What ? Where?

Team Leader Team Members P-D-C-A Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Dec-07
Actual
Who ?
S5 = Shitsuke
[Self - discipline
at workplace]
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]
S4 = Seiketsu
[Create a highly
standardised
workplace]
Gemba-2:
Gemba-1:
S0 = Enablers
[Motivate people
for 5-S
implementation]
Actual
S3
S0
When?
'5-S' Road map - Department
Plan S0
S0
S1 S2 S2
To do
Plan S0 S2
S0
S0
S1 S2 S3
Jan-08 Feb-08 Mar-08
1 ] Through continuous education,
training, display of results & PDCA
improvement cycles
Zero setup PQCDEFSHE
1 ] CLIA: Deploy Clean-Inspect-Lubricate-
Adjust 2 ] CPCP
Zero
accidents
PQCD
1 ] SOPs Developed & Displayed 2
] Establish SDCA
Zero
breakdown
PQCD
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/
More
space
EFSHE
1 ] PEEP: Place for everything &
everything in its place
Zero
waiting
PQCD
Remarks
Why ?
S4 S4 S5
MOP
When?
'5-S' Road map - Department
S4 S4 S5
Requisites Who Freq Status Remark
Official information HOD Once
5-S Billboards / Camera TL X
Participation of all TL N/A Gemba identified & teams formed
Effective training TL / TM Weekly X
PQCDEFSHE objectives TL / TM Qtr 5S awareness sessions
1-30-300 principle TL / TM Qtr 5S awareness sessions
Roadmap TL Once Prepared & displayed
5-S as a part of Kaizen roadmap
Progress review TL / Auditor Qtr
Publishing & widely communicating about the progress TM Monthly
Active involvement of the teams TL
Regular meetings TM Fortnight
Developing suggestion schemes TM Weekly
ACTION PLAN FOR "S0" Enablers
Motivating people for 5S implementation (J ul - Aug 07)
Requisites Area Who Status Remark
TM
TM
TM
TM
TM X
TM X
TM X
TM X
X
X
X
X
TM X
TM X
TM X
TM X
TM X
TM X
TM X
TM X
Listing Wants in an Area after
eliminating waste
Audit / Visual Inspection of wants /
wastes
Scrap Disposal
TL
ACTION PLAN FOR "S1" Seiri
Work Area
Sorting out what is required & dipose unwanted (Aug - Sep 07)
Classification in work areas
Gemba
Work Area
TM
Freq. Rare Never Good Worst Yes No Yes No Yes No
Process / Equipment / Item in area
Condition Repairable
Better
Substitute
avl
Usage
outside area
(S1) Waste Identification Checklist
Waste
Usage
(S1) Waste Identification Checklist
Remark
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 in compliance with PEEP &
Identifying missing / abnormal item or
structure
ACTION PLAN FOR "S2" Seiton
Organising wants in an area in terms of
usage / value / importance to process / life
cycle
Systematic Arrangement of wanted (Oct - Nov 07)
Identifying amenities / infrastructure / tools
required for correct organisation (P tags)
Gemba
Work Area
TM
Process / Equipment / Item in area Usage Value Qty (Nos)
Critical to
process
Total Pref. No
0
0
0
0
0
0
0
0
0
0
0
0
(S2) Systematic arrangement checklist
List down amenities / tools / structure for correct arrangement. When identified
can be purchased or can be picked up from scrap
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
Requisites Area Who Status Remark
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
All Items / Process / Equipments easly
identifiable / accesible / safe
ACTION PLAN FOR "S3" Seiso
External / Internal man power
arrangement for through cleaning
Systematic Arrangement of wanted (Nov - Dec 07)
Through cleaning done & scrap disposed
safely
Requisites Area Who Status Remark
TM X
TM X
TM X
TM X
TM X
TM X
TM X
TM X
ACTION PLAN FOR "S4" Seiketsu
Daily Inspection / Reporting
abnormalities
Systematic Arrangement of wanted (J an - Feb 08)
Action for deviation / 5S awareness
session or training
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
Gains in terms of value, life cycle,
availability to be published
ACTION PLAN FOR "S5" Shitsuke
Monthly / Qtrly. "5S" audit by Internal /
External accesor
Systematic Arrangement of wanted (Mar 08)
5S awareness session / training for
continual improvement / Visits
Action for deviation / findings /
document learnings
0 1 2 3 4
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
0 1 2 3 4
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
0 1 2 3 4
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
0 1 2 3 4
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
Sub Total 0 0 0 0 0
0
Check Item Description
Score
0
1S Check Item Description
2S
3S Check Item Description
Score
S
E
I
R
I
Score
S
E
I
T
O
N
S
E
I
S
O
0
4S Check Item Description
Score
0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very Good
S
E
I
K
T
S
U
0
0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very Good
0 1 2 3 4
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
S
H
I
T
S
U
K
E
0
0
5S Check Item Description
Score
SEIRI 0
SEITON 0
SEISO 0
SEIKTSU 0
SHITSUKE 0
0
0.5
1
SEIRI
SEITON
SEISO SEIKTSU
SHITSUKE
Audit Result