5S PRACTICE MANUAL

(LEAN MANAGEMENT WITH 5S TECHNIQUE)

PT. CITRA TUBINDO TBK.






5S PRACTICE MANUAL

(LEAN MANAGEMENT WITH 5S TECHNIQUE)

















PT. Citra Tubindo, Tbk., Hang Kesturi Street KM 4 Kabil, (62) 778 711 888


5S PRACTICE MANUAL

(LEAN MANAGEMENT WITH 5S TECHNIQUE)



By:

5S Team of PT. Citra Tubindo Tbk.




Layout (Setting):
Susanti, SS
(a.k.a Susan)




Advisor :
Andi Tanuwidjaja



First Edition, 22 June 2014

Printed for own circle












PT. Citra Tubindo, Tbk, Hang Kesturi Street KM 4 Kabil, (62) 778 711 888


5S PRACTICE MANUAL

(LEAN MANAGEMENT WITH 5S TECHNIQUE)




Department _____________________________


Bookplate _____________________________


Title _____________________________


Employee No. _____________________________
























PT. Citra Tubindo, Tbk, Hang Kesturi Street KM 4 Kabil, (62) 778 711 888

The Author Dedication


The authors dedicate this book to the PT. Tubindo Citra Tbk, with particular
thanks to the 5S God Father ( Mr. Eric Atton ) which ever mentions the word "
5S " the first time to the author when newly joined the company two and a half
years ago.

To Mr. Andi Tanuwidjaja are entrusted to the author to continue the journey in
the company's 5S program. The entire 5S Area Leader, Sub Area Leader,
Zone , Auditor and all employees who participate, support and strive to
succeed in this program.

Finally, the partner of author Mark P. Hubbard as tutors and personal trainers
author who has been sharing experiences and valuable knowledge to the
author when developing its work during the process of implementing a 5S
program is underway at the company.





















TABLE OF CONTENTS


TABLE OF CONTENTS
PREFACE
THE STRUCTURE OF WHEEL COMMITTEE
COMPANY HISTORY
MANAGEMENT COMMITMENT PT. TUBINDO CITRA Tbk.

CHAPTER I. INTRODUCTION
A. History of 5S Concept
B. The Definition of 5S
C. Why need 5S
D. The Purpose of 5S application
E. The Advantage of 5S application
F. The Objective of 5S application
G. The Benefit of 5S application

CHAPTER II. APPLICATION AND KEY SUCCESS OF
5S APPLICATION
How is the application of 5S
Key Success of 5S application
The Impact of the 5S application

CHAPTER III. AUDIT OF 5S





CHAPTER IV. BOOSTER FACTOR AND IMPLEMENTATION OF 5S
OR 5R
A. The Booster Factor
A.1 The Management Commitment
A.2 Organization
A.3 Training and Promotion
B. Implementation of 5S/5R
B.1 S1 (Seiri)
B.2 S2 (Seiton)
B.3 S3 (Seiso)
B.4 S4 (Seiketsu)
B.5 S5 (Shitsuke)

CHAPTER V. 6S (5S + 1S SAFETY)

CHAPTER VI. CLOSING















PREFACE

This book is the result of passion and hard work of the team 5S, ie. all
employees at PT. Tubindo Citra Tbk. in the application of the 5S concept in
the workplace. This book also as the proven commitment of all employees of
PT. Citra Tubindo Tbk., to make the Company as the World Class
Manufacturing that achieving the standardization level of clean, healthy and
save of working area.

Cleanliness arise from a pure soul, able to produce thoughts, behavior,
atmosper environment which will delivered to a life that is clean, clear,
beautiful and peaceful in every way. The life as it is desired by the faithful .



-------------------------- @ @ --------------------------
Name : Susanti (a.k.a. Susan)
Title : 5S Coordinator (Authors)
-------------------------- @ @ --------------------------


5S program has been implemented in Citra Tubindo since 2011, but the
dissemination and promotion of the 5S program not complete communicated
to all employees in the company. Lack of awareness of the 5S program that is
the foundation of discipline and moral patterns of employees to work in the
work environment, resulted in the adoption and implementation of 5S
becomes less good and less effective, thus there arose a wide range of waste
going on in the company.

In 2013, 5S program returned intensively done by way of training, both theory
and practice as well as promotion to all employees from superiors to
subordinates without exception, the implementation of the patrol, weekly
meetings, regular evaluation of the implementation of 5S to involve the
employees themselves, learn discipline, communicate well and lead members
in each department of the 5S projects, provision of support facilities, as well
as 5S competition, was able to make all employees of PT. Tubindo Citra Tbk.
aware of the importance of the working environment which is clean, beautiful,
healthy and safe, in order to smooth productivity, happiness and comfort
together while working at the company.

With proud of this year PT.Tubindo Citra Tbk. has become a pilot (
Benchmark ) by the company Vallourec shareholders of some countries, such
as Singapore, France, Saudi Arabia, UK, etc. As well as the company's main
Petromas Hymindo for the implementation and execution of one of the
concepts of lean management with basic techniques 5S.

Although the implementation of 5S in PT. Tubindo Citra Tbk was not perfect,
but the author believes that continuous improvement is constantly being
made and upgraded as possible during this sturdy stand firm in Indonesia
beloved motherland.



-------------------------- @ @ --------------------------
Name : Andi Tanuwidjaja
Title : Operation Director (Advisor)
-------------------------- @ @ --------------------------

In order to participate in global competition and competes against numerous
competitors locally and globally, PT Citra Tubindo Tbk is continuously looking
to find ways to reduce cost, improve quality and delivery time. For this reason,
PT Citra Tubindo Tbk is implementing lean manufacturing, which allows
improvements in processes while increasing the quality of the products.

5S is one of the most fundamental of lean manufacturing. Its application is
simple, however, the advantages are endless.


One of the great aspects of implementing 5S is that everyone can participate
and its use is not limited to production area but office can also achieve
productivity gains from implementation of 5S.

The following is a list of most obvious benefits which can be derived from
implementation of 5S at PT. Citra Tubindo Tbk :
Reduce lead time thereby improving delivery times
Reduce equipment downtime, maintenance and cycle time
Reduce changeover time
Reduce cost by reducing space requirement and number of scrap
Improve working condition and increase employees moral
Improve quality by reducing the amount of defects
Improve safety thereby reducing the cost of workers injuries
Improve visual communication

After years of implementation at PTCT, 5S has raised the bar to a new
standard. Continuous effort from everyone at all level, top management
commitment, and follow up procedure to maintain are the key components for
maintaining the level of excellence.














COMPANY HISTORY

PT. Tubindo Citra Tbk was established on August 23, 1983 in the context of
Domestic Investment ( DCI ) and the legal domicile in Batam, Indonesia.
Company's Head Office and factory located in Jl. Hang Musk I, Kav.C1, Kabil
Industrial Estate, Batam, Indonesia.

