APS-5S-DH-201012-01

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Author

Date

Version

APS Deployment Handbook

5S

A.Ressicaud

February 20

0

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What

Tool Defnition

How

Tool

implementation

5S Defnition

! "hat is your opinion#

! "hat is 5S# Sort

Set in order

Shine

Standardi$e

Sustain 2 main phases

%&erproduction

5S Game5S Implementation

! Preparin' the (orkshop

! "orkshop timin' indication

! st S sort

! 2nd S set in order

! )rd S shine

! *th S standardi$e

! 5th S sustain

+able o, -ontents

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5S De/nition"hat is your opinion#

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5S is an Organisation and Management Method whichcomes rom Japan and wich is symbolised by 5 words

!Seiri Sort

!Seiton Setn

%rder

!Seiso Shine

!Seiketsu Standardi$e

!Shitsuke Sustain

5S De/nition"hat is 5S#

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1. Sort

! lot o things are stored inthe wor"

area b#t are re$#ently not#sed

%his is a waste o space%hey dist#rb the &ow and

red#cethe e'ciency o the wor"place

Separate the #se#l rom the#seless

(liminate #nnecessary things

SORT

5S De/nitionS%R+

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)oo"ing or ob*ects is timespent witho#t any added+,al#e

-ed#ce the time wastedin thewor"place by logically placingand identiying all wor" items

%here is a place or e,erythingand e,erything m#st be in its

place

SET IN

ORDER

5S De/nitionS+ 3 %RDR

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Dirtiness. lea"s and d#st ha,e to becontrolledand eliminated

Ha,ing a clean wor"place is a step

towards contin#o#s impro,ement Organise cleaning acti,ities tomaintain cleanliness andto chec"e$#ipment #nctions

Grad#ally eliminate root ca#ses odirtiness

Obtain a permanent cleanliness

SHINE

5S De/nitionSH3

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%he res#lts achie,ed d#ring steps/.0. 1 m#st be maintained

2inalise and display simple and,is#al standards 3 r#les to ed#catepeople and detect any abnormality

4est practices6 determined in steps /.0. 1 are standardised7 !ny abnormalitybecomes apparent immediately

STANDARDIZE

5S De/nitionS+A3DARD6

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5. Sustain

S#stain the moment#m to maintainand impro,e the res#lts

In,ol,ement o the management tos#pport and monitor 8a#dits. $#ic"reaction. root ca#ses analysis9:

S#staining is needed to maintain thestandards7 ;ew habits and re&e

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SORT SET IN ORDER SHINE

STANDARDIZE SUSTAIN

CREATE THE CONDITIONS FOR A HIGH-

PERFORMANCE WORP!ACE

MAINTAIN AND IMPRO"E IT

5S De/nition5S 9 Remind t(o main phases

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Lets Do the 5S GAME

Lets Do the 5S GAME

5S :ame

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5S :ame+H -8RR3+ S+8A+%3

+ry to /nd the ri'ht number ;e

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5S :ame5S S%R+

Remo&e (hat is not a number ;letters>

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5S :ameS+ in %RDR

%r'ani$e the space to access lo'ically to the numbers

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5S :ameSH3? 3SP-+

S(eep the numbers

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5S :ameS+A3DARD6

Standardi$e the ,ormat to ease /ndin' the numbers

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5S :ameS+A3DARD 3%+ RSP-+D

+he situation deteriorates rapidly i, the standard is not res

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5S :ame5S S8S+A3

Here? ne( numbers ha&e been added? respectin' the stan

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5 #$% &1 '( 1)*

1*11 1% 1( 15 1' 1#1&1$ %)

%1

5 10

1)

%)

*)

()

sign

posts

%*%% %( %5 %' %#%&%$ *)

***1 *% *( *5 *'

5S :ame5S @ S8S+A3? PR%V

Here? the standard has been impro&edby orderin' the numbers in a more

&isual (ay

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5S :ameDo you (ant to 'o back as initially #######

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5S mplementationPreparin' the (orkshop

