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5s Master Plan
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english for turkish people intermediate level
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english for turkish people intermediate level
'5-S' Road map - Department Who ?
To do What ? S0 = Enablers [Motivate people for 5-S implementation]
Where?
S1 = Seiri [Sort out what is needed and Gemba-1: what is not] S2 = Seiton [Do systematic arrangement for all S3 needed = Seisoitems] [Ensure spic & span cleanliness with inspection] S4 = Seiketsu [Create a highly standardised workplace] S5 = Shitsuke [Self - discipline at workplace]
Gemba-2:
When?
Team Leader Team Members P-D-C-A
Jul-07
Plan
S0
Actual
S0
Plan
S0
Actual S0
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
S1
S2
S2
S3
S1
S2
S2
S3
Department Jan-08 S4
S4
Feb-08 S4
S4
Mar-08 S5
S5
Remarks
Why ?
MOP
1 ] Demonstrate PQI by doing Kaizens 2 ] Remove 3 D's at Gemba
Zero defect
SHE
1 ] Develop criteria for need/want to release 50% place
Zero inventory/M ore space
EFSHE
1 ] PEEP: Place for everything & everything in its place
1 ] Through continuous education, training, display of results & PDCA improvement cycles
Zero setup PQCDEFSHE
ACTION PLAN FOR "S0" Enablers Motivating people for 5S implementation (Jul - Aug 07) Who Freq Status HOD Once √ TL X TL N/A √ TL / TM Weekly X TL / TM Qtr √ TL / TM Qtr √ TL Once √
Requisites Official information 5-S Billboards / Camera Participation of all Effective training PQCDEFSHE objectives 1-30-300 principle Roadmap 5-S as a part of Kaizen roadmap Progress review Publishing & widely communicating about the progress Active involvement of the teams Regular meetings Developing suggestion schemes
TL / Auditor TM TL TM TM
Qtr Monthly Fortnight Weekly
√
Remark
Gemba identified & teams formed 5S awareness sessions 5S awareness sessions Prepared & displayed
ACTION PLAN FOR "S1" Seiri Sorting out what is required & dipose unwanted (Aug - Sep 07) Requisites Area Who Status TM √ TM √ Work Area TM √ TM √ TM X TM X Classification in work areas TM X TM X X X Audit / Visual Inspection of wants / TL wastes X X TM X TM X Scrap Disposal TM X TM X TM X TM X Listing Wants in an Area after eliminating waste TM X TM X
Remark
(S1) Waste Identification Checklist Gemba Work Area TM Process / Equipment / Item in area
Usage
Condition
Freq. Rare Never Good Worst
Repairable Yes
No
Better Usage Substitute outside area avl Yes
No
Yes
No
Waste
Remark
ACTION PLAN FOR "S2" Seiton Systematic Arrangement of wanted (Oct - Nov 07) Requisites Area Who Status TM X Organising wants in an area in terms of TM X usage / value / importance to process / life TM X cycle TM X TM X TM X Identifying amenities / infrastructure / tools required for correct organisation (P tags) TM X TM X TM X Organising in compliance with PEEP & TM X Identifying missing / abnormal item or TM X structure TM X
Remark
(S2) Systematic arrangement checklist Gemba Work Area TM Process / Equipment / Item in area
Usage
Value
Qty (Nos)
Critical to process
Total 0 0 0 0 0 0 0 0 0 0 0 0
Pref. No
Scores can be 1/ 3/ 5 for low / Med / High categories repectively & Pref. no will be in descending order of total score Item with pref. no "1" should always be the easiest accesible and further on 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
Requisites External / Internal man power arrangement for through cleaning
Through cleaning done & scrap disposed safely
All Items / Process / Equipments easly identifiable / accesible / safe
ACTION PLAN FOR "S3" Seiso Systematic Arrangement of wanted (Nov - Dec 07) 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
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
ACTION PLAN FOR "S5" Shitsuke Systematic Arrangement of wanted (Mar 08) Area Who Status 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
Remark
0 = Very Bad
SEIRI
1S
SEITON
2S
SEISO
3S
SEIKTSU
4S
Check Item Materials / parts Machines / Equipment Papers / Plastic Mtrl Visual Control
Check Item Floor / Work station M/c & Equipments Cleaning Stewards
Check Item Improvement Idea Standard procedure Future scope First 3S
1 = Bad
2 = Avg
3 = Good
4 = Very Good
Description
0
Does the inventory or in-process inventory include unneeded mtrl / parts Are there any unused machines or other equipment Is there any paper / plastic scrap around Is the waste identified Sub Total
Description
Is any action plan in place for its deployment Is the 5S implementation plan documented / published / communicated Any continual improvement idea / process / recognition Is Seiri / Seiton / Seiso maintained
3
4
0
0
0
0 Score 2
1
0
3
0
4
0 0
0
Are floors / work station shiny to spot any waste Are they Dust free, running healthy with allowed noise / vibration Is there a dedicated staff / do they do it voluntarily Sub Total
Description
1
0
Are shelves and other storage areas marked with addresses Do the shelves have signboards showing which items go where Are Max / Min Inventory levels indicated Storage areas / Process Area / Units marked Sub Total
Description
Score 2
0
0
Score 2
1
0
0
1
0
0
3
0 Score 2
0
4
0
3
0
0
4
0
0 Sub Total
SHITSUKE
5S
Check Item Equipments / Process Stock levels Training Support 5-S Billboards
0
Description Are they easily gettable / managable Is the inventory control adhered to Is Training / 5S awareness in progress Is top management active support available Are they updated Sub Total Grand Total