PT. Tubindo Citra Tbk is engaged in trade and industry, providing services in
the field of oil and gas industry and mining. To achieve its goals and
objectives the company carries out business activities such as create, provide
service, repair tools and equipment to support the oil and gas industry. The
company's vision as a company that produces World Class Oil Country
Tubular Goods ( OCTG ), maximizing profits Shareholders and improve
people's lives. The mission of the company to be able to grow and compete
on an ongoing basis achieving superior operational performance, able to
meet customer needs in terms of price, quality and timeliness of delivery,
innovate and invest in research and development ( R&D ), maximizing
shareholder profits, exporting world-class products.

- Preserving the Environment Being a leader in environmental issues and
prevent any kind of pollution, conserve water and neutralize waste
- Using technology that is clean and safe
- Reducing carbon emissions and waste disposal
- Using energy-efficient

The company operated its activities in accordance with the goals and
objectives set forth in the Articles of Association of the Company, namely as
the suppliers of " Oil Country Tubular Goods " ( OCTG ), pipes and drill pipes
for oil and gas companies, which include seamless pipe with "
AmericanPetroleum Institute " API and Premium Connection, seamless pipe
and seamless pipe drilling.

Fields and Business Company activities :
Pipe threading and services
- Perform fabrication of various types of classes as well as connections
and pipes and accessories under the license given by the famous maker
of seamless pipes in the world including, Vallourec, NSSMC and
Tenaris.
- Performing the production of the threading protector and packing
systems for threadguard that reduce dependence on suppliers.
- Whorls manufacture of steel pipe, either with seam or without seam,
according to the standard API, in a variety of sizes from 2-3/8 " to 20 ".
- Making pipe connections ( coupling ) according to the standard API.
- Straightness testing pipes and pipe fittings and pipe whorls resistance
by using the power of certain water pressure. Manufacture of pipe
accessories, among others : " Pup Joint ", " Cross Over " and " Blast
Joint ".
- Coating and plating threading pipe with phosphate, tin, copper and zinc
materials.
- Providing the inspection services, repair and cleaning of the pipe and its
threading.
- Producing various types of pipe threads and its accessories under
license from various steel pipe mill " seamless " in the world, including
leading technical assistance from : Vallourec and Nippon Steel and
Sumitomo Metal Corporation to manufacture and repair the pipe
threading and accessories type VAM and BIG OMEGA.
- Thermal Spray Aluminum (TSA) to control the corrosion in the special
pipes.

Heat Treatment Facilities
Commercial operations since 1992 and has received a certificate of
recognition quality of the API in March 1992. Factory installed production
capacity reaches 120,000 metric tons per year for the pipes diameter
between 2-3/8 " to 13-3/8" according to the standard American Petroleum
Institute ( API ) and Premium Grade.

The Company Testing Facilities has a reliable testing facility and calibrated
to ensure the quality of products produced, that is :

a. Destructive Testing
Pull test : to find out the strength of ductile and pull a product with its
flexibility.
Spectrometer test : to measure the metals content to suit the needs of
consumers.
Hardness test : to ensure that the hardness of the product remains in
force tolerance given in the final product.
Flexibility test : to test the flexibility of the pipe at room temperature or
in freezing temperatures.
Metallurgical test : to be able to describe the structure of the metal in
the micro and macro, so that the final product is acceptable according
the specifications of consumers.
External pressure test : to ensure that the pipe can receive a
maximum pressure from the outside in accordance with the
conditions established international standards.

b. Non Destructive Testing
Special End Area Magnetic Particle Inspection : the method of testing
conducted for the presence of defects at the ends of the pipe.
Magnetic Particle Inspection : used to ensure the absence of defects
in the coupling.
Ultra Sonic Testing.
Electro Magnetic Testing.
Hydrostatic Testing.
Dimens Testing.

c. Production Process
The process of making the raw pipe to become finished goods through
the following steps :
Measurements and chemical analysis on the raw pipeline to ensure
the pipes are listed according to the size of its factory-certified steel.
Once it is stored in the field.
The upsetting process for the tubing pipe which has small diameter
that need the broadening at the end of the pipe so it will increase the
thickness. While for casing pipe which has the size 5 inch or more,
the outside diameter of the pipe will be adjusted in the process of
sizing mill with controlled temperature of the pipe. Then the pipe
based on the certain size, tubing and casing, through three roll
hydraulic straightener with the controlled temperature.
De-rusting process is to clean the rust in the surface of the end of
the pipe which has box tip that will be heated or threaded.
The thermal maintenance process is to change the metal chemical
composition to become austenite, the formation of hard and strong
metal, through the process of hardening or austenizing. The level of
hardness of the pipe can be arranged upon request by heating the
pipe at temperature between 500
0
C up to 700
0
C through the
tempering process to form a pipe in accordance with the mechanical
character.
Cooling Process by spraying large amounts of water quickly to
change the microstructure of the steel. Pipe is allowed to cool with a
controlled pattern to maintain straightness and other characteristics
needed for further processing.
Processes lab to analyze the level of strength, microstructure and
hardness levels pipe, according to the standard API and requests of
customers by :
-- Wet magnetic particle method to check the upper end of the pipe
damage;
-- Electro-magnetic inspection, optional;
-- Ultrasonic examination conducted by third parties, companies that
use machine Truescope " ultrasonic inspection ", can give results
above 100 % detection of imperfections pipe lengthwise and
sideways as well as 100 % of the thickness of the pipe. All pipes
must be processed through this section and only that can perfectly
into the next process.
Phosphate process is to give the layer (covering) in the pin pipe-tip,
after the process of threading, both with the connection of API or
premium.
The Coupling was made from seamless pipe where in the part of its
pipe wall thicker than the part of body of pipe wall that will be
connected. Coupling pipe will be heated to become similar type with
the part of the pipe, then will be cut according to the size, threaded
and given given a phosphate coating or lining " electroplated ".
Installation of coupling on each pipe with prescribed procedure
depends on the type of connection whorls both premium and API.



Weight and length measurements were recorded after the pipe is
ready for delivery , with a mark on each pipe through the recording of
" pipe tracking system " in which the verification is done by the search
parameters in accordance with a predetermined. Each pipe was given
a layer of security.
Internal and external inspection to verify that the order is correct and
ready for shipment.

































COMMITMENT

MANAGEMENT OF PT. CITRA TUBINDO Tbk.


PT. Tubindo Citra Tbk. realize the importance of creating workplace
conditions that are safe, comfortable, orderly, clean, and well maintained
consistent in its efforts to create products of high quality, increase efficiency
and savings in the process, reduce the risk of accidents, the risk of pollution
and waste, as well as raise the profile of company in the eyes of the
customer.

