5S MILL AUDITOR TRAINING

BY:MARWANI HIRMI MUDA

1. Complete first 3S by December 2012.

2. Complete 4th S for manufacturing processes by June 2012.

3. 5S audit score of 3.5 by December 2012

MNI 5S Target

S1 Sort out unnecessary itemsS2 OrganiseS3 Cleaning & InspectionS4 Standardization/Visual controlS5 Discipline

5S CONCEPT

                                                                                                                                                                                                                       Zones 5S Leader                                                                       Paper Mill (exclude maintenance office) Barry                                  Pulp Mill (include sludge building & Chem. Prep.) Selvam                                  Finishing Marwani                                  Biomass Zainol                                  CHPP Rosli MA                                  RWETP ( includes pump house ) Razab                                  RPW Markus                                  Store (include gas storage & store open yard) Hup                                  Workshop Sanjivi                                  Roll shop ( includes used oil ) Prekash                                  Site and admin ( excludes open yard & Tech. lab ) Bakhtiar                                  Labs ( wet end, Dry end & Tech. Lab) Romizan                                  TNB substation & transformer Wan Sabree                                  Finishing Product warehouse Adnan                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    

StoreWorkshop

Pulp MillPaper Mill

Recovered paper 

Warehouse

Biomass Plant

CHPP Plant

ETP

RWTP 

Open Space

AdminRoll Shop

Car Park

TNB Substation

Finished Product 

warehouse

Finish

ing

Mill Zone

Zones 5S Leader

Paper Mill (exclude maintenance office) Barry

Pulp Mill (include sludge building & Chem. Prep.) Selvam

Finishing Marwani

Biomass Zainol

CHPP Rosli MA

RWETP ( includes pump house ) Razab

RPW Markus

Store (include gas storage & store open yard) Hup

Workshop Sanjivi

Roll shop ( includes used oil ) Prekash

Site and admin ( excludes open yard & Tech. lab ) Bakhtiar

Labs ( wet end, Dry end & Tech. Lab) Romizan

TNB substation & transformer Wan Sabree

Finishing Product warehouse Adnan

Zone and Leader

Scope

1. Covers the entire MNI facilities including off site installations like the river pump house and pipe lines

Duties & Responsibilities

2. Setting of 5S audit standard and format3. Working closely with the Training Sub committee to ensure

sufficiency in competent auditors4. Setting up annual audit calendar5. Conducting regular audit and tracking of the audit results6. Participate in Hong Leong Group inter company cross 5S audit

Mill Scope & Duty

7

Team A Team B

Marwani ( Leader) Markus Buas ( Leader)

Yushak Lamin Mitchelle Ting

Noor Rafidah Mohd Saidi Ali

Chim Moo Shim Ahmad Mazeli

Mohd Fairus Talhah Sivalingam

Mill 5S Audit Team

        2011 2012No Activities PIC Status Feb Mac APr Ma

y June July Aug Sept Oct Nov Dec Jan Feb MarAPr Ma

y June

July Aug Sept Oct Nov Dec

1 Mill 5S Committee Set Up AT Completed 23                                            2 Form Mill 5S Audit Team TKH         30                                      3 5S audit team training Marwani           1,9                                    4 3S check sheet and report template Marwani         12                                      5 5S check sheet Marwani           31                                    6 5S Score Board Marwani           31                                      3S Audit                                                6 Finishing/ Main Lab Team A /B                                                7 ETP/Bomba pump house/FPW Team A /B                                                8 TNB sub station & transformer / HV/ CHEM PREP Team A /B                                                

9 RWETP/ Intake / RPW / Sorting Plant Team A /B                                                

10 Admin/Mill wide site / DE,WE Lab/Rollshop/Workshop/Biomass

Team A /B                                                

11 RCF/ CHPP/Maint Off Team A /B                                                12 PM / Store Team A /B                                                  5S AUDIT (Visual Control)                                                13 Finishing/ Main Lab Team A /B                                                14 ETP/Bomba pump house/FPW Team A /B                                                15 TNB sub station & transformer / HV/ CHEM PREP Team A /B                                                16 RWETP/ Intake / RPW / Sorting Plant Team A /B                                                17 Admin/Mill wide site / DE,WE

