Super 5S is for Everyone

72

The Structure of Part 4:

• Twelve Focal Points Super 5S Auditors Should Examine

• Rules for Participation in Super 5S Inter-Departmental Competitions (four

pages)

• A Super 5S Evaluation Form for Factory / Operation Site

• A Super 5S Evaluation Forms for Office

• A Super 5S Evaluation Summary

• 5S Guidance Stickers (here is a need for Seiri, Seiton or Seiso)

• 5S Guidance Stickers (here is an excellent example of 5S practice)

• Ten Useful Hints for Winning Super 5S Competitions

• Passport to Successful 5S - pages 1 and 4

• Passport to Successful 5S - pages 2 and 3

5S5S

How to Audit and GuideHow to Audit and GuideHow to Audit and GuideHow to Audit and Guide

SUPERSUPERSUPERSUPER5S 5S 5S 5S ActivitiesActivitiesActivitiesActivities

PARTPARTPARTPART 4 4 4 4

73

A 5S audit is conducted according to the method of Super 5S inter-departmental competitions.

Auditors evaluate and record each department’s level of 5S practiceaccording to its achievement in the six major objectives of Super 5Sprogram: Productivity, Quality, Cost, Delivery, Safety and Morale.

Auditors may use the Super 5S evaluation forms (for factory / operationsites and offices).

The method for filling out the Super 5S evaluation forms is described in therules for participating in Super 5S inter-departmental competitions.

Twelve Focal Points Super 5S Auditors Should ExamineTwelve Focal Points Super 5S Auditors Should Examine

l Do the CEO and managers support Super 5S program?

l Are people proud of their workplaces?

l Are workplaces clean and organized?

l Are workplaces safe for people to work in?

l Are machines and equipment clean and well maintained?

l Are items easy to retrieve?

l Are machines and tools conveniently located?

l Are inventories stored for FIFO retrieval?

l Are products free from dust?

l Do people clean daily without prompting?

l Are the uniforms worn by people clean and tidy?

l Is a good image of the enterprise reflected in its people?

74

materials / partswork-in-processfinished productsdefective / rejectsmachines / equipmentwiring / pipingdies / tools / jigsspare parts / lubricantscontainers / palletsracks / shelves / cabinetscarts / wagons / forkliftslifts / conveyers / cranesdesks / tables / chairsforms / files / recordsfloors / passages / stairwayswalls / windows / ceilinglighting / ventilationworking wears / shoessafety devicesfire extinguishers / fire exitscleaning tools / waste basketscanteens / toilets / lockersexternal areas / gardenssecurity guards / car parks

are they conveniently located and labeled for easy retrieval?are they conveniently located for easy handling?are they conveniently located and labeled for easy retrieval?are they clearly labeled for separation from good items?are they clean, safe, well-maintained and convenient to operate?are they laid out in a tidy, safe and convenient manner?are they conveniently labeled and placed at designated locations?are they conveniently labeled and placed at designated locations?are they clean and conveniently placed at designated locations?are they dust-free, tidy and conveniently labeled for items stored?are they well-maintained and placed at designated locations?are they clean, tidy, safe and well-maintained?are they clean and organized inside and outside?are they up-to-date, easy to retrieve and at convenient locations?are they dust-free, tidy, safe and well-maintained?are they dust-free, tidy, safe and well-maintained?are they adequate for efficient operation?are they clean and do they present a good image?are they conveniently located for use and well-maintained?are they adequate and cleaned regularly?are they clean, tidy and well-maintained?are they clean, tidy and well-maintained?are they clean, tidy, safe and do they present a good image?are they clean, tidy, safe and do they present a good image?

TOTAL SCORE (a)

ADJUSTED SCORE = (a) / (b) x 10

BONUS SCORE FOR SUPER 5S PRACTICE

FINAL SCORE

NO. OF ITEMS EVALUATED (b):

AUDITOR: DATE:

COMMENTS FOR IMPROVEMENT:

ITEM FOCUS SCORE

SUPER 5S PRACTICE IDENTIFIED:

SUPER 5S EVALUATION FORM - FACTORY / OPERATION SITE DEPARTMENT:

20 15 10 5 0

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10 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 2

Rules for Participating in Super 5S Inter-Departmental Competitions - 1Rules for Participating in Super 5S Inter-Departmental Competitions - 1

1. Objectives

Proposed competitions are aimed at improving the organization stotal productivity through everyone s participation in the Super 5Sprogram.

Qualification for Participation

Any department which is implementing 5S on a certain level is eligiblefor participation.

3. Competition Period

Each competition will be organized for a period of 6 months, two timesa year on a continuing basis.

4. Auditing Team

An auditing team appointed by the Super 5S Steering Committee willvisit each competing department and evaluate its Super 5S activities atthe end of each competition period.