For that the company is determined :
1. Applying and implementing the 5S system in every area of work for all
employees of the company sphere;
2. Includes an active role of top management and all employees in order
to achieve successful implementation of 5S system in the company;
3. Including aspects of 5S in any activity that is continuously improved by
continual improvement team and internal auditing.

The successful implementation of 5S is highly dependent on the active
participation of all parties. For that all employees are expected to increase
self-discipline and sense of responsibility to the 5S system in each work area.













CHAPTER I

INTRODUCTION



Probably 5S was no longer strange anymore for the people who has been
working in the industry or for the people who has the education background of
industrial engineering. 5S is as the one of the important fundamental in lean
process
*
. By 5S, the Company gain many benefits. Without 5S, so the
advantage from the lean will less optimal. However, it does not mean you
could not implement lean as integral part from the Lean Process, and thereby
you can increase the performance of the Company.

The 5S program as one of the effective means of enhancing the positive
habitual of the worker, because this program is effectively proven, in
reducing the production cost, shorter lead-time, high quality of output, and
reducing the accident that emerged with the existence of the better working
condition. Generally the people states that 5S of the Housekeeping (clean-up
activity) is only to be done by the servant, housewife or hygiene officer.

The general view above is not true, particularly in the Company, however, 5S
as the tool of problem solving in work place (Tool of Problem Solving). Before
start it, you may face with the various problems that confused enough. So you
can answer these questions:
Do you have ever looking for the document for several hours?
Looks for goods and never find it, then you have to buy again?
Feels does not have enough place to keep the document or goods?
Do you have wasting time to walk up and down?
You do not know whose was borrowing your document or goods?

*
Lean Process is about how to eliminate many kind of WASTE (the activity which not
given added value) along with business flow process.
The important document mixed with other documents or material in process
mixed with the finished goods?
The responsibility toward the cleanness and tidiness in the office and plant
(workshop) is unclear?
Are you often to consider (wasting your time) because you are unwilling to
waste it so you take the conclusion to let it or move it to other area? If this is
the fact, so it is to move the new problem to other place, is not it? These
extravagance will be revealed and to be resolved by the application and
training of 5S.

Through this manual book, PT. Citra Tubindo wants to ensure that 5S will
directly influencing toward the productivity. So it is correct, if you have
convinces that this manual book as the practical manual to be used as base
application of 5S system, even in the work place, home, social environment,
and any projects being done.

5S MUST BE AS A PART OF THE JOB


Enjoy your reading
HISTORY OF 5S CONCEPT
More than sixty (60) years ago, the program of 5S to be introduced for the
first time in Japan. After Second World-War, Japan, as the founder of Toyota,
Sakichi Toyoda, the son of Kiichiro Toyoda, and as their Chief Engineer,
Taiichi Ohno, has developed Toyota Production System (1948 and 1975).
Toyota Production System (TPS) is the philosophy that remain to regulate, to
maintain the tidiness of manufacturing facility and free of chaos that
generates the productivity and logistic in Toyota, including the interaction with
the supplier and the customer. Then in the 1995s to be introduced 5S system
by Hiroyuki Hirano as the movement of undoubtfulness to perform sorting
(seiri), ordering (seiton), cleaning (seiso), maintenance of steady condition
(seiketsu), and awareness of the habitual to be needed to perform the better
job (shitsuke). At this time, the factory and offices in the world has applied the
philosophy and TPS practices (Toyota Production System) including one of
them is our Company, PT. Citra Tubindo Tbk, Batam.

DEFINITION OF 5S
What is 5S? This is not just as slogan or words, 5S is the concept of
management in order to manage the work place. In short, 5S is the
methodology and culture to create the safety and comfortable in the work
place. 5S could be applied in the office, building, workshop area, home, or
any social environment.

With this system we can to coordinate how the work place to become more in
order, clean, safe and comfortable, so the activity of our job will not interfere
so finally the purposes (objectives) want to be reached can be met.

5S as abbreviated from Kanji language of Japan Seiri, Seiton, Seiso,
Seiketsu, and Shitsuke. In Indonesia is as the term of 5R, while in English
as 5S.
TABLE OF ABREVIATION OF 5S
JAPAN ENGLISH INDONESIA
Seiri Sort Ringkas
Seiton Set in Order Rapi
Seiso Shine Resik
Seiketsu Standardize Rawat
Shitsuke Sustain Rajin




WHY NEED 5S?
5S as the one basic to realize the World Class Organization (Company) (A
Standard of World Class Manufacturing) prepared to follow every changes
and competition of global era as follows:
Maintain the competition with eliminate (reduce) waste as the care
form toward environment.
Respond toward the customer needs that always changes.
Reduce the long-term cost, reduce wasting the time and reduce
working accident.

The initial step to other improvement program
Enhance the company image in the eye of the stakeholder,
shareholder and the related parties with the Company.
Enhance the work productivity of the employee, when everything set in
order and clean working environment so it can make the employee can
work comfortable and faster.

THE PURPOSE OF 5S APPLICATION
5S is important and needed to increase the work culture of the employee
through the changes started from the work place.
Working culture
Working attitude
Working habitual
Working behavior
Working place

THE BENEFITS OF 5S APPLICATION
1. Zero Breakdown
It means better maintenance. Example:
a. Scrap, dust, infuriated and pieces in the floor and machine becomes
decreasing;
b. With cleaning the machine accurately and regularly you know the
machine condition anytime;
c. Daily inspection and maintenance could prevent the damage of the
machine to become worst in the future day.

2. Zero Defect
It means better quality. Example:
a. If everything is in place, you can avoid taking the wrong goods.
b. Clean work place will give the high working spirit to anyone.
c. Measurement tool and indicator can work well so the quality will be
better also.

3. Zero Waste
It means reducing cost and enhances the efficiency. Example:
a. Inventory and less of goods is being processing.
b. Spaces are being used for unnecessary goods becomes decreasing.
c. The unnecessary movement such as avoiding and searching becomes
decreasing.
d. Reducing unnecessary production movement such as lifting, putting,
accounting and removing.

4. Zero Set Up Time
It means there is no wasting of time. Example:
a. Because everything is set in order so the wasting time to search the
tool can be depressed.
b. Clean work place is able to enhance the efficiency and the person
understand its operational easily, even a training participant can
operate it easily too.

5. Zero Late Delivery
It means capable to meet the timely customer demand. Example:
a. There is no damage production so you are capable to meet the timely
customer demand.
b. Good working environment can run the production process faster, no
wasting and increasing efficiency.



6. Zero Injury (Accident)
It means better working safety. Example:
a. Clean and shiny equipment is easier to observe the damage and
hazard;
b. If you know where the equipment are being kept, you can take it if
necessary faster.
c. If you put something safely so you can avoid that equipment fallout
befalls you.
d. If there is the fire and earthquake, you know where the emergency
door is and fire fighting extinguisher.

