Supplemental Material:

Program Administrationfor 5S Roll-out

Safety – 5S Implementation Guide

5S Implementation Guide

1. 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

1. 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

Area Preparation

Identify workers, processes, and functions of the area.

1. 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

Sustain

Area workers have not had 5-S training

5-S is not performed routinelyPersonal belongings are not stowed neatly Standard Work is not available or up-to-dateDaily 5-S audits are not performed

Sort

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

Straighten

Correct places for items are not obvious

Items are not in their correct placesAisles, workstations, equipment locations are not identifiedItems are not put away immediately after useHeight and quantity limits are not obvious

Floors, walls, stairs, and surfaces are not free of dirt, oil, and greaseEquipment is not kept clean and free of dirt, oil, and greaseCleaning materials are not easily accessible

Lines, labels, signs, etc. are not clean and unbrokenOther cleaning problems of any kind exist

Shine

Standardize

Necessary information is not visibleAll standards are not known and visibleStandard Work doesn’t exist for all cleaning and maintenance jobsAll quantities and limits are not easily recognizable

Items cannot be located in 5 seconds

BEFORE AFTER

Note: Check all that apply, plan countermeasures.

• A place for everything and everything in its place

• Cleaning, and looking for ways to keep it clean and organized

• Systematically maintain and monitor the first three S’s

• Stick to the rules

• Distinguish between what is needed and not needed

Sort Guidelines

1. The team lead should work with management to develop a work schedule to complete the Sort process in a expeditious manner.

2. If necessary management should provide 5S training to new team members.

3. 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

SortRed 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

Inspect the walls, boards, etc.Items hung on walls

Bulletin boards

Signboards

Other

Raw materialsSuppliesPartsWork in processFinished productsShipping materials

Identify unnecessary material / supplies

Work clothesHelmetsWork shoesTrash cansOther

Inspect storage placesShelvesRacksClosetsShedsOther storage areas

FloorsAislesOperation areasWork StationsCorners, behind/under equipmentStairsSmall roomsOfficesLoading docksInside cabinets and drawers

MachinesSmall toolsDiesJigsBitsConveyance equipmentPlumbing, pipes, etc.Electrical equipmentWire, fixtures, junction boxes

CabinetsBenches and tablesChairsCartsOther

Tag Log

Item Serial # Date Tag Status Notes /Disposition

Disposition GuidelinesDirections • 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• Throw away• 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”. 1. 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

2. 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

FurnitureCabinetsBenches and tablesChairsCartsShelvesRacks

Materials / supplies / inventoryRaw materialSuppliesPartsWork in processFinished productShipping materials

Cleaning supplies

Other items

Charts, graphs, etc.Books, checklists, etc.Bulletin boardsSignboardsPens, pencils, rulers, etc.Work clothes

HelmetsWork shoesTrash cansPersonal items

EquipmentMachinesSmall toolsDiesJigsBitsConveyance equipment

Cleaning equipmentElectrical equipmentFixtures, junction boxes, etc.Computer equipment

• Identify location for each • Move item to designated place• Enter a X when a category is inspected

Shine Guidelines

1. The team leader should assign team members specific areas to clean (see Initial Cleaning Plan).

2. 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.

3. 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.

• Use this with the Initial Cleaning Plan• Enter a X when a category is completed

ShineInspection Sheet

Directions

Surfaces of equipment and furnitureMachinesConveyance equipmentPlumbing, pipes, sinksElectrical equipmentFixtures, junction boxesChairs

Other itemsMaterials and suppliesTrash cansBulletin boardsLabels and signsSmall toolsHoses, cords, tubing, etc.

Other

Large Surfaces

CeilingsAislesWork StationsCorners, behind/under equipmentStairsLoading docks

WallsDoorsPillars and postsFloorsOther

Carts

Shelves

Racks

Inside equipment / furniture

MachinesConveyance equipmentClosetsDrawersCabinetsSheds

Tool boxes

Storage bins

Initial Cleaning Plan

Target Area

List tasks and complete the columns below

Task Area Who When Materials & Tools

Standardize Guidelines

1. 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.

2. 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.

5S Assignment Chart

Target Area

List tasks and complete the columns below

Task Area Who When Materials & Tools

Sustain Guidelines

1. The basic purpose if event lead should work with management to develop a working schedule to cover the 5S.

2. Management should assemble the team and provide 5S training overview.

3. 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.

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.

Sustain Guidelines

5S Audit Form

5S Audit Form

5SAudit Form

Sort Straighten Shine Standardize Sustain

Level 5Habit

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 4Commitment

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 3Organization

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 2Awareness 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 1Initial 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 = Total = Total = Total = Total =

5S Rating Form5S Rating Form

5S Assessment Form

File:

Department: 5S Rating for week of: 5S Rating: ___ / ___ / ___ Opportunities for Improvement:

Event Closeout & Follow-up

1. The event lead should work with management to develop a working schedule to cover the 5S.

2. Management should assemble the team and provide 5S training overview.

3. 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.