5. Super 5S Evaluation Forms

One of the following Super 5S Evaluation Forms will be used by theauditors according to the function of the participating departments:

75


(a) Super 5S Evaluation Form - Factory / Operation Site

(b) Super 5S Evaluation Form - Office

6. Evaluation

1) Two Aspects of the Evaluation

Evaluation scores will be recorded by each auditor in two aspects ofSuper 5S activities for each participating department:

(a) Scores on the 5S Level Achieved

(b) Scores on the Super 5S Practice Identified

2) Evaluation on the 5S Level Achieved

Each auditor is expected to mark his score on each itemized questionlisted on the form and enter the added total score in the space TOTALSCORE (a). ADJUSTED SCORE (maximum 100) will be obtained by thethe following formula:

ADJUSTED SCORE = TOTAL SCORE (a) / NO. OF ITEMS EVALUATED(b) x 10



TOTAL SCORE (a)



FINAL SCORE


AUDITOR: DATE:


ITEM FOCUS SCORE



20 15 10 5 0

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101112131415161718192021222324

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76



TOTAL SCORE (a)



FINAL SCORE


AUDITOR: DATE:


ITEM FOCUS SCORE



20 15 10 5 0

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3) Evaluation of the Super 5S Practice Identified

Each auditor is also expected to look for Super 5S practice(s)implemented in each department, and give an additional score tosuch good practice(s) according to it(s) value(s) in the space BONUSSCORE FOR SUPER 5S PRACTICE(S) provided on the form(maximum 20).

4) Final Score

The ADJUSTED SCORE (for 5S level achieved) and the BONUSSCORE FOR SUPER 5S PRACTICE(S) are totaled and become theFINAL SCORE (maximum 120).

5) Auditor s Explanation on Super 5S Practice(s) Identified

Each auditor should explain his reason(s) for awarding a BONUSSCORE in the space SUPER 5S PRACTICE(S) IDENTIFIED.

6) Auditor s Comments for Future Improvement

Each auditor is advised to state his comments for future improvementsuggested in the space COMMENTS FOR IMPROVEMENT.

77


7. Awarding

With better results and psychological effects in mind, theimplementing organization should work out an awarding method thatcan encourage, but not discourage, the participating colleagues anddepartments toward intended objectives.

IMPROVE YOUR PRODUCTIVITYIMPROVE YOUR PRODUCTIVITY

THROUGH 5S ACTIVITIESTHROUGH 5S ACTIVITIES

IN 5S INTER-DEPARTMENTAL

COMPETITION

PRODUCTIVITY AWARDPRODUCTIVITY AWARD

FORFOR

BEST WINNER 1997BEST WINNER 1997

Congratulations!

78

Enlarge this form to A4 size.



TOTAL SCORE (a)



FINAL SCORE


AUDITOR: DATE:


ITEM FOCUS SCORE



20 15 10 5 0

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79


20 15 10 5 0

TOTAL SCORE (a)



FINAL SCORE


AUDITOR: DATE:

COMMENTS FOR IMPROVEMENT:SUPER 5S PRACTICE IDENTIFIED:

desks / tables / chairscabinets / shelvesdocuments / filesforms / office suppliestelephonesfacsimilestypewriters / word-processorscomputers / monitorsprinterscopying machineselectric wiringlighting / ventilationfloors / walls / windows / ceilingfire extinguishersemergency exitssafety devicesworking clothes / shoeswaste baskets

are they tidy and conveniently organized?are they clean and labeled for the easy retrieval of things needed?are they clean and systematically organized?are they tidy and conveniently stored for retrieval?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?are they clean and well-maintained?Is it tidy, safe and conveniently laid out for operation?are they adequate for efficient operation?are they dust-free and well-maintained?are they adequate and well-maintained?are they adequate and clear of obstacles in case of emergencies?are they adequate and well-maintained?are they clean and do they present a good image?are clean and well-maintained?

ITEM FOCUS SCORE

SUPER 5S EVALUATION FORM - OFFICE DEPARTMENT:

10 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 210 8 6 4 2

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80


DEPARTMENT DATE OF AUDIT ADJUSTED PT. SUPER 5S PT. TOTAL PT. AUDITORRANKING

SUPER 5S EVALUATION SUMMARY ORGANIZATION: DATE:

81

Three kinds of stickers in different colors for SEIRI (red), SEITON (blue)and SEISO (green) are used respectively by the 5S auditor for correctiveactions as illustrated below:

Here is a need forHere is a need for

SEIRISEIRI


SEIRISEIRI


SEIRISEIRI


SEIRISEIRI


SEIRISEIRI


SEITONSEITON


SEITONSEITON


SEITONSEITON


SEITONSEITON


SEITONSEITON


SEISOSEISO


SEISOSEISO


SEISOSEISO


SEISOSEISO


SEISOSEISO


SEITONSEITON


SEITONSEITON


SEITONSEITON


SEITONSEITON


SEITONSEITON

When the auditor identifies a

place in need of 5S Kaizen,

paste an applicable sticker to

the specific location for action

by the individual or group in

charge. In these examples,

stickers for SEITON are

applied.