7. Zero Customer Claim
It means the customer put their high level of trust:
a. The factory which is well-arranged and clean do not produce the
damage goods.
b. The factory which is well-arranged and clean is capable to produce the
goods which secure the safety of the user.

8. Zero Deficit
It means the Company always in advanced. Example:
a. If the 5S (5R) has performed better, so the work place becomes
comfortable and interesting, there is no waste, no accident, no damage
of the machine and there is no damage of products. You can meet the
desire and expectation of the customer.

OBJECTIVE OF 5S APPLICATION
1. Clean workplace created, set in order, safe, comfortable and pleasant.
2. Tool and equipment is maintained as well as the building during the
working process.
3. Realization of discipline that is needed to gain work standardization.
4. Safety and working stability maintained as well as the production quality
during the operation taken place.
5. Improvement of job quality created with reducing variance of output.
6. Improvement of efficiency is well held in each of the department.


7. Its constructive of working climate which comfortable and pleasant,
discipline and appreciation to each other among the employees.











BENEFIT OF 5S APPLICATION

Basically, better implementation of 5S in the Company will give the good
benefits to the employees, company, supplier, or stockholder (funder).

The benefit of 5S is maintained working environment so it capable to prevent
the working accident, also to change the characteristic of the worker getting
more discipline who having the sense of high awareness to motivate every
person get involve to keep working area in the condition of set in order, save
and productive, then finally will enhance the welfare of the employees,
company and satisfaction of the customer.

For THE WORKER will feel:
Safety
Comfortable
Health
Not get bore (high working spirit)
Positive working attitude (constructive)

For THE COMPANY will increase:
Image (solvent)
Business speed
Profit gained
Its ability

For THE CUSTOMER will get satisfaction because:
Minimize mistake (wrongness)
Speed and proper of services

For THE SUPPLIER will gain the satisfaction because:
Speed and proper of services
Minimize of mistakes

For THE FUNDER (STOCKHOLDER) will gain the satisfaction because:
Confidence or trust upon its effort
The sample of business























CHAPTER II
APLICATION, KEY SUCCESS
AND
IMPACT OF 5S (5R) APLICATION

A. HOW IS THE APLICATION OF 5S

Direct support from the top management party toward the implementation of
5S program will very affecting to motivate the entire of employees in the
implementation of 5S program. It is clear, that the commitment of the
Company is being needed to perform this program. Without any supporting
from the top management party, the application of 5S program is very difficult
to get success.

5S could be well implemented, if all of the employees from the top
management, middle, or lower get involved in the process of implementation
of 5S.

In order to the 5S application that will reach the objective being targeted, it is
important to know the activity or task related to 5S so it is able to understand
the direction of implementation of 5S for themselves and the Company.




1. SEIRI (SORT)
The application steps are as follows:
a. Specify the implementation schedule of SEIRI
b. Implementing SEIRI in each area of their responsibility with sorting of
items in its area is divided into 3 (three) as follows:
Necessary : fixed in working area, but the amount is according
to the requirements.
Unnecessary : unnecessary and not valuable item necessary to
throw away, and the unnecessary item but still
valuable placed on TPS (Tempat Penampungan
Sementara) or Temporary Relocation Place (use
Red Tag); prevailing the deadline.
Doubtful item : placed on TPS (use Red Tag); prevailing the
deadline.
c. Items in TPS is being brought to the internal meeting department to
decided its status, if the Head Department or Manager could not decide,
then to be forwarded to the Steering Meeting Management to be decided.


d. Standardization of SEIRI in the workplace area.
e. The evaluation of SEIRI application and its visualization.

2. SEITON (SET IN ORDER)
The application steps are as follows:
a. Specify the implementation schedule of SEITON
b. Classifying the place of keeping and items (functional, uniform, the
frequency of usage)

c. Preparing the place of keeping and give the label (badge) and regulating
the layout of the workplace
d. Standardization of rules and discipline of tidiness
e. The evaluation of set in order (tidiness) and its visualization

Checklist: Has the process of selecting (sorting) been done and to determine
goods unnecessary in the workplace environment, wasting or thrown away,
therefore in workplace floor is not seen again unnecessary goods scattered
around, such as cigarette butts, waste paper, personal stuff, waste PPE,
secondhand cloth, unnecessary tools and waste material.



3. SEISO (SHINE)
The application steps are as follows:
a. Specify the implementation schedule of SEISO
b. Preparing cleanness means and perform initial cleaning
c. Carry out of SEISO in the area (tools or machine), elimination source of
dirtiness cause and system control visual
d. Making routine cleanness schedule in the work area by determine the
personnel who take responsibility toward each of working area
e. Evaluation of clean up application

Doing clean up or cleaning in the equipment or machine sometimes having
the special technique not just the only spraying with the jet pump, but also
ask for the direction from the Superior or the person who more understanding
so there is no severe mistakes toward the machine.

4. SEIKETSU (MAINTENANCE) (STANDARDIZE)
The application steps are as follows:
a. Perform discipline order and standardization of SEIRI, SEITON, SEISO
b. Maintain the optimum condition and application of visual control
mechanism, anti-idiocy
c. Determine efficiency targets (productivity)
d. Evaluation of SEIKETSU application and its visualization


5. SHITSUKE (FREQUENTLY) (SUSTAIN)
The application steps are as follows:
a. Applying timely information
b. Applying positive habitual (timely, promise precise)
c. Realizing learning opportunity (determine topic, group, and learning
schedule or discussion)
d. Determine the target (group up to personal)
e. Evaluation of SHITSUKE application and its visualization


B. KEY SUCCESS OF 5S APPLICATION
1. Involvement of every person.
2. 5S program demands the responsibility and commitment of top
management.
3. The management must be as the leader of program executor.
4. 5S program must be supported by all of the parties.
5. 5S program must be independent.
6. The management has to perform personal tour to the offices, plant
(workshop/yard) periodically.
7. In the first stage, it must be exhibit the relevant impact.
8. Implementation of 5S program must be in line with the safety program
and other kaizen.




C. Impact of 5S (5R) Application
The review to the impact of 5S (5R) application both qualitatively or
quantitatively in what unit or field will indicate the increasing of :
Productivity : level of productivity
Quality : product quality or service produced
Cost : amount of the cost to be paid
Time delivery : meet the customer needs timely
Safety : safety and working health
Moral : working spirit of the personnel
Work environment : working environment








CHAPTER III
5S AUDIT

The implementation of 5S audit is performed by the team has been
commissioned to assess the implementation of 5S. In addition, this team also
performs the documentation (taking the photograph) at the place requiring of
attention.

