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GUIDELINES FOR STANDARDIZING AND

SUSTAINING ‘5S’

SORT
(Do we need this?)

SET
(Do we have a good place for this?)

SHINE
(Is it in the designated place, labeled and clean?)

STANDARIZE
(Is there a written procedure for this?)

SUSTAIN
(Are we auditing and maintaining the written standard?)

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TABLE OF CONTENTS

GENERAL Pages 3-4

 General Guidelines
 Area Division
 Daily Activities
 Weekly Activities
 Audits
 Floor Taping
 Floors, Wall, Aisles, Ceilings

MAIN CELL Pages 5 - 6

 Cell Operation Areas
 Kanban and Queue Locations
 Supermarket
 SFGI and SFGI Overflow
 Communication Areas

TECHNICIAN AREA Page 7

 Troubleshooting and Repair
 Troubleshooting Test Fixture Storage
 Tool and Misc. Equipment Storage

ADMIN AND MATERIAL SUPPORT Pages 8-10

 Desk Areas
 Quarantine
 Staging area
 Reject Area

SECTIONS TO BE DEVELOPED N/A

 Annex
 NPI cell

Appendix: Page 11
 Floor Taping Guidelines
 5S Operator Daily Check Sheet
 5S Audit Sheet - General

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GENERAL

 The guidelines for 5S in each area of the Signal Sources cell will be maintained in
a clearly labeled binder at the cell leader bench.

 Any employee may suggest updates to the documentation.

 Cell leaders and managers are responsible for maintaining updates. Only the
current approved version will be stored in the binder and this will be the only
authorized copy for setting the 5S expectations within the area.

The Signal Sources area of responsibility is divided into separate locations for the
purposes of conducting 5S activities. These areas are:
1. The Cell Operation area (cell “proper”). It includes the Supermarket as well as
operations on the main route from board test though shipping. Also included are
the communication (stand-up) areas, shift report and SQDC/QDIL board content.
2. Troubleshooting and Repair area. This includes technician benches and the
storage locations within this area. Also included is test fixture storage, and board
repair benches.
3. Administration Areas: This includes manager, cell lead and material handler
desks as well as the staging, quarantine and rejects storage areas controlled and
managed by these individuals.
4. Annex and NPI lab:

DAILY ACTIVITIES:
Each operator, technician, material handler and manager will conduct a 5S audit of
their individual work area at the end of each shift. All tools will be verified and left in
the appropriate positions. Work surfaces will be clean. Floors will be free of debris.
Any unnecessary items will be removed. Trashcans will be emptied. Calibration dates
will be verified.

WEEKLY ACTIVITIES:
All employees will participate in weekly audits and corrections to findings during the
audits.

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AUDITS:
Audits will be conducted by each shift on a weekly basis at the end of the shift.
Results will be posted on the SQDC/QDIL board. “Outside” audits will be conducted at
least once per quarter by an individual who has been trained to do so from any other
group or support function.

FLOOR TAPING:
Refer to the reference sheet titled Level 3: Visual Controls – Floor Taping at the end
of this document.

FLOORS:
Floors are to be kept free of debris. Normal scuff marks are the responsibility of the
weekly cleaning service but any lack of service should be called to the attention of the
cell manager and the site manager for Washington Group.

WALLS and VERTICAL SURFACES:

Building walls and cubicle may be used as approved by managers to display
information, posters and pictures relevant to our business, events or current
information.

AISLES:
Aisle ways will be kept clear at all times even if a manager has authorized temporary
overflow. Trip hazards and obstacles to safe exit from the area are to be avoided at all
times.

CEILINGS:
Ceiling tiles should be free of obvious stains, breaks or holes. Burned out bulbs
should be brought to the attention of Washington Group for maintenance. Note that
some areas have bulbs removed with management approval

CELL OPERATION AREAS

 Each work bench will use shadow boards for tools or have taped out space for
items that belong on horizontal surfaces.
 Benches and PC’s should be regularly cleaned.
 Cords and cables should be neatly dressed or stored and off the floor.
 Work Instructions are posted on the company web site and will be open and used
for each build sequence.
 Clipboards will be hanging at each station for displaying current waivers and bench
inventory sheets)
 Kanban disciplines are TBD.
 Only necessary items are to be present. Necessary items are to be clearly
labeled. All necessary items present and in their proper location at end of shift.
 All equipment has current calibration dates.
 No trip hazards
 At no time should food items be found within the ESD protected cell area.
 The stand up area should be free of chairs, instruments and material other than
what is needed for “show-and-tell”.

KANBAN AND QUEUE LOCATIONS

 TBD

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SUPERMARKET:

 Flow Racks should be clean, labeled and orderly.

 All part locations for storage are to be marked on both the front and back of flow
racks.
 All individual boxes and totes are to be labeled with the current part numbers (no
use of –xx suffix).
 Water skipper carts are to be left in taped out locations except when in use.
 Personal notes, etc. are allowed on the work surface of the cart or pc location
during the shift but must be removed at the end of each shift.

SFGI and SFGI OVERFLOW:

 Instruments will be placed on the approved storage racks/locations in an orderly
fashion.