Lab/Rollshop/Workshop/BiomassTeam A /B                                                

18 RCF/ CHPP/Maint Off Team A /B                                                19 PM / Store Team A /B                                                  Repeat 5S AUDIT (Those below mill score target)                                                20 Area TBC Team A /B                                                21 Area TBC Team A /B                                                22 Area TBC Team A /B                                                23 Area TBC Team A /B                                                24 Grand presentation - ETP, TNB Substation,

FPW                                                

25 Grand presentation - Pulp Mill, RPW, Site & admin

                                               

26 Grand presentation - Roll shop, Workshop, Biomass

                                               

27 Grand presentation - Paper Mill, CHPP, RWTP, Store

                                               

Mill 5S Auditor Calander

5S = house keeping only5S Benefits

Heinrich PrincipleHeinrich Principle

Critical Accident1

29

300

Minor Accidents

Factors of Accident（ near miss ）

BreakdownBreakdown

Eg. Motor

Did not Rotate

Over HeatVibration

Abnormal Sound, etc.

Dirty (Sand, Cutting chips etc.)

High HumidityOil Mist

Heavy Load, etc.

Prev

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e M

aint

enan

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Improvement ( Countermeasure ) focus not only on the problems,but also inclusive the contributing factors.

Indi

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5S. A

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Meaning, Definition and Purpose of 5S

Meaning of 5S

GOODARRANGEMENT

( SEIRI )

GOOD ORDER( SEITON )

CLEANING

( SEISO )

NEATNESS

(SEIKETSU)

DISCIPLINE

(SHITSUKE)

Definition

Separate necessary& Unnecessary

Things

Determine a Layout Enabling Ready Use of Necessary Things at the Necessary Time

Clean it by Removing Dirt, Stain and Foreign Substances

Ensure the 3S above(Maintain Neatness in

Terms of Hygieneand Environmental

Contamination)

Encourage Obedience to

the Rules

Definition

Separate necessary& Unnecessary

Things

Determine a Layout Enabling Ready Use of Necessary Things at the Necessary Time

Clean it by Removing Dirt, Stain and Foreign Substances

Ensure the 3S above(Maintain Neatness in

Terms of Hygieneand Environmental

Contamination)

Encourage Obedience to

the Rules

Example of EffectExample of Effect

Reduced inventoryReduced inventory

Efficient use of limited spaceEfficient use of limited space

Prevention of missing things Prevention of missing things

Prevention of leakage of air and oilPrevention of leakage of air and oil

Prevention of searching for last itemsPrevention of searching for last items

Elimination of unstable stateElimination of unstable state

Maintenance,improvement of capacity of facilitiesMaintenance,improvement of capacity of facilities

Important points of facilities can be cleaned and inspected

Important points of facilities can be cleaned and inspected

Improved environment of work shopImproved environment of work shop

Elimination of causes of accidentElimination of causes of accident

Reduced carelessnessReduced carelessness

Observation of rulesObservation of rules

Achievement of better human relationsAchievement of better human relations

Purpose

CostReduction

CostReduction

ImprovedEfficiency

ImprovedEfficiency

ImprovedQuality

ImprovedQuality

ReducedBreakdown

ReducedBreakdown

ImprovedSpirit of

Challenge

ImprovedSpirit of

Challenge

Assurance of Safe-ty and Prevention of Environmental

Problems

Assurance of Safe-ty and Prevention of Environmental

Problems

Purpose

CostReduction

CostReduction

ImprovedEfficiency

ImprovedEfficiency

ImprovedQuality

ImprovedQuality

ReducedBreakdown

ReducedBreakdown

ImprovedSpirit of

Challenge

ImprovedSpirit of

Challenge

Assurance of Safe-ty and Prevention of Environmental

Problems

Assurance of Safe-ty and Prevention of Environmental

Problems

Purpose

CostReduction

CostReduction

ImprovedEfficiency

ImprovedEfficiency

ImprovedQuality

ImprovedQuality

ReducedBreakdown

ReducedBreakdown

ImprovedSpirit of

Challenge

ImprovedSpirit of

Challenge

Assurance of Safe-ty and Prevention of Environmental

Problems

Assurance of Safe-ty and Prevention of Environmental

Problems

Aims Typical Activities

1. Throw out the things you do not need.2. Deal with the causes of dirt and leaks.3. Housecleaning.4. Treat defects and breakage.5. Inspect covers and troughs to prevent leak age and scatter.

