Draw 5S Plan

lay out

Explain 5s

elements to

all staff

Select the

Task force

members

5S Implementation Process

5S Roll Out

Step 1:

Sorting out

carry out

workshop

Revamp-

Major 5S

Step 2:

Set in order

Step 3:

Shine

Scan the

Premises

Step 5:

Self

Discipline

Step 4:

Standardize

5S-Step1 implementation

Sort (Sieri)

Start the 5S Sort- to clear the mess!

The guide assigns 5S Task Force members for the

sorting event.

members move from workstation to workstation

tagging items and removing them to the sorting

area.

Red, Green and yellow tags identify different

actions quickly.

The task force member fills the

information and attaches the tag to

item

Sort out resistance from

staff on the spot.

workstation should only

contain a small amount of

work in progress and the

tools and supplies needed to

do the work

Clear the sorting area by

following the above three 3

colored disposition rules.

Managing tagged area

See the tagged items.

Can even paste the

red tags if items are

large

Unwanted obsolete

equipment moved to sort area

Result is a clean,

efficient & pleasant

work station

Useless papers removed

to Sort area/disposed off

Logging tagged items

Date Location

Item Description

Qty In working order

Obsolete

Not needed

Scrap/defective

14/09/10 A Power window switch

1 x

14/09/10 B Wiper motor 2 x

14/09/10 B Brake pad 2 x

16/9/10 C Tire pressure gauge

1 x

16/09/10 C Door mirror front 1 x

16/9/10 C Wheel alignment printer old model

1 x

16/09/10 C Starter pinion 1 X

16/09/10 D Door mirror front 1 x

16/09/10 D Work bench broken

1 x

16/09/10 D ½” DE spanner broken

1 x

Decision for Disposal

Sell scrap

Sell scrap

Return to stores

Return to special tools section

Sell scrap

Sell

recycle

sell scrap

Repair as standby

Sell scrap

Decisions on the tagged items

Store these items in a separate area

Task force can make a decision about disposing

off the item

Some person may express that a particular item

can still be used in future ‘Write a tentative date

of disposal on the yellow tag.

Red tagged items can be scrapped

Extra items or the one which will be definitely

required in future, are tagged green and can be

kept for use as needed.

Task force can make decisions as above in a

monthly meeting.

By following sort, the place will have only

necessary items.

5S-Step2 implementation.

Set in order (SEITON)

Wake up Sleeping Giants !!!!

Step 2:

SEITON (Set in order or straighten)

A place for everything and every thing in its place

Perform Daily walks to each station & watch

the employees work.

Take note of wasted movements, because

there would be something out of reach of

employees.

Regularly used items should be placed in a

central location accessible to all (like oil

filters, fuel filters.

All Service literature, manuals must be

available, labeled

Divide the areas into various sections, bays

and demarcate them with yellow lines.

In each bay, mark yellow lines for allocating

places for keeping work benches, trash box,

equipment , tool trolley.

Label each area as A,B,C,D and allocate each

area to one person

Tools must be put in place when not in use

All movable objects must have markings

for their locations

Machines and equipment must have all

parts in place(Safety)

Visual displays must be in place

All the tool trolleys to be cleaned and lined

up in a separate room at end of the day.

Arrange special tools in a shadow board,

label each tool and create a reference

sheet for each label and tool description

Visual examples of straightened workplace

A place for everything and every thing in its place-

A place for everything and every thing in

its place--contd

Fast moving items like oil filters, oil

cans, fuel filters, brake pads, bulbs

placed near the parts entrance for

quick reach to workers.

Bin nos. for

reference of parts

locations

Fast moving Parts ready for issue

before work starts ( Pre picked in

baskets)

Please follow the module 4