! Select a pilot area ;or areas>

De/ne the scope o, (orkshop and take some Bbe,oreC pictures o, the area

! denti,y a (orkshop o(ner

A person (orkin' in the area

! denti,y a (orkshop coach

Someone that (ill support and coach the (orkshop o(ner

! denti,y team members ake a picture o, the (hole team

! Discuss (ith the (hole team (hat you (ant to achie&e? and (hy? and by (hen

-apture data to describe the current situation ;space used? number&olume(ei'ht o,items? lost time? (alkin' reEuired? etc.>

! Set up a proect communication board ;see ne

"ith all the abo&e in,ormation? in the area o, the (orkshop

+he communication board has to display in the area

! Ha&e the responsible mana'er si'n the (orkshop proposal

! Set the schedule o, the (orkshop

! Set up the action sheet on the proect communication board

At the end o, each S? /ll the action sheet accordin' to the result o, checklist

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%he impro,ement wor"shop comm#nication board

Write project title (what?

where? why?)

Write down the project n, and the

method you are using (here: 5)

!e"ine the o#jecti$es o"

the project

%a&e a picture at the end o" the

project, and descri#e &ey

characteristics

'rac& results (eg, audit scores or

an *! per"ormance indicator)

+a$e the managers

sign o"" at the end

+a$e the managers

sign o"" at the start

!e"ine the project

schedule (5 phases)

%a&e a picture at the start o" the

project, and descri#e &ey

characteristics

ut a picture o" the

project team and their

names

What area-.one is the

project "ocused on

!escri#e the issue/ist each meeting

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%he action sheet (Template APS-19-TP2)

What is your

organi.ational entity?

ut the date that

you wrote down the

action

!escri#e the action you

ha$e to ta&e to eradicate

the issue or answer the

need

Write down any notes made during

chec& acti$ity

'rac& progress (action planned,

done, chec&ed-$eri"ied and

possi#ly acted upon poor uality or

lateness o" the action)

When was it actually

done?

When does it need to

#e done?

Who is responsi#le

"or the action?

!escri#e the issue or

need

ndicate the team or

area-.one

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5S mplementation"orkshop +imin' indication

%he deployment in prod#ction and administrati,e areas canbe done #sing this typical time+phased plan

Sort S+t in

Or,+r Sin+

Stan,ar-

,i+Sustain

W/ 1 W/ % W/ * W/ ( W/ 5 0

W/ 1 W/ % W/ * W/ ( W/5 0

Pro,ution

O22i+

1 % * ( 5

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5S mplementation+he st S9 Sort

ssue

! "e ha&e many items in the (orkplace that are unnecessary orat least not reEuired now

%becti&e

! -reate a (ork place (here only the currentlyreEuired itemsare present

Ho(#

! Remo&e all nonnecessary items ,rom the (orkplace

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G#idelines = 4-ed %ag Strategy6

! :o throu'h all items in the area

! denti,y unnecessary items by ta''in' ;BPost tC can be used>

! Andor separate them physically

Put unnecessary redta''ed items in a Euarantine area i, theycannot ust be thro(n a(ay directly

Put yello(ta''ed items in a central area ,or later decision ;date tobe de/nedG>

%nly nonta''ed items stay in the area and 'o to ne

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(

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%he $#arantine areabeore97

%he area $#arantineater>


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Sort ?hec"list

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5S mplementation+he 2nd S9 Set in %rder

ssue

! tems are not al(ays in a 'ood place considerin' ho( (e usethem? or dicult to /nd

%becti&e

! A place ,or e&erythin'? and e&erythin' in its placeHo(#

! Put all reEuired items in a 'ood place in your (ork place

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G#idelines

! "here should locate the item #

Related to its use #

! Al(ays store items in the same place @ use labelin' and $onin'

! Sort items by ,reEuency o, use

! Ieep ,reEuently used items close and in reach

! 8se sprin' balancers (ith tools on retractable cords

! Store tools in the seEuence o, use

! Store parts pre,erably in ,ront o, operator ;Pointo,8se>

! Assure parts (ill be used FF% (hen stored ;usin' Jo( racks so that

'ra&ity (ill do the ob? and not the operator>! -are,ully think o, the (aste o, mo&in' and transport? and er'onomics

in positionin' and handlin' items

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G#idelines

! "here should locate the item#

+akin' into account sa,ety#

! 3o cables and pipin' on the Joor or in (ay

! ase o, access reEuired ;and e&acuation>#

! Ieep passa'e(ays clean and empty

-onsiderin' its si$e and (ei'ht#

! Hei'ht in relation to si$e(ei'ht and reachin'li,tin'

n order to maintain its Euality#

!+o pre&ent dust and particles on parts and eEuipment

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@oning e

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Set in Order

?hec"list

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5S mplementation+he )rd S9 Shine

ssue

! "hen you need certain items? they are not al(ays in 'oodcondition or order? and ready ,or use