SEITONSEITONK.T.

6/16/97

6/16/97

6/16/97

82

Here is anHere is an

Excellent ExampleExcellent Example

of of 5S5S PracticePractice

























The sticker for congratulation is used by the 5S auditor when he identifies a

Super5S practice as shown below:

here is anhere is an



K.T.K.T.

6/16/976/16/97

83

Seven Categories of Waste:

1) Waste arising from overproduction

2) Waste arising from defects

3) Waste arising from waiting time / delays

4) Waste arising from the accumulation of work-in-process

5) Waste arising from transport

6) Waste arising from process

7) Waste arising from unnecessary motions or actions

If you make a thorough analysis into the origin of these categories of wasteand practice Super 5S so as to eliminate this waste, you will reduce costsand improve productivity.

Ten Useful Hints for Winning Super 5S CompetitionsTen Useful Hints for Winning Super 5S Competitions

l Two heads are better than one - try brainstorming.

l Look for inconvenient areas to improve.

l Look for disorganized areas to improve.

l Look for unsafe areas to improve.

l Look for dirty or untidy areas to improve.

l Look for seven categories of waste to eliminate.

l Clean the surface of machines extensively.

l Pay more attention to common areas including

canteens, toilets, gardens, external passages and car

parks.

l Show evidence that more colleagues are involved in

Super 5S activities.

l Make your Super 5S practices more visible.

84

Copy this on one side of the paper and copy the next page on the reverseside, to make a handy 5S manual.

What is 5S?

Sort and discard unnecessary items in the

workplace.

Arrange necessary items so that they caneasily be selected for use.

Clean your workplace completely so that

there is no dust on the floors, machines or

equipment.

Keep one s workplace productive and

comfortable by repeating Seiri-Seiton-

Seiso.

Train people to follow good work habits.

Seiri:

Seiton:

Seiso:

5S Contributes to PQCDSM

Productivity - increased competitiveness

Quality - no defects

Cost - no waste

Delivery - no delays

Safety - no accidents

Morale - good teamwork

STEP 1

Seiri 1

Seiton 1

Seiso 1

Seiketsu 1

Shitsuke 1

Keep onlynecessaryitems

Assign itemsa place.

In eachsection cleanone machinewell

Create acleanworkplace

STEP 2

Seiri 2

Seiton 2

Seiso 2

Seiketsu 2

Shitsuke 2

Do not putanything onthe floor

Make neededitemsaccessible

Increase thenumber ofcleanmachines

Create acomfortableworkplace

STEP 3

Seiri 3

Seiton 3

Seiso 3

Seiketsu 3

Shitsuke 3

Separate workareas frompassageways

Reducesearchingtime


Create ahealthy andsafeworkplace

STEP 4

Seiri 4

Seiton 4

Seiso 4

Seiketsu 4

Shitsuke 4

Create morespace foreffective use

Reducewalkingdistances

Keep all themachinesclean andshiny

Create ahighlyproductiveworkplace

Discardunnecessaryitems moreoften

Arrangeitems by typeand size-

Select amachine andclean itcompletely

Clean one s

workplacedaily

Use wagonsto transportitems-

Removeobstaclesaroundneeded items

Use moreconvenientcleaningtools

Set up acleaningschedule

Draw lines toseparatepassagewaysfor people

Use labels tosimplifyretrieval-

Preventmachinesfrom gettingdirty

Eliminatehazards

Reduceexcessinventory-

Placefrequentlyused itemsclose by

Combinecleaningwithinspection

Introducecreativethinking

T

A

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G

E

T

S

A

C

TI

O

N

S

4 1

Seiketsu:

Shitsuke:

How to do 5S Step by Step PASSPORT TO SUCCESSFUL 5S

5S is fundamental to productivity improvement

85

Copy this on the reverse side of a copy of the previous page, to make ahandy manual.

1

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checkpointsscore score

The 5S Activity Bulletin Board is well-

organized and data are updated

The locations for materials, components and

work-in-process are labeled for easy retrieval

Dies, jigs, fixtures and tools are conveniently

located so that there is no need to search

Bolts, nuts, components and other materials

are not kept on the floor

Passages and operation areas are clearlyindicated and separated by distinct lines

Failures found are immediately fixed (uneven

floor, projections, machine failures, etc.)

