What Does Good Look Like

5S

LeanTPM Visual Standards to drive performance

Carlsberg Asia

March2017
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5S Tools for Visual Brewery

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What does Good Look Like – 5S

Physical Standards (5S)

Is this an organized workplace we are proud of?
• Look, Listen, Smell to observe physical abnormalities
• No safety issues, PPE requirements visually defined
• Only necessary materials are available in the zone
• All materials / tools are in the right place
• The area is clean, tidy and well lit
• Equipment and area is clean and good condition
• Necessary cleaning tools, bins are available at the zone
• No leakage (air, water, product, steam, chemical…)
• No broken bottles, unnecessary crates on the shopfloor
• Objects hanged on the wall, not standing on the floor (if
applicable)
• Visual standards for target conditions available
• No rework process happening on the shopfloor
• Visual Brewery Tools are implemented where 4

applicable
1) 5S & Visual Brewery Tools

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Tools of 5S / Visual Brewery

Checklist Color-Coding Diagram Example

1 2
Used to display items
that complete a
process
3 4
Used to classify items Used to depict the
or identify storage arrangement of
locations mechanical systems
Used to illustrate a
product or raw
material, standard or
defect

Indicator Kanban Label Layout / Map

5
Used to specify key
control points, physical
limits or process
6 Used as a physical
reminder to
standardize reordering
7 Used to identify an
item and its storage
location
8 Used to depict the
arrangement of a
territory
conditions
Tools of 5S / Visual Brewery

Outline Performance Photograph Planner (TIP)

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10
Used to identify an item’s
storage location using
silhouetting, mounting,
nesting and shadowing
Boards (PMS)
11 12
Used to illustrate product Used to display a
Used to display or material, standards or team’s Tactical
information about a defects, cleanliness Implementation Plan
team’s performance stndrds, target conditions to deliver goals

Principles Procedure Red and Yellow Schedule

13
Used to display
guidelines for team
conduct
14 Used to display
Standard Operating
Procedures (SOP)
15 Tags
Used to classify tools, parts
and equipment that are to
16 Used to display a
team’s time
committments
be discarded or fixed

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Tools of 5S / Visual Brewery
Signage
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Used to identify storage
locations or areas within a
territory
Specification Striping Symbol
18 19 20
Used to display Used to delineate item Used to identify items,
product, material, locations, hazards and tools, areas or other
equipment or cost areas within a territory information through
information visual language
2) Examples of 5S Tools

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5S Tools - Checklist

2016 Run Right 'Every Day' - O2 Management

TO ACHIEVE Q,
AT STANDARD

REQUIRED
ACTION
C and D
*NOTE: RunRight standards assume operator capability, good maintenenace, housekeeping, product in specification, raw materials in specification and good workplace organisation. We have an
'Essential other' section to catch some essential question which should not be in RunRight Standards but are consistent issues.

Transfer elements sealed properly to avoid air intake Method Target Visual Display Check
Correct positioning-no
Are all gaskets undamaged and seated correctly? Visual - As per SOP misalignment-gasket not SOP - Visual IPS Run Right
damaged
Visual check during autosplicing / Visual check of blades
No dead ends are present at the piping? Clean cut / No damage blade Visual IPS Run Right
during weekly maintenance
Are swing bends fitted properly correct to the standard? Check operator screen 150-220°C Operator screen IPS Run Right

Check the gauge if present / If not, check the autosplicing

Is pump pressure during transfer correct to the standard? As per OEM target / Clean cut Visual / Gauges IPS Run Right
quality

Visual check of rollers and carton position at SA infeed No misalignment Visual IPS Run Right

Are pumps starting to run in sequence? Visual check after production No damage Visual IPS Run Right

Pretreatment of tanks and pipework to remove oxygen

Is the counterpressure (CO2) controlled properly to avoid O2 intake Check operator screen if present As per OEM/plant specs Operator screen IPS Run Right

Is timer during strip splicing correct to the standard? Check operator screen 1300 ms (milisecond) Operator screen IPS Run Right

Good quality of splice - No break

Is strip splicing piston working correctly? Visual check if splicing is correct Visual IPS Run Right
of strip

Are rollers and their springs in good condition? Visual check after production No damage Visual IPS Run Right

Is induction energy value during strip application to the carton correct to the TPIH screen /
Check TPIH screen As per OEM/plant specs IPS Run Right
standard? Automated
Dosing elements
Manually as per SOP before production / Operator screen Operator screen /
Is additives dosing elements are sealed properly to avoid O2 pick up? 30-50% IPS Run Right
during production hourly Automated
Operator screen /
Is deaerated water used for slurry preperation for additives? Check from operator screen during production hourly 77-83°C IPS Run Right
Automated