1.Everything has a clearly designated place. 2. Thirty-second storage and retrieval. 3. Filing standards. 4. Zoning and placement marks. 5. Eliminate lids and locks. 6. First in, First Out

6. Clean the grounds.7. Organize the warehouse.8. Eliminate grime and burrs.9. Eliminate oil pans.

7. Neat notice boards. 8. Easy-to-read notices. 9. Straight lines and right angles. 10. Functional placement for

materials, parts, carts, shelves, tools, equipment and everything else.

1. Quick 5S drills.2. Individual responsibility.3. Make cleaning and inspection easier.4. Sparkling clean campaigns.

5. Everybody is a janitor (priority 5S).

6. Perform cleaning inspections and correct minor problems.

7. Clean even the places most people do not notice.

Organization (Seiri): Stratification management and dealing with the causes.

Neatness (Seiton):Functional storage and eliminating the need to look for things.

Cleaning (Seiso):Cleaning as inspection and degrees of cleanliness.

Preparedness Towards 5S

1. Okay marks.

2. Danger zones marked

on meters.

3. Thermal labels.

4. Directional markings.

5. Belt-size labels.

6. Open-and-shut

directional labels.

7. Voltage labels.

8. Color-coded pipes.

9. Oil labels.10. Warning colors.11. Fire extinguisher signs.12. . Responsibility labels.13. 5S calendars.14. Wire management.15. Inspection marks.16. Precision-maintenance

labels.

17. Limit labels.

18. Color coding.

19. Preventing noise

and vibration.

1. All-together cleaning.

2. Exercise time.

3. Pick-up practice.

4. Wear your safety

shoes.

5. Public-space

management.

6. Practice dealing with emergencies.

7. Individual responsibility.

8. Telephone and communication

practice.

9. 5S manuals.

10. Seeing is believing.

Standardization (Seiketsu): Visual management and 5S standardization.

Discipline (Shitsuke):Habit formation and a disciplined workplace.

Visual ControlAims Typical Activities

5S Awareness Training

Drawing up aMaster plan,Setting up Target

Forming up5S Teams

Carry out 5SStep by Step

5S Audit using 25 point Check sheet

5S Competition(Gold,Silver,Bronze metal)

Fixed Positionphotograph

Five Steps

To Shaping UpThe Shop Floor 5S

Visual Control

The first 3 ’S’

The 4th ‘S’

Identify area ofImprovement“Show Room Concept “

Red tag CampaignRed EagleSaman System

5S Implementation

　 Initial phase of 5S activityHLYM 25 point check sheet

No Check Point

1. 5s Promotion system

2. Cleaning ( score unit : each facility )

3. Dirt source

4. Portions difficult to be cleaned.

5. Take out & put back in 30 seconds ( File , Jig & tool measurement tool, parts etc.)

6. Measures for safety ( for facilities )

7. visual control 1 - indicating the direction of flow ( pipe lined materials)

8. Visual control 2 - Valve open-shut indication.

9. Visual control 3 - Maintaining wire ropes

10. Visual control 4- Indications of the extinguishers

11. Visual control 5- Thermo label

12. Visual control 6- G (good) marks (for fastening -up)

No Check Point

13. Visual control 7- Cooling fan (tape, windmill) etc.

14. Visual control 8- Check mark ( for daily check )

15. Visual control 9- Indication of the rotating direction

16. Visual control 10 - Indication of belt size & number

17. Visual control 11. 15 -block ( line ) & floor

18. Visual control 12 - Meter Control zone

19. Visual control 13 -Measuring Instrument

20. Visual control 14 - Three- piece set.

21. Visual control 16 - Cleaning tool

22. Visual control 17 - Oil substation

23. Visual control 18 - Electric distribution board

24. Visual control 19 - Air

25. Visual control 20 - Lighting equipment

Level 0 : Red Tag                  campaign

5S committees have been formed and actively promoting 5S at the shop floor (according to zone)