%becti&e

! Assure all items are in 'ood condition and ready ,or useHo(#

! -lean? inspect and possibly repair the items in your (ork place

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G#idelines on cleanliness

! De/ne rules to'ether

"hat is clean#

"hy the eEuipment is not clean? ;cause o, dirtiness>

Ho( to reco&er the aspect o, a K ne( eEuipmentM#

"hat state should eEuipment be in#

! Fluid le&els# S(itches#

! ake standards as &isual as possible

ake pictures

Put in place &isual si'ns Display standards in the respecti&e area

nclude checklists ,or key points to be checked

! Ho( to react (hen de&iations ,rom the standard (ill beidenti/ed ;prede/ned action and o(ner>#

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l i

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S l i

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Shine

?hec"list

5S l i

2 ) * 5 4

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5S mplementation+he *th S9 Standardi$e

ssue

! n the area? (e do not ha&e a re,erence o, (hat the (orkplaceshould look like? so it is dicult to ud'e (hether thin's are asthey are supposed to be

%becti&e

! Pro&ide a clear description o, (hat the (orkplace should looklike

Ho(#

! -apturin' and pro&idin' standards ,or the (orkplace

2 ) * 5 4

5S l t ti 2 ) * 5 4

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StandardiAation principles e

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G#idelines on locationBorderliness = 4Signboard Strategy6

! All si'nboards and labels should at all times indicate9

"hat @ "here @ Ho( any#

! 8se color codin' and color consistency in labelin' items andtheir respecti&e locations

! Si'nboards should be linked to the $onin' strate'y

! Si'nboards should link to maps a&ailable in the areas to beable to Euickly /nd areas and items

2 ) * 5 4

5S l t ti 2 ) * 5 4

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G#idelines on locationBorderliness

! denti,y all areas

-reate an address system ;like a city map usin' streets? blocks?and address numbers>

denti,y areas (ith &isible address locations or identi/cation ;incl.

color codin'>

Pro&ide inde< map o, total area at the entry o, the area and linkedto them? pro&ide routines and plannin' ,or cleanness

! -reate &isual standards

8se shado( boards or Boutlinin'C to con/rm correct location o,

items 8se Bseethrou'hC cabinets

8se photos to e

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2 ) * 5 4


2 ) * 5 4

5S l t ti

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2 ) * 5 4


2 ) * 5 4

5S l t ti

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2 ) * 5 4


2 ) * 5 4

5S mplementation

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5


2 ) * 5 4

5S mplementation

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Also in your oceG


sa,o6 ;oar, +=a79+

5S mplementation 2 ) * 5 4

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Also in your oceG


StandardiAe

?hec"list

5S mplementation

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5S mplementation+he 5th S9 Sustain

ssue

! 3iceO but ho( do (e make sure it (ill stay like this#

%becti&e

! -ontinuously maintainin' and impro&in' upon the (orkplace

standardsHo(#

! n&ol&in' and moti&atin' all people in the site in continuouslyassurin' the standard is applied @ sel,control and autonomy;obecti&es @ re'ular audits and daily actions>

5S mplementation

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G#idelines

! Pro&ide 5S status and pro'ress insi'ht in area

5S A(ard (ith team competition

aintain audit records in area

5S mplementation

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Manager 8#p to the ?(O: sho#ld set the e

! %ce 5S is reEuired in parallel applyin' e

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! Durin' the proect? eachstep (ill be &alidated byan audit ;5>

! A,ter the proect? the ,ollo(up o, the proect (ill bedone trou'h sel,assessment andsur&eillance audits ;i'htcross audit>


5S mplementation

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S#stain

?hec"list

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