5S audit is performed at least once a month with the controlling time every
week then to the area/department/group which much successful in
implementing 5S program in the period of 3 months, 6 months, respectively,
will be given the reward (if any), while the lowest in its assessment will be
given the warning. Below is the kind of 5S audit performed by PT. Citra
Tubindo Tbk :

1. Internal Audit
Audit is being performed by the Auditor or Auditor Team (> 1 person) from
its own department once in a month is on January, February, April, May,
July, August, October, and November.

2. External Audit
Being performed by the Auditor from Steering Committee Team or from
another Company in the area specified once in 3 months is on March,
June, September, and December.

To know the successful of 5S implementation it requires to arrange the
evaluation or 5S audit as the investigation toward weather the implementation
of that program was good or not and how its effect toward the employees.

The announcement of 5S audit outcome will be announced to all of the
departments and managements, so it will encourage the implementation of
5S will be more increased continually.

AUDIT ACTIVITY
























Preparation of Audit
Review
Preparation for Field Audit
Implementation of
Field Audit
Preparation and
distribution audit report



Completion of Audit



Audit Follow-up
CHAPTER IV
THE ACTIVATED FACTOR
AND
STANDARD OF 5S (5R) IMPLEMENTATION

A. Driven Factor
A.1. The Commitment of Top Management
a. Company Policy
The top management has specified the policy (stipulation,
determination) of the Company related to the 5S application in the
Company.
b. Top Management Agenda
The top management will attend to the 5S special program (kick
off or tool box meeting, morning briefing, giving the reward,
direction, and so on).
c. Company Program
The effort of 5S application and enhancement has been
contained in the company program such as DQO (Department
Quality Objective).
d. 5S Management of Organization
The member involvement of top management corps in the 5S
management organization.
e. Field Visited
The top management will carry out the field visited to know the
development (progress) of 5S application.

The top management has shown the commitment toward the 5S
application and development (to be understood, communicated, carrying
out management review and ensure the resources availability).

A.2. 5S Organization
a. The formation of 5S organization
5S organization has been formed in the Company.
b. The meeting of 5S organization
Routine 5S organization meeting to discuss the 5S application
program has performed.
c. 5S Area/zone distribution
The entire area in the company has been divided into 5S detailed
area (zone).
d. Responsibility party and program
In every 5S area (zone) has specified the working group
responsibility party and has have each work plan.
e. 5S administration
The administration of 5S application has been well documented.
A.3. Training and Promotion
a. Explanation (training)
All of the company personnel from its superior to subordinate got
the explanation (training) and has been well understood about 5S.
b. Spreading of Visual Reinforcement
There has been visual reinforcement about 5S in the 5S area
(zone) in the company to socialize 5S (to be written, banner,
poster, logo, slogan, merchandise, and so on).
c. 5S information board
In every 5S area (zone) has the 5S information board with the
relevant and actual of information material.
d. Target and objective
Target and objection of 5S application program has socialized and
to be understood by the whole of the company employees.


e. Outcome information and impact of 5S application
The outcome (impact or advantage) of 5S application for the
company or personnel has to be informed and socialized to the
whole of the company personnel.

B. Implementation of 5S (5R)
B.1. SEIRI SORT
SEIRI is the activity to separate all something goods that really
necessary and then throwaway unnecessary goods from the work
place.

In the work place there are so many things can often causing of
operational disruption emerges in working, such as about the
complaint of every person that complaint his or her narrowed
workspace because of too many stuffs.

Keeping the useless stuffs or the stuffs is being used but
excessive that causing the disadvantages as following:
In the narrowed workspace will increasingly emerge the
impression that the room (space) more narrowed and
uncomfortable.
Usage of working area becomes less productive.
Rack and filling cabinet, its usage becomes ineffective.
Becomes more difficult to distinguish which the needed stuffs
in the work place and not.
Keeping the excessive stuff is like having a lot of money but
did not being kept in the bank (loss of bank interest).
Letting the goods condition becomes rusty, damage or
ancient is like wasting the money.
Having the excessive stuffs in the production process could
impact in many factors such as lowering the quality, damage
of the machine, late of raw material and disadvantages in the
time when machine setting up.
Allocation more time in the inventory inspection will increase
the expenses and causing chained-reaction upon the loss in
the future day.

How to know that actually we are keeping the unnecessary
goods or we are keeping the goods excessively?
Try to investigate around of you in the following places and you will
find the stuff is exceeding the requirements.

Investigate racks
Check the unused and useless stuffs
Check another stuff other than specified stuffs
The upper and lower rack as the main place to keep this
stuffs

Investigate locker (wall-cupboard) of toolkit, drawer, and
cabinet
Check all of tools such as hammer, cutter, gauge, and others
Check gauge such as compass, slide-gauge (vernier) and
dial gauge (indication gauge)
Check the personal stuff usually kept in here, such as
magazine, meal equipment, and others

Investigate the floor
The end-section or corner of the floor as the place requires
attention.
Check heavy equipment is not being used and unnecessary,
trolley.
Generally, among the production goods there is raw material
heap or waste material is tending to experience of lowering
the quality.
Check among the production goods that quality unknown
usually being heaped in the hidden place. Such as being kept
under conveyor, under the window, under the workbench,
and around the path line.
Check the oil bin, is the kind of wasting is being prohibited to
be used in the factory.

Investigate spares storage and raw material
Check spare-part and raw material which during through
years never been removed and dusty, requires the attention.

Investigate outside working area
Check the raw material which is not removed as long as for 5
years and have been rusted.
Check trolley palette and container that are not being used
but still being kept.
Check the rest of raw material heaped.
Check the machine and equipment are not being used but
still being kept.

Investigate office (including the office lies inside the working
area)
Check rack, wall-cupboard as the place of document and
wall-cupboard as the place of unused documents.
Check sample product, demonstration product, catalog and
others.
Use RED TAG technique to assist this stage.


Steps are as follows:
Prepare RED TAG that already available.
Perform Genba (to the work place). Hang RED TAG to the
object unnecessary in that area. Throw away immediately if
the object is known as the invaluable waste. Follow the
procedure of valuable product wasting by communicating it to
the Superior and use write off.
Remove the object given RED TAG to the TPS (Temporary
Keeping Place) to be evaluated of follow up toward that
object. The depository deadline is 2 weeks, if needed further
review no longer than 30 days to 3 months (if required).
Recording to the RED TAG log book and take a picture if
necessary, this log file as the reference in the future day.
If the object is being RED TAG has to be decided, loose RED
TAG bearer, then returned to its place.




B.2. SEITON SET IN ORDER TIDY
SEITON is the activity to organize the layout of equipment, supply,
material or activity goods so it is easier to search, find, and return it, also it
emphasizes of safety, quality, and effectiveness.

Why should we wasting time to SEARCHING?
The many scattered and unused goods around of us, causing we
must to search the object is being needed.

