I. What is 5S?
The process and method aim at creating a clean, neat and orderly workplace with good performance.
It's the necessary conditions of improvement and strict disciplines.
II. Why do we need 5S activities?
1. Make our employees more satisfied
2. Popularize the standard operation
3. Improve the quality of our products
4. Implement the visual management in all respects
5. Identify all kinds of waste sources
6. Improve the plant production safety
III. 5S activities
Step 1: Sort-out / selection – separation and discarding
“Remove any of those under suspicion”
Step 2: Sort-out / classification – arrangement and identification
“Each has his own task”
(1) Convenient for use
(2) Implementation of “arrangement and identification”
A. Determination of the location for placement based on frequency of use
B. Utilization of material number and establishment of address system for such number
C. All packing covers must be marked with material number
D. Lower and upper limitation must be noted if necessary
E. Develop a good habit of arrangement (in strict accordance with Step 1–4)
(3)Tips:
(4) Color code
Step 3: Sweeping – sweeping and daily inspection
“A clean workplace play an useful role in improvement of product quality, production safety and employees’ sense of pride”
(1)Implementation of “sweeping and daily inspection”
(2) Identification of sweeping activities and definition of daily maintenance
(3) Establishment of working standards and standardization of operation
(4) Implementation of daily 5S inspection
Step 4: Cleaning / keeping clean – frequent revisits
“No need of cleaning in the case of satisfactory cleanliness”
(1) Implementation of “frequent revisits”
(2) Weekly inspection for abnormalities
(3) Ascertain of causes of all abnormalities
(4) Take measures to avoid abnormalities
Step 5: Employees’ quality / self-discipline – initiative spirit
Set examples in management; “practice of promise”
(1) Leadership plays a key role
(2) Management personnel shall give their commitments
(3) The persons in charge shall ensure qualification of workplace conditions
(4) Standardization of operation and persistence in long-term supervision
(5) Quantization of inspection results about workplace
(6) Results publicity concerning obvious locations
(7) Advocacy of “initiative spirit”
(8) Utilization of 5S performance billboard
(9) Management personnel set examples
(10) Daily inspection by the supervisors
(11) Participation of all personnel
(12) Improvement of measures implemented by all staff
(13) Publicity of good results
Always remember: It is a good strategy that the managers set examples to make employees proud for better competition
Daily sort-out is only a small part of 5S
IV. 5S visual control methods
|
Control methods |
Purpose |
|
Utilization of red labels Labeling
Tool plate
Color code
Floor line
5S daily inspection sheet
5S performance billboard
Pennant, slogan and autograph |
Separation and discarding Arrangement and identification
Arrangement and identification
Arrangement and identification
Arrangement and identification
Sweeping and daily inspection
Frequent revisits with “initiative spirit”
Initiative spirit |
V. Achievement
1. All participation
2. Great necessity of participation of the executive management
3. Implementation of 5S into daily work
4. More advertising on: necessity of 5S, employee roles and implementation methods
5. Implementation by all departments and the entire plant
6. Making great efforts with long-term persistence
7. Improvement activities supported by 5S
VI. 5S improvement activities
1. Selection of implementation areas
2. Selection of team players / leader
3. Start of 5S process
VII. 5S process
1. Observation / Interview / Evaluation
2. Create separation area
3. Launch red label process
4. Conduct a common review on summary
5. Determine additional resource requirement
6. Clear entire area
7. Observe again
8. Evaluate the area with 5S score sheet
9. Analyze causes and propose measures
10. Repeat steps 6 - 8 to improve 5S scores
11. Post evaluation results with 5S performance board
12. Determine review period