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'5-S' Road map - Department

To do Who ? When?
What ? Where? Team Leader Team Members P-D-C-A Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Dec-07
S0 = Enablers
[Motivate
people for 5-S
implementation] Plan S0 S1 S2 S2 S3
S1 = Seiri
[Sort out what
is needed and Gemba-1:
what is not]
S2 = Seiton
[Do Actual S0
systematic
arrangement for
all
S3 needed
= Seisoitems]
[Ensure
spic & span
cleanliness with Plan S0 S1 S2 S2 S3
inspection]
S4 = Seiketsu
[Create a
highly
standardised Gemba-2:
workplace] Actual

S5 = Shitsuke
S0
[Self - discipline
at workplace]
Department
Jan-08 Feb-08 Mar-08 Remarks Why ? MOP

1 ] Demonstrate PQI by doing Kaizens


2 ] Remove 3 D's at Gemba
Zero defect SHE
S4 S4 S5

Zero
1 ] Develop criteria for need/want to
inventory/M EFSHE
release 50% place
ore space

1 ] PEEP: Place for everything & Zero


PQCD
everything in its place waiting

1 ] CLIA: Deploy Clean-Inspect-


Zero
Lubricate-Adjust PQCD
accidents
S4 S4 S5 2 ] CPCP

1 ] SOPs Developed & Displayed Zero


PQCD
2 ] Establish SDCA breakdown

1 ] Through continuous education,


training, display of results & PDCA Zero setup PQCDEFSHE
improvement cycles
ACTION PLAN FOR "S0" Enablers
Motivating people for 5S implementation (Jul - Aug 07)
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 "S1" Seiri
Sorting out what is required & dipose unwanted (Aug - Sep 07)
Requisites Area Who Status Remark
TM √
TM √
Work Area
TM √
TM √
TM X
TM X
Classification in work areas
TM X
TM X
X
Audit / Visual Inspection of wants / X
TL
wastes X
X
TM X
TM X
Scrap Disposal
TM X
TM X
TM X
Listing Wants in an Area after TM X
eliminating waste TM X
TM X
(S1) Waste Identification Checklist
Gemba
Work Area
TM
Better
Usage
Usage Condition Repairable Substitute
Process / Equipment / Item in area outside area Waste
avl
Freq. Rare Never Good Worst Yes No Yes No Yes No
Remark
ACTION PLAN FOR "S2" Seiton
Systematic Arrangement of wanted (Oct - Nov 07)
Requisites Area Who Status Remark
TM X
Organising wants in an area in terms of TM X
usage / value / importance to process / life
cycle TM X
TM X
TM X
Identifying amenities / infrastructure / tools TM X
required for correct organisation (P tags) TM X
TM X
TM X
Organising in compliance with PEEP & TM X
Identifying missing / abnormal item or
structure TM X
TM X
(S2) Systematic arrangement checklist
Gemba
Work Area
TM
Critical to
Process / Equipment / Item in area Usage Value Qty (Nos) Total Pref. No
process

0
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
ACTION PLAN FOR "S3" Seiso
Systematic Arrangement of wanted (Nov - Dec 07)
Requisites Area Who Status Remark
TL / TM X
External / Internal man power TL / TM X
arrangement for through cleaning TL / TM X
TL / TM X
TM X
Through cleaning done & scrap disposed TM X
safely TM X
TM X
TM X
All Items / Process / Equipments easly TM X
identifiable / accesible / safe TM X
TM X
ACTION PLAN FOR "S4" Seiketsu
Systematic Arrangement of wanted (Jan - Feb 08)
Requisites Area Who Status Remark
TM X
Daily Inspection / Reporting TM X
abnormalities TM X
TM X
TM X
Action for deviation / 5S awareness TM X
session or training TM X
TM X
ACTION PLAN FOR "S5" Shitsuke
Systematic Arrangement of wanted (Mar 08)
Requisites Area Who Status Remark
TL / Auditor X
Monthly / Qtrly. "5S" audit by Internal / TL / Auditor X
External accesor TL / Auditor X
TL / Auditor X
TL / TM X
Action for deviation / findings / TL / TM X
document learnings TL / TM X
TL / TM X
TL / TM X
5S awareness session / training for TL / TM X
continual improvement / Visits TL / TM X
TL / TM X
TL X
Gains in terms of value, life cycle, TL X
availability to be published TL X
TL X
0 = Very Bad 1 = Bad 2 = Avg 3 = Good 4 = Very Good

Score
1S Check Item Description
0 1 2 3 4
Materials / parts Does the inventory or in-process inventory include unneeded mtrl / parts
SEIRI

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 0
Sub Total 0 0 0 0 0

Score
2S Check Item Description
0 1 2 3 4
Location Indicators Are shelves and other storage areas marked with addresses
SEITON

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 0
Sub Total 0 0 0 0 0

Score
3S Check Item Description
0 1 2 3 4
Floor / Work station Are floors / work station shiny to spot any waste
SEISO

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
0
Sub Total 0 0 0 0 0

Score
4S Check Item Description
0 1 2 3 4
Improvement Idea Is any action plan in place for its deployment
SEIKTSU

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 0
0
Sub Total 0 0 0 0 0

Score
5S Check Item Description
0 1 2 3 4
Equipments / Process Are they easily gettable / managable
SHITSUKE

Stock levels Is the inventory control adhered to


Training Is Training / 5S awareness in progress
Support Is top management active support available
0
5-S Billboards Are they updated
Sub Total 0 0 0 0 0

Grand Total 0
SEIRI 0
SEITON 0
SEISO 0
SEIKTSU 0
SHITSUKE 0
Audit Result
SEIRI
1

SEITON SHITSUKE

SEISO SEIKTSU