, materials, tools etc. Pictures should be taken in advance of and after the event to provide before and after perspective

Sort Red Tag Checklist Directions Tag every item that may not be needed Enter a X when a category is inspected Examine all items in each category Directions Floors Aisles Operation areas Work Stations Corners, behind/under equipment Stairs Small rooms Offices Loading docks Inside cabinets and drawers Inspect storage places Shelves Racks Closets Sheds Other storage areas Inspect the walls, boards, etc. Items hung on walls Bulletin boards Signboards Other Machines Small tools Dies Jigs Bits Conveyance equipment Plumbing, pipes, etc. Electrical equipment Wire, fixtures, junction boxes Raw materials Supplies Parts Work in process Finished products Shipping materials Identify unnecessary material / supplies Work clothes Helmets Work shoes Trash cans Other Cabinets Benches and tables Chairs Carts Other

Tag Log Item Serial # Date Tag Status Notes /Disposition

Disposition Guidelines Directions Determine the category each tagged item belongs Determine required yellow tag action, record status on tag and update log Take action Category Action Obsolete Sell Hold for depreciation Give away Throw away Defective Return to supplier Repair Scrap Remove to proper location Trash /Waste Dispose of Recycle Not needed in area Relocate to new location Used daily Keep at place of use Used weekly Store in area Used monthly Store adjacent to area Seldom used Store in distant location Unknown use Determine use and storage location

Straighten Guidelines “Everything should be assigned to a designated place and everything should be in its place”. The team should identify specific locations based on work performance and frequency of use for each piece of equipment, tool and materials that are in the work area. Note: When possible place frequently shared items on carts to establish mobility Refer to the 5S training for examples on how create designated locations for tool shadowing in tool boxes and placement on shadow boards, etc. 3. Pictures should be taken in advance of and after the event to provide before and after perspective. Note: Default to company policy for the application of tape protocols i.e. colors, patterns etc.

Straighten Inspection Sheet Directions Identify location for each Move item to designated place Enter a X when a category is inspected Equipment Machines Small tools Dies Jigs Bits Conveyance equipment Cleaning equipment Electrical equipment Fixtures, junction boxes, etc. Computer equipment Materials / supplies / inventory Raw material Supplies Parts Work in process Finished product Shipping materials Cleaning supplies Other items Charts, graphs, etc. Books, checklists, etc. Bulletin boards Signboards Pens, pencils, rulers, etc. Work clothes Helmets Work shoes Trash cans Personal items Furniture Cabinets Benches and tables Chairs Carts Shelves Racks

Shine Guidelines The team leader should assign team members specific areas to clean (see Initial Cleaning Plan). The work area and each piece of equipment should be cleaned, assuring the removal of excess grease, oil fluids etc. to assure equipment isn’t leaking or in need of repair. Assure the work area is cleaned (inspection ready) to establish a baseline score. 4. Pictures should be taken in advance of and after the event to provide before and after perspective.

Shine Inspection Sheet Directions Use this with the Initial Cleaning Plan Enter a X when a category is completed Large Surfaces Ceilings Aisles Work Stations Corners, behind/under equipment Stairs Loading docks Walls Doors Pillars and posts Floors Other Inside equipment / furniture Machines Conveyance equipment Closets Drawers Cabinets Sheds Tool boxes Storage bins Carts Shelves Racks Other items Materials and supplies Trash cans Bulletin boards Labels and signs Small tools Hoses, cords, tubing, etc. Other Surfaces of equipment and furniture Machines Conveyance equipment Plumbing, pipes, sinks Electrical equipment Fixtures, junction boxes Chairs

List tasks and complete the columns below Initial Cleaning Plan List tasks and complete the columns below Target Area Task Area Who When Materials & Tools

Standardize Guidelines The basic purpose of ‘standardizing’ is to prevent set backs of the first three S’s. Management’s focus is to make them a daily habit assuring that sort, straighten and shine are maintained in there fully implemented state. Immediately after the event has been completed management should establish a 5S job chart and assign work space personnel with daily responsibilities to maintain the 5S’d area in accordance with established standards.