There is no adequate place to keep
There is no indication label
Wrong keeping

The procedure to minimize this SEARCH action can be divided into
7 (seven) steps as the following:
Throw away everything useless. Follow the important facts
explained previously in the SEIRI topic.
Clean the depository racks. Using the space for racks and place of
keeping the file is specified in the SEIRI must be sub-grouped
again. Besides, additional rack is being made as minimum as
possible with considering the presence of requirements and proper
arrangement.



Specify the repository
Arranges the meeting to specify the manner to keep easily and simply
considering the matter as follows:
Goods is often being used must be kept close to the user.
Goods is often being used must be kept in the place as high as in
the part between elbow and shoulder.
Goods is seldom being used must be kept in other place by
distinguish it according to the usage (collect all of the goods seldom
being used in the same place). Store that goods by same of usage
in the specified place such as screwdriver must be kept together
with the screwdriver, collect it when it is being used the parts
necessary from each place to be paired.

Make the mark which show its repository
Why we need to make the mark which indicate the repository?
Imagine that you are looking for the coin in the drawer in the coin
repository which do not have the number of drawer or room of patient in
the big hospital which do not have the number of the room that you have
to visit one of your friend in that hospital, you can imagine what will
happen.

The mark of the repository can be divided into 2 categories (this part
is important technically). The first category is location mark and second
is equipment label.

Location mark
-- Certain rack number (code) indicates the place of that rack.
-- Meeting room, parking area or locker must be having certain
number (code).
-- Anytime we need to take something we have to understand
where its repository.

The way to determine the number (letter) of location mark
Determination the number (letter) must be simply and do not too
complicated so every person can remember it easily. For example
rack is being close to each other will be given number 1, 2, 3, or
the letter A, B, C, starting from left side and each of rack must be
given label with the number (letter) alternately and vertically.

Equipment mark
-- A symbol that indicates the type of equipment will be placed on
the rack where the place of the rack will be.
-- In the hospital the name of the patient must be printed in the
rooms door; in the parking area the car which is hired for the
long-term the car license-plate or the name of vehicles owner
must be printed in the place of that owner whose park its car.

Why we need label?
The professionals disbelieve the opinion that although rack do not
given label but whatever exist over there can specify what the form
is looks like and telling its content.
The equipment has been used must be returned to its repository
consistently.
If the rack is not given the label yet, you must be grumble and
complain because there is someone who did not keep it in its place
again, dont you? What is being used?

The goods has been kept must be given label too.

With this label we know what is being kept.
If the goods are the demo goods, make the record about the
demo that explains the type of job to be demonstrated. Another
example, such as the employee must wear the identity card and the
car has the number of vehicle.

Why is it necessary?
To ensure again whatever is to be kept in that rack is what we need.

How to display label
Label attached in front of the equipment should be easily seen,
distinguishable, and easily to be understood even by one of the
worker who did not know at all the way of the machine work.
The equipment is being used collectively without label which
distinguish it, it is better having the number or symbol that showing
the difference size (try to imagine if there is no distinguished
number lies behind of the back of an athlete). Use many kind of
appropriate color standard.

Where the goods lied should be contained in the table.
Rack location must be recorded in the table.
To distinguish the properly location what is to keep, it is by
registering what goods are contained in the rack in the table
according to the type of the product and production process. For
example the tuning machine table, standard of production and table
of inspection.
One of our friends to be brought to the hospital to get the medical
treatment. If there is someone who visit him or her so he or she will
record the name of the hospital, place and the rooms number of
that patient so anyone between us can visit him or her easily in the
properly room.
Requirements
If registered in the form of table, although without any completed
explanation we still easily to seek and gain what we need.

The way to display properly
Anytime we need to take the stuff required from many kinds of
place to be used, so we can economize the time if we follow the
order shown in that table. Therefore, the display must be easily to
be recognized so it can economize the time of searching of the
goods.

The inspection of giving the repository label to return to its place to
maintain the normal condition. Such important factors to maintain that
condition as specified.
1. Anyone is mandatory to place the equipment according to the label or
as specified. Therefore, for that reason it to be needed the mechanism
to ensure that everybody in that area has understanding the
mechanism storage and the returning of the goods in that area.
2. We can carry out the innovation or find another way in the name of
practical simplicity.
3. Joint agreement is :
The assessment to prove that its implementation according to what
has been specified
Unless, find out the area which is not fulfill the standard
This area must be repaired immediately
(All of the three factors mentioned above must be continually
repeated to gain the appropriate implementation)



The mark or label must be easily to be check or easily recognized if
in the wrong placement.
-- Everything that is in the wrong placement or inappropriate with the
label must be placed on the place easily to be seen.
-- Although has been undergoing the joint inspection with any person
from other department, outside party or even the president or every
person basically who did not having the knowledge about that
department, after see that mark and label must be able to say that
something being placed on inappropriate location specified.

B.3. SEISO CLEAN SHINE
SEISO is the activity to clean the work place, machine, equipment, and
working equipment from dust and dirty that is sticking, is being done
routinely so it is always in the clean condition and out of damage,
degradation and abnormality.

Clean the floor (sweeping, omit and clean the dirty).
Surrounding the working area with the pleasant feeling
The cleanness of the floor is as the first step to form the good
relation with the work place. In addition, this condition is having the
great effect so every person will stay and ready for work over there.
The shiny condition can influence human psychologically with
making them feel comfortable and not being stress.


Being realizing the importance of tidiness aspect, cleaning the floor
is as the next priority after throw away all of useless or unexpected
goods.

The important steps:
First, start to clean using broom.
At least sweep the work area completely and throw away all of
things no use. While certain work area must be with the special
technique of clean up the floor from oil, coolent and so on must
follow that technique.
While holding the broomstick or other hygiene equipment, the
Superior can sweep the floor and neat his or her own workroom to
exemplify to its subordinate.
Determine the border to divide the area.
The separation line for walking
Determine the symbol in the floor such as there is no barriers in
that area and so on
The picture in the floor is showing the location usually there is the
object in small size such as trash bin, fire fighting extinguisher, and
so on.
Eliminate the causative incidents of dirty which can make that area
being dirty.
The oil machine leakage. Trace the leakage and then repair it.
The water leakage from water tank or pipeline
Make the record of the event and then repair the damage
respectively from its source.
Dust and spreading particles
Use the cover, repair the cover or move the cover to the
appropriate place
Check the product and transportation material system (is it leak,
spill or over loading)
Repair or set the dust ventilation system
Sweep and clean the small area often ignored
Clean trace of oil in the floor with the cleaning agent
Perform painting or brush with wax to prevent thick dirty
In the area where the accuracy and precision of the working
equipment is to be needed such as in the laboratory it must be the
action taken to prevent extremely toward the dirty such as dust and
rest of dismissal. Therefore, you are advice directly to use your
hand to touch the dust is sticking above the floor.
Perform the cleaning carefully and develop the better environment
in the following area.
Surrounding the floor, wall partition, wall and corner
Upper side, inside and under the machine
Up of the roof, corner and the other side along the pipe
Light-bulb tube and its corner
Upper and under the desk including around the rack
Outside upper and inside the container or boxes, storage rack
Path or around the pipe racks toward the wood cutting shiver and
other trash
Inspection of the machine through the cleaning. Cleaning (wipe with
the hand) is as the simple way to check.