All possible (at each zone)-cleaning points -Dirt sources-Difficult cleaning points-Tools/ files Retrieval -Safety points have been identified and abnormalities can be detected easily

　 Initial Phase of 5S ActivityNo Check Point

1. 5s Promotion system

2. Cleaning ( score unit : each facility )

3. Dirt source

4. Portions difficult to be cleaned.

5. Take out & put back in 30 seconds ( File , Jig & tool measurement tool, parts etc.)

6. Measures for safety ( for facilities )

7. visual control 1 - indicating the direction of flow ( pipe lined materials)

8. Visual control 2 - Valve open-shut indication.

9. Visual control 3 - Maintaining wire ropes

10. Visual control 4- Indications of the extinguishers

11. Visual control 5- Thermo label

12. Visual control 6- G (good) marks (for fastening -up)

No Check Point

13. Visual control 7- Cooling fan (tape, windmill) etc.

14. Visual control 8- Check mark ( for daily check )

15. Visual control 9- Indication of the rotating direction

16. Visual control 10 - Indication of belt size & number

17. Visual control 11. 15 -block ( line ) & floor

18. Visual control 12 - Meter Control zone

19. Visual control 13 -Measuring Instrument

20. Visual control 14 - Three- piece set.

21. Visual control 16 - Cleaning tool

22. Visual control 17 - Oil substation

23. Visual control 18 - Electric distribution board

24. Visual control 19 - Air

25. Visual control 20 - Lighting equipment

All critical inspection areas must have proper visual control and Inspection checklists are prepared accordingly.

Workers are carrying out the 5SInspection everyday (5min beforeand after starting work)

HLMG 5S Council members Audit in action HLMG 5S Council members Audit in action

Audit Findings & Areas for ImprovementGeneral 

Wiring

Structural

Safety

Audit Findings & Areas for Improvement

Fire extinguishers

Visual Control

Electrical distribution board

Audit Findings & Areas for Improvement

Wire ropes, Oil sub station, Motor belts , spare parts … cleaning tools 

Visual Control

Audit Findings & Areas for Improvement

requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1

18 Drawings/ catalogs / posters N

19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1

25 5S work routine improvement system 1

Average 2.21

requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1

18 Drawings/ catalogs / posters N

19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1

25 5S work routine improvement system 1

Average 2.21

Floor Wiring

Common Used items

Desks & Chairs

Audit Findings & Areas for Improvement

requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1

18 Drawings/ catalogs / posters N

19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1

25 5S work routine improvement system 1

Average 2.21

requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1

18 Drawings/ catalogs / posters N

19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1

25 5S work routine improvement system 1

Average 2.21

Ceiling

Walls, curtains or shades

Stationery

Audit Findings & Areas for Improvement

requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1

18 Drawings/ catalogs / posters N

19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1

25 5S work routine improvement system 1

Average 2.21

requirement rate1 Floor 42 Common used 23 Desks & Chairs 24 Telephones 35 Drawing Boards N6 Cabinets 17 White boards 48 Trash cans 29 Ceilings 210 Fluorescent lights 311 Walls 412 Curtains or shades 213 Windows 214 Doors 415 stationery 216 Common Files 117 Inside of Ind. Drawers 1

18 Drawings/ catalogs / posters N

19 Books N20 Storing of samples N21 Where about boards 122 "one best policy" N23 File Volume N24 5S Promotion system 1

25 5S work routine improvement system 1

Average 2.21

Common filing & cabinets

Individual Drawers Storing of samples

Audit Findings & Areas for Improvement

Noteworthy EffortsNoteworthy efforts Noteworthy efforts 

Beginning of 5S promotion

5S Deployment started

Good 5S initiatives (Standardizations are required)

Noteworthy efforts Noteworthy efforts 

Conducive Office environment

Neat arrangement of file & Centralized storage of Stationery 

Promote Go Green

Initial 5S cleaning and sorting were observed

Noteworthy Efforts

Discussion : Audit Preparation & Procedure

BEFORE  AUDIT:

1. Scope of audit2. Zone/Area layout3. Check sheet4. Camera, 5. notebook

.