Areas difficult to clean are cleaned

periodically

Without searching tools or documents can be

retrieved in less than 30 seconds

Rules for 5S practice are implemented and are

observed without prompting

A 5S patrol is regularly conducted by

supervisors for continued improvement

5S inspections are practiced and recorded at

starting and closing times

Jigs and tools are easy to return to theirdesignated locations

Dirt and stains on machines are removedimmediately

Things that cause dirt or stains are eliminated

-

Tools and measurement devices are

periodically checked and failures are fixed

People are active in implementing Kaizen for

the improvement of safety, quality and cost

Violators of rules are warned by colleagues

-

Components, tools and documents are labeled

and easy to retrieve

Rules are strictly observed (punctuality,

cleaning at the end of the day, etc.)

5S is well maintained and upgraded throughcreative activities

checkpoints

Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1 Score: Satisfactory - 5 Tackled - 3 Not Tackled - 1

Checklist for Step 3 Checklist for Step 4 3

86

SUPERSUPER5S5S Practices Practices

A Collection ofA Collection of

PhotographsPhotographs

IllustratingIllustrating

PARTPARTPARTPART 5 5 5 5

The Structure of Part 5:

• Photographs Taken at 4 Model Organizations in Singapore

• Photographs Taken at 9 Model Organizations in Thailand

1 2 3 4 5 6 7 8 9 101112

HE�E �� HE�E �� HE�E �� HE�E ��

E�� E��E�� E��E�� E��E�� E��

�� 5S5S5S5S ��

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CHECKNORMAL STOP

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TOOLS AFTER USE

TOOLS IN USE84

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Postscript

Have you decided to implement the program of Super 5S? It is a matter of

course that before participating in this program you must prepare elaborate

plans (preparations and plans) according to the cycle of management (plan,

do and see). At this stage, since seeing is believing, a very effective

approach to success would be to visit or organize study tours to model

Super 5S companies and exchange information with those involved in

implementing Super 5S activities.

As I said before, since 1986 I have had the experience of guiding 5S

activities in many countries for about ten years. During this time I have tried

to improve this book to make it easier for non-Japanese to understand. The

title of this book has changed according to these revisions as follows:

1986: How to Implement 5S Activities in Your Organization

1990: Introduction to Advanced 5S Activities

1995: Introduction to Super 5S Engineering

1997: Super 5S is for Everyone

The reason I have lately added super is that I intend to make the program

surpass the generally understood level of 5S. I want to indicate to those

involved in 5S practices the objectives and substance of being more and

more creative, being more human and contributing more to productivity.

The EndThe EndThe EndThe End of the of the of the of the

PresentationPresentationPresentationPresentation

Thank You Very MuchThank You Very MuchThank You Very MuchThank You Very Much

for Your Participationfor Your Participationfor Your Participationfor Your Participation

Kazuo TsuchiyaKazuo TsuchiyaKazuo TsuchiyaKazuo Tsuchiya

133

What is 5S?


workplace.

Arrange necessary items so that they can

easily be selected for use.



equipment.

Keep one’s workplace productive and


Seiso.


Seiri:

Seiton:

Seiso:




Cost - no waste




STEP 1

Seiri 1

Seiton 1

Seiso 1

Seiketsu 1

Shitsuke 1





STEP 2

Seiri 2

Seiton 2

Seiso 2

Seiketsu 2

Shitsuke 2





STEP 3

Seiri 3

Seiton 3

Seiso 3

Seiketsu 3

Shitsuke 3


Reducesearchingtime



STEP 4

Seiri 4

Seiton 4

Seiso 4

Seiketsu 4

Shitsuke 4








Clean one’sworkplacedaily








Eliminatehazards





T

A

R

G

E

T

S

A

C

TI

O

N

S

4 1

Seiketsu:

Shitsuke:



What is 5S?


workplace.

Arrange necessary items so that they can

easily be selected for use.



equipment.

Keep one’s workplace productive and


Seiso.


Seiri:

Seiton:

Seiso:




Cost - no waste




STEP 1

Seiri 1

Seiton 1

Seiso 1

Seiketsu 1

Shitsuke 1





STEP 2

Seiri 2

Seiton 2

Seiso 2

Seiketsu 2

Shitsuke 2





STEP 3

Seiri 3

Seiton 3

Seiso 3

Seiketsu 3

Shitsuke 3


Reducesearchingtime



STEP 4

Seiri 4

Seiton 4

Seiso 4

Seiketsu 4

Shitsuke 4








Clean one’sworkplacedaily








Eliminatehazards





T

A

R

G

E

T

S

A

C

TI

O

N

S

4 1

Seiketsu:

Shitsuke:



134

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Passages and operation areas are clearly

indicated and separated by distinct lines



Areas difficult to clean are cleanedperiodically









Jigs and