Although you are not mastering the machine as professionals, if you are
wipe with your hand, you can feel there is something wrong in that
machine. So in this case we can detect whatever damage generally to be
ignored in common. This is called as the inspection of the machine
through the cleaning).
The machine is being dirty will difficult to maintain.

The dirty machine is the consequence of negligent

The machine is being dirty always be ignored and not to be check
carefully in common.


If the completely inspection is not to be done, the unpredicted
damage previously will occur and tend to be causing much more
trouble.


Therefore, the machine will be less cleaned up will usually causing
the trouble will be repeated again.

The inspection procedure with cleaning. The main factors.
Pre-assessment
Perform the inspection with cleaning up
The involvement of technical advisor
Other the inspection with cleaning, try to find the small spots to be
seen
Pre-assessment by the meeting of the member
Collect information related to the type of issue and the frequent of
causing of the trouble
Determine the sounding upon the big issues occurred with the
reason and outcome accompanied it
Choose the factor is most possible to become the reason of
causing the trouble
B.4. SEIKETSU MAINTAIN STANDARDIZE
SEIKETSU is the activity to maintain the work place facility, machine,
equipment and goods regularly so that:
No longer to be met the unnecessary goods in the working area
(S1)
The work place becomes more tidy (S2)
Free from dirty (damage) (S3)
The optimum condition can be maintained and to be kept (S4)


In the same time the application of visual control (visual control
photograph) as the means of improvement can be assumed as the
standardization because it able to enhance the visual auxiliaries to ensure
the implementation toward to the right direction. Therefore, S4 can be
divided into 2 main parts as follows:
Standardization to maintain the stability of S1, S2, and S3
Standardization through the visualization so the implementation
able to run properly and fulfill the standard (visual control)

Standardization to maintain the first Three S.
1. The steps in standardization
In determining the standard, the participation of the entire small group
in the organization will be needed. The standard will be specified by
each of the small group after applying the first three S, then by the
management will determine the minimum value at 80 for the year of
2014. Each of the small group will determine the standard each of
group that will be discussed in the discussion. Equipment, goods and
area with the similar characteristic must have the same standard which
the further more things will be fixed in its status in every small group.
So it is with each of the department must determine the standard and
discuss the improvement needed through the same process with that
small group. In this case, to determine the standard of each group,
then perform the adjustment or improvement to meet the organizations
standard.
Set standard area
Discuss the standard specified by each of small group and
improve the difference to meet the standard of department
Collect the standard of department to be developed as the
collective standard of the Company
Make the improvement so appropriate with the new standard
specified by the administrator (the standard of the company).
Then apply that standard in the group.

2. The principles to determine the standard
Determine the standard in the area such as floor, walking path,
wall, ceiling, door, window, and curtain.
Determine the standard in the object or equipment being used in
the different location that possibly cannot be applied, such as in
the office, toilet, pantry, meeting room, first aid room, workshop,
repository, machine and so on. For example, the equipment
requires the standard determination in the office.
-- Workbench
-- Chair
-- Wall-cupboard and filling cabinet
-- Whiteboard
-- Telephone
-- Photocopy machine
-- Trash bin
-- Fax machine
-- Door label
-- Racks
-- Electrical, lamp light, electric socket, connector and kettle
-- Fan
-- AC (Air Cooler)
-- Key holder and so on
Example: Equipment or item requires the standard determination in the
rest room (toilet).
-- Finger bowl
-- Lavatory
-- Roll tissue
-- Mirror
-- Hand dryer
-- Trash bin
-- Soap and so on

3. Table of 5S Implementation (5S Standard Activity Form)
Each of work area must make a table of 5S time clearly consists of the
schedule of ignition and cleaning inspection, standard photo of work
area and recording of the findings to be done of the improvement. The
schedule of Big Cleaning Day (General Cleaning) can be inserted too
to this table. Example:

Table of 5S implementation in the office or workshop (plant)
exist in each of work area.


The schedule of activity in office held at least once in a week
while in workshop or plant, such as at the Yard perform the
5S activity in daily basis on Monday morning while at other
workshop is to be done before and after daily working.

4. 5S Audit Schedule
To motivate and measure the outcome from every improvement to be
done, an audit must be done every month is from on date 1 up to 15.
Canceling and delaying cannot be accepted, unless there is very
important problem arisen. In this case, to prevent the employee that
ignores the importance of an audit and appreciation to the 5S activity
consistently.

5. Determine the standard of control visual
Among all of five human senses, the eye is assumed as the best signal
receiver before the message transmitted to the brain. Therefore, the
various communication method to be tested to ensure the most
effective visualization method will be applied so that it able to
understand the fast and accurate message. In the manufacturing
factory, the ability to understand the way the machine can be operated
quickly, to ensure reduction of the damage will be occurred. This in the
main reason why the visual control is being done in the manufacturing
factory today. For the office block the visual control will assist to reduce
the time being wasted useless for searching the equipment (goods)
being kept in somewhere. With application of the visual control the
entire organization will increase its ability to yield and perform
effectively and efficient operational.





Types of visual control
Label, either symbol or letter, for example:
Use the symbol of colored sticker to indicate the control of
lubricating oil.
Use the label (sign) when handling the complicated working
process.
Use the sign or sticker to indicate the inspection of the
equipment in the assessment period.
Sign will indicate the temperature of the machine
Use the sign to indicate the responsibility
Other types of signs




Control limit
Use the symbol that indicates the measurement status such
as the normal or abnormal condition and the actual condition.
Use or exhibit using certain symbols that refers to the normal
condition such as the Match Mark.
Use the symbol such as the line or spot to find the repository.

Smart visual
Use the transparent material so it able to see inside the
machine to understand the way the machine can be best
operated.
Make the indicator that showing the machine condition.
Make a map states that the area or location is having the
problem must to be treated carefully in the factory.
Create the more effective and faster way in tracing the level of
storage of the equipment.

Example: Type of different visual control
The sign or symbol that refers to the safety
The sign or symbol that is preventing the mistake of using the
machine
The sign or symbol for the equipment repository
The lines that indicate the zone or distribution of area
Indication of condition or abnormal situation
Labels of the machine, equipment and location
Direction labels of arrow of pipeline of water, gas, oil,
chemical, and so on
Procedure images of work flow (work flow process chart)
The signs indicate direction of way
B.5. SHITSUKE FREQUENTLY SUSTAIN
SHITSUKE is the activity to civilize and habituate of working according to
the system and procedure as well as the development of positive working
behaviors of the employee in the work place as the discipline habitual.

