Module 3-5S
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This document provides instructions for implementing the first step ("Sort") of a 5S process. It describes tagging unwanted items and removing them to a sorting area to clean up workstations. Only necessary tools and supplies needed for work should remain. Tagged items are categorized by color codes and decisions are made about whether to store, scrap, or dispose of them. The goal is to only keep necessary items so the workspace is clean and efficient. Step 2 ("Set in Order") instructions involve arranging the workspace so everything has a designated place and common items are easily accessible to reduce wasted time and movements. Areas will be marked off and labeled, tools put away when not in use, and all parts and equipment kept in their proper places for safety and
Module 3-5S
- 1. 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
- 3. 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.
- 4. 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.
- 5. Managing tagged area See the tagged items. Can even paste the red tags if items are large
- 6. Unwanted obsolete equipment moved to sort area Result is a clean, efficient & pleasant work station Useless papers removed to Sort area/disposed off
- 7. Logging tagged items Date Loca tion Item Description Qty In working order Obsol ete Not need ed Scrap /defe ctive 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
- 8. 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.
- 9. 5S-Step2 implementation. Set in order (SEITON)
- 10. Wake up Sleeping Giants !!!!
- 11. 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
- 12. 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
- 13. 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
- 14. Visual examples of straightened workplace A place for everything and every thing in its place-
- 16. A place for everything and every thing in its place--contd
- 19. 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)
- 20. Please follow the module 4