AFTER  AUDIT:

1.  Give comments and findings on the same day

DATE   AREA AUDIT  

TEAM  

No Requirement Score (P) Request Item Tools

1 5S Promotion System 1  An organization chart, action plan & education promotion.

Committee, Action plan, Zoning, Training material

    2  5S meeting held periodically, team understand problem MOM, Ownership, Layout with 25 marking

  Scope: 3   5S activities implemented on routine basis 5S activities  1. Form commitees 4   Plan for improvement and counter measures. Kaizen improvement  2.Maste r Plan 5   Activities achieved 100% target Control indices/Target

  3. Area to tackle defined      

  4. Job clearly assigned Sub Score  

  5. Target established        2 Cleaning 1   Cleaning plan, a duties plan and schedule Cleaning schedule

    2   The falicities are cleaned On site checked  Scope: 3   Additional equipment & devices are cleaned On site checked

  1. Equipment clean 4  A check plan drawn up & perodically cleaning is performed Cleaning check sheet

  2. Method cleaning.  5   identify potential defects and takes control measures Easy inspection  3. Fast and easy cleaning            Sub Score  

3 Dirt Source 1   Education is prevailing & sources are identified Dirt source map    2   A map & plan to control available Map and action plan  Scope: 3   Over 50% counter measures achieved Dirt source contained  1. Dirt source is isolated 4   Over 80% counter measures achieved Dirt source contained  2. Reduced & eliminated 5   very high improved  with cleaning is performed 100% Dirt source isolated  3. Can be removed easily          4. Kaizen to remove dirt Sub Score  

3 S Audit Check Sheet

4 Portions difficult to clean 1   Education is prevailing & portions area identified Difficult areas    2   A map & plan to control available Difficult areas cleaning map  Scope: 3   Over 50% counter measures achieved    1. Machine's top 4   Over 80% counter measures achieved    2 Machine 's back 5   very high improved with cleaning is performed 100% Facilities covers/ Kaizen

  3. Inside machine        

  4. Under cabinet Sub Score    

  5. Special cleaning tools        

5Take out & put back in 30s 1   Necessary & unnecessary items identified On site checked

    2   Storage set in place Location of storage: On site checked  Scope: 3   Portios are placed as indicated On site checked  1. Systematic arrangement 4   Improved method for easy retrieval On site checked  2. Easy to identify 5   take out and put back 30s. 30s retrieval system: on site checked

  3. Easy retrieval        

  4. Aware by all & neat Sub Score    

6 Measures for safety 1   Safety education is performed, safety policy/check sheet Safety policy, procedures, check sheet    2   Unsafe areas/activities detected with signage Safety signage/ indication  Scope: 3   Problems identified with safety counter measures 50% On site: sensor, guides  1. Establish indices/target 4   Problems identified with safety counter measures 100% On site: sensor, guides  2. Identify unsafe area/act 5   High safety awareness with improvement periodically Safety check sheet, safety index/target

  3. Permanent measures        

  4. Signage/ indicator Sub Score      5. PPE regulations        

  6. Operation standard        

GRAND TOTAL SCORE 0

% SCORE 0%

Additional Comment:

3 S Audit Check Sheet

No. Area SCORE 3S AUDIT % S SCORE SCORE 5S AUDIT % S SCORE1 Finishing        2 Main Lab        3 ETP        4 Bomba pump house        5 FPW        6 TNB sub station & transformer / HV        7 CHEM PREP        8 RWETP        9 Intake pump house        10 RPW / Sorting Plant        11 Admin Office        12 Mill wide site         13  DE and WE Lab        14 Rollshop        15 Workshop        16 Biomass        17 Maint Office        18 PM        19  RCF        20 CHPP        21 Store        

5S Scoreboard