In order to 5S is able to give the satisfactory outcome, these
following factors must be met:
1. The ability to develop S4 (Standard determination) is the ability to gain
the full cooperation in determining the base standard. Therefore, with
determining the strong base then the application of 5S can be
implemented with the most effective way.
2. Making the Monthly 5S Inspection Sheet has been taken from the
standard procedure specified in the S4.
3. Performing tightly 5S audit every month with planning the annual
schedule that is date, time, area and the inspector to perform the
assessment (audit). Do not perform cancelation or delay and visit
unless the condition which very abnormal happened.
4. Perform the weekly or monthly meeting of small group, department and
organization. This meeting will ascertain again that those activities are
going well because the problems can be predicted are open to be
discussed that is consisting the group brainstorming in handling the
problem, so it is reduce the communication barrier between the
members of the group.

After it has been applying 5S for 3 years, it required the consideration to
increase assessment standard (DQO Minimum Score), example: in 2012
minimum score per audit of area is 60, in 2013 it becomes 70 and in 2014
is 80. If the outcome indicates reduction of damage in the working process
then the system of 5S has formed in that organization. Likewise, the
determination of new standard to S4 must be considered as the better
standard so it can increase the entire productivity.

* Evaluation
Evaluation Procedure
The evaluation process of 5S activity made based on the score making
system related to the objective specified previously with the score weight
higher toward the important activity. However, the total appraiser equal to 100
point or one score of the percentage. The evaluation process must be
performed every month with determination of date and time of inspection.
Area will be evaluated have to give the written report toward the progress has
gained to the appraiser of their every visit to be done. The appraiser (auditor)
will fill the 5S assessment form according to the report and the actual area
that will be inspected then make the comment and advice of improvement if
necessary. Furthermore the score has been accounted will be sent to the 5S
coordinator and to be compared with the outcome has gained in that
organization before making the final conclusion upon the entire activity
progress.

The standard assessment S1-S5 will be made according to the assessment
of the auditor where each of the auditor will assess the outcome and account
the average of final score or perform the meeting that is discussing each of
the point of view of auditor before conclude the score for each of the area to
be valued.

The assessment will be performed in the three level of different position that
are inside that own group, then the level of chief of the department (middle
management) and the level of director (top management).

Note. Internal team has to assess their performance consistently every month
even after has passed the final inspection by the head of the department and
top management to ascertain again the best standard.























CHAPTER V
6S (5S + SAFETY)



Safety must be as the main priority in the working activity. Although, you
cannot increase the safety before other S component that is 5S fulfilled.
The awareness concerning the importance to the safety must be emerged in
order to minimize the accident happened, injury or other incidents. Therefore,
each person must have the role and responsibility in the case of safety as
well as understanding how is the way to prevent the accident happen. Every
person who having the role and responsibility in the case of safety must
observe too and correcting if there is the behavior of the fellow worker who is
ignored the safety.

The first thing must to be done is hazard recognition is covering analysis to
recognize the hazardous situation emerged by the equipment, material, up to
the environment in the certain work area. If the hazard found, then utilize the
certain sets of equipment that can be used to enhance the safety.

The last S (safety) added to 5S to become 6S or 5S + 1 as one of the main
part in the ergonomics. 5S itself has been in line with ergonomic and it can be
said as the part of ergonomic. Ergonomic is the science about working, while
5S is the method to arrange the work place and optimized it. With the 5S so it
can be created the better working morale as well as it the most important is
the effectiveness, efficiency, and increased working productivity, it means
generally it can enhance the working performance. This case can cause 6S
become an issue that close-related to the ergonomic.

In order to win the competition in the global competition era, the company or
organization demanded to be efficient and effective in every line. The system
presence today is offering many ways that if it is integrated-implementation
and it supported by strong and trained Human Recourse so it is possible in
the brief tempo will place the company or organization in the World Class
Category.

5S + 1 (Safety) as the one of the system is offering the way to upgrade the
company or organization performance with the focus in the working
environment organization effectiveness and standardization of working
procedure. 5S + 1 (Safety) will simplify our working environment, also to
improve the quality of efficiency and working safety.
5S + 1 (Safety) as the most elementary system to enhance the working
productivity by growing on the forming of job ethos from the employee to
make its working environment being comfortable and safe, so will arise the
sense of feeling that it is in the future will encourage the worker to perform the
improvement toward its working environment and training them to reduce the
redundancy, downtime which is unplanned and in-process inventory.

After integrated implementation and application, 5S + 1 (Safety) will increase
the workers morale, create positive impressions from the customer and
enhance the company efficiency as well as the organization. The worker is
not just feel comfortable with its working environment, the effect to perform
the continually improvement will encourage reduce in redundancy, the better
quality and shorter lead-time. All of these in the future will make the
organization become more benefit as well as competitive in the world market.

5S + 1S Philosophy
The improvement process if fully applied and continually will give:
The influence of morale enhancement from the worker holistically
Create the positive impression from the side of customer
Enhance the company or organization efficiency

Why do we need to apply 5S + 1S
Tidiness and cleanness of working environment will give comfortable,
health and safety to the worker
Tidiness and cleanness of working environment will increase the
working productivity
Tidiness and cleanness of working environment will increase the
efficiency toward working time
Tidiness and cleanness of working environment will produce the high
quality product with the lower amount of defect
Tidiness and cleanness of working environment will promote the
organization (company), visually control and cleanness toward to the
customer or candidate of the customer.

CHAPTER VI
CLOSING

And there is no enjoyment to be gained, except after hard working
(previously), Arabian aphorism.

Dear reader, with the strong will and full of confidence, lets create the 5S
culture (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) with all of the potential
available to gain every opportunities in front of us. Prepare yourself with the
high motivation to better step forward with the 5S mission and precise
strategy. Then, complete with our best movement.



















(Back cover)

SYNOPSIS

You are probably often experience the condition where there are much stuffs
sprawled, irregular, untidy, unsightly, dirty, seldom to be used, damage or
even it has not being used anymore. There will emerge the redundancy, time,
cost, energy, thought, and so on. The productivity and the high level of
accident because less of awareness and self-discipline. You are probably can
experience the similar things in your home, your social environment, or even
more in your work place.

Therefore, it is right if you decide this Manual Book of 5S as the proper
solution all at once as the reference because it is arranged according to the
experience and practical in our company.

What are you waiting for, got a move on immediately and create the good
working environment start from our own self, so our world will be as the
heaven of life that is having the meaning, high-grade and comfortable.

Copy right 2014