5s implementation plan at work place
DESCRIPTION
Step by STep plan drawn for implementing "5S" at work place.Includes detailed audit at each stageTRANSCRIPT
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'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]
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'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
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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
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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
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(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
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(S1) Waste Identification Checklist
Remark
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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
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(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
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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
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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
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ACTION PLAN FOR "S3" Seiso
Systematic Arrangement of wanted (Nov - Dec 07)
Remark
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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
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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
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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
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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
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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
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0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very Good 0
0
0