List tasks and complete the columns below 5S Assignment Chart List tasks and complete the columns below Target Area Task Area Who When Materials & Tools

Sustain Guidelines The basic purpose if event lead should work with management to develop a working schedule to cover the 5S. Management should assemble the team and provide 5S training overview. Management should provide information and materials to support the following: Focused area where the event will occur Expected outcomes including allotted time to conduct the activity Directions (criteria) and materials to sort and tag equipment, materials, tools etc.

Sustain Guidelines Without organizational commitment to Sustain the benefits of the 5S activities quickly falls apart. Positive conditions to support Sustain are: Awareness – Use approved communication methods to help sustain 5S Time – schedule time to perform the 5S Support – management should provide acknowledgement, leadership and resources Rewards & Recognition – Good efforts should be rewarded. Conduct scheduled audits to maintain focus.

Organization Understanding 5S Audit Form 5S Audit Form Sort Straighten Shine Standardize Sustain Level 5 Habit Needed items can be retrieved in 30 seconds or less. Obsolete materials are routinely removed from the area. Preventative measures are in place to keep unnecessary items, reports etc. from entering the area. Anyone can walk into the work area and easily locate work by priority. Corrective measures are in place to address abnormal conditions. Work area housekeeping is a routine way of life. Corrective action measures are in place to address cleanliness issues. Team is adhering to standards work methods, visuals and work area controls. A system of improving work methods and work area controls is clearly being utilized Information on the area information board is meaningful and influences the daily decisions of the work area. Root causes of problems are eliminated and actions focus on preventative methods. Level 4 Commitment All work material has been sorted according to what will be worked today, this week. Materials, tooling, files and reports are routinely reviewed for necessity. Team members can easily determine what items are currently in-use and their priority. Visual controls are in place to indicate normal / abnormal work conditions. Work area housekeeping responsibilities are established and being followed on a daily basis. Cleaning materials are stored and readily available. Team is utilizing standard work methods and work area controls on a daily basis. Possible for visitors to tell what work is performed and where in most cases. Team routinely checks area to maintain the 5S's. Information on the area information board is meaningful to the work area. Source and frequency of problems are documented and corrective actions taken. Planning occurs to reach next 5S levels. Level 3 Organization Understanding Only documents and tools necessary to the work area are stored at the workstations and are stored in an orderly manner. A priority system has been established to highlight the order in which jobs will be performed. All tooling, gages, hand tools have designated locations. Cleanliness problems have been identified and preventative measures are documented and in place. Team has documented needed items, work methods, and work area controls and has made them available in the work area. Possible for visitors to tell what work is performed and where in some cases. 5S presentation has been made to all Team members and a general understanding for the need and direction exists. Area information board is present, visible, and maintained. Level 2 Awareness of Need Needed and unneeded items have been identified and unneeded items have been removed from the area. Nothing is placed on top of machines, cabinets, etc. Needed items have been organized according to use, including production tooling, hard tools and work procedures. Initial cleaning has been performed. All machines and equipment are neatly painted. Workbenches and desks are free of unnecessary objects. Team has agreed on needed items, work methods, and work area controls. Hard for visitors to tell what type of work is performed and where, but employees generally know. Team members have knowledge of and are employing some aspects of 5S. Level 1 Initial Effort Team has identified needed items for the work area. Alll needed items are present in the work area. It is not difficult to determine Area cleaning is performed on a random basis. Work methods are documented in some cases. Some 5S awareness exists among Team members in the area. Overall Score (Sum of Totals divided by 5) _____ 5 = Total = The factory 5S evaluation form (explain how it is used to the audience).

5S Rating Form

Event Closeout & Follow-up The event lead should work with management to develop a working schedule to cover the 5S. Management should assemble the team and provide 5S training overview. Management should provide information and materials to support the following: Focused area where the event will occur Expected outcomes including allotted time to conduct the activity Directions (criteria) and materials to sort and tag equipment, materials, tools etc.