Is H2O2 contact time within specification Automated by the machine motion control system 55 sec Automated IPS Run Right

Is level of H2O2 in the bath within range? Level sensor As per plant specs Automated IPS Run Right
Is there a label on the H2O2 drum indicating time for chemical shelf life (Best
Check if it is expired BBD not expired Visual IPS Run Right
Before Date)?
Visual check after production / Verify H2O2 residual in the No damage on rollers / H2O2
Are scrapping rollers working correctly? Visual / SOP IPS Run Right
package residual is less than 0,5 ppm

Are pressure of scrapping rollers within specifications? Gauges 2-5 bar Gauges IPS Run Right

Visual check after production / Verify H2O2 residual in the No damage on knives / H2O2
Are air knives working correctly and in good condition? Visual / SOP IPS Run Right
package residual is less than 0,5 ppm
Gauges /
Is sterile air pressure in air knives within range? Gauges 20-50 kPa IPS Run Right
Automated
Operator screen /
Is sterile air temperature in air knives correct to the standard? Check operator screen if not automated 180-200°C IPS Run Right
Automated
Water deaeretion
Is positive air pressure inside the aseptic chamber maintained within Operator screen /
Check operator screen if not automated 100-950 Pa IPS Run Right
specifications? Automated
Is water flow rate correct to the standard? Flowmeter As per OEM specs Automated IPS Run Right
Operator screen /
Is air sterilization temperature within specifications? Check operator screen if not automated 360°C (min 330°C) IPS Run Right
Automated
Is temperature of aseptic chamber within specifications? Temperature probe 70-110°C Automated IPS Run Right

Is steam temperature in aseptic product valve within specifications? Temperature probe 105-125°C Automated IPS Run Right
5S Tools – Color Coding

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5S Tools - Diagrams

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5S Tools - Examples

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5S Tools – Indicators

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5S Tools – Kanban

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5S Tools - Label

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5S Tools – Layout / Map

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5S Tools - Outline

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5S Tools – Performance boards

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5S Tools - Photos

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5S Tools – Team Performance Tracking / Planners

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5S Tools - Principles

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5S Tools – Procedures / SOPs

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5S Tools – Tags

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5S Tools – Schedule

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5S Tools - Signage

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5S Tools – Standard Settings / Specifications

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5S Tools - Striping

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5S Tools - Symbols

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3) Implementation of 5S Tools
to SHOPFLOOR

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What does good look like – Dharuhera Brewery B&P Area

Watch out: We suggest not

to put footprint on the floor,
just identify the pathway by
straight lines
 What does good look like – Dharuhera Brewery Packaging Area

Watch out: We suggest not

to put footprint on the floor,
just identify the pathway by
straight lines
 Floor, pathway & cross over marking – Paonta Brewery

Yellow line identification

for movable things

Black and Yellow

Line on every crossover

Pathway in
Utilities Pathway in
Packaging
Kanban in Packaging and Utility area: Paonta Brewery

Color identification for minimum Maximum level for Tape, CAN LID,
CO2 storage tank level, Liquid Ammonia in receiver
Marking in Pressure & Temp. gauges, pipe Line as per colour coding
Paonta Brewery
Gauges Visual display

Pipeline color coding Visual display

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5S good practices In Lab
Paonta Brewery

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5S good practices In Lab
Paonta Brewery

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OPL In Packaging & brewing
Paonta Brewery

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Some good practices – 5S and visualization
China
B&P and Packaging Dep.

Visualization Labelling Zoning

Some good practices – 5S and visualization
China
QA Dep.
Identification Straighten

Visualization

labelling
Some good practices – 5S and visualization
China
QA Dep.
Identification Straighten

Visualization

labelling
Some good practices – 5S and visualization
China
B&P Dep.

B&P pipe labeling Jumper pipe

Auxiliary ingredient room

Some good practices – 5S and visualization
China
QA Dep.

Each plug has its own position,

direction of arrow guides the
recipients

Color management of tube

position and specifications

Use red, yellow and green

colors identify each drug
inventory
Each tool in the foam has a
shadow
Some good practices – 5S and visualization
China
Non-Packaging Maintenance Room
Zoning/Labeling

Shadowing Stock Control

Some good practices – 5S and visualization
China
Chemical Lab
Chemicals List
Chemical Cabinet

Zoning/Labeling

Stock/Level Control
Some good practices – 5S and visualization
China
Spare Parts Warehouse
Lay-out Map Color Code

Spare Parts List

Label with same color in

Lay-out Map and list
Some good practice – L’ship
China
Board: Excellent Employees in LeanTPM

Achievements Presentation
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