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TECHNICIAN AREA

TROUBLESHOOTING AND REPAIR

Technician bench tops and shelves are for tools, equipment and reference material to
be shared by bench partners. Items on the bench top and shelves will be neatly
organized and clearly labeled. The only items to be stored at the bench are those
items which are used frequently throughout the week.

Items used less frequently than on a weekly basis but are still needed for current work
activities will be stored in the storage cabinet. All items in this cabinet will have a
designated and neatly labeled location for storage.

The top bench drawer should contain shadow boards for tools. The bottom drawer will
contain neatly stored and organized reference material such as personal copies of
schematics or personal notes and other reference materials.

TROUBLESHOOTING TEST FIXTURE STORAGE:

 Each fixture is to be labeled with name or part number.
 Fixtures are to be stored in designated locations or taped out floor locations when
not in use.
 As fixtures are needed they are moved to a work bench. They are to be returned
to storage at the end of the shift or when finished working with them.

TOOL and MISC EQUIPMENT STORAGE:

Items infrequently used and shared by technicians will be kept in a storage cabinet
adjacent to the test fixture storage. Items in the cabinet will be neatly labeled and
stored.

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ADMINISTRATIVE AND MATERIAL SUPPORT AREAS

The purpose for these standards is two-fold:

1. Desk areas should be kept visually appropriate for tours, important customers and
other visitors.
2. In the event of an unplanned absence, the desk area should be organized and
labeled well enough to allow a person with general knowledge of the role to take
over with a minimum of difficulty in understanding what stage various tasks were
left in and where necessary records are stored.

ADMINISTRATIVE DESK AREAS:

 Administrative desk areas should be neat, well-organized and free of clutter at the
end of each work shift.
 Nothing shall extend above the height of higher cube walls.
 Work surfaces shall be clean of stains and debris.
 Drink and food items and containers should be properly stored away in the break
area, personal lockers or designated drawer space at the end of each shift.
 No appliances (coffee pots, microwaves, refrigerators, etc.)
 Desks which are not shared with others are allowed personal items so long as they
do not impede on required workspace if others need to use the desk.
 Personal items should be appropriate to a business environment.
 Floors should be clear of items other than trash can, one recycle box and personal
heaters or fans approved by managers.
 Miscellaneous supplies should be neatly stored in pencil and desk drawers.
 Only currently active work should exist on the desktop.
 Cabinet surfaces should not be used for desktop overflow but may be labeled and
used for appropriate holding space for work.
 Drawers, cabinets and work in progress should be labeled well enough for others
to step in during an absence.
 Reference material posted on interior walls should be current and necessary.
 All parts and assemblies temporarily at a desk will be properly protected. They will
be re-located to their proper storage locations before the end of the shift.
Exceptions are allowed only for overnight attention and communication to the next
day’s shift.

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QUARANTINE:
The quarantine area is used to temporarily store material or instruments being
evaluated or with some kind of problem causing it need to be kept apart from
supermarket inventory. Items kept in this area must be labeled with the following
information:
 What it is
 Why it is in quarantine
 Who is responsible or owns the items/problem
 Date the item went into quarantine and if known, how long it is expected to be
stored there.

Items in the area should be reviewed at least on a monthly basis to be sure they do
not linger for long periods of time without action.

STAGING AREA:
Items in the staging area are instruments staged for work activities that are not part of
the cell daily rate or are waiting for some support activity. Examples are:
 Code 5 warehouse returns
 Waiting for rework
 Production Hold.

As items move into the staging area the white board will be updated with the following
information:

 Date in
 Who is responsible
 Reason for the item being in the staging area
 What needs to happen for it to move out and/or expected date for it to move out

As items leave the staging area they should be erased from the white board so that
the white board is always up-to-date with the current content of the staging area. This
area should be audited as part of the end of shift clean up activities each work day.

This is not a location for storing parts or collecting unnecessary items.

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REJECT AREA:

Reject parts must be clearly labeled and should be found in only one of three areas:

1. Cell lead desk tops have clearly marked bins for parts coming off the line as
material needing to be rejected. Cell leaders print the appropriate tags and do all
necessary quality record entries. This work should generally be completed before
leaving for the day.
2. Once rejects have been appropriately labeled and transacted by the cell lead, they
are moved to the black bins on the reject carts adjacent to the staging area.
Material Handlers process these items on a daily basis by transacting them in
Oracle. As they do so, the material is moved to the orange bins for an
engineering review prior to having the parts scrapped. Engineers will make the
final determinations as to whether these parts can be used “as is”, returned to
vendors or discarded as scrap.
3. Cell lead benches also have separate bins for returning reject parts to each shift
cell leader when the reject tags have not been properly filled out. This ensures the
correct individual gets the appropriate feedback for corrective action in the future.
These bins are not to be used to deposit reject parts for any other reason.

No part should linger in any one location for more than two business days. Exceptions
should be brought to the shift managers attention so that additional help can be called
for as needed. Rejecting parts in a timely manner ensures we can keep appropriate
inventory levels and have knowledge about leading edge quality problems.

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APPENDIX

 Floor Taping Guidelines………………………….Page 12

 5S Operator Daily Check List…………………….Page 13
 5S Audit Sheet – General…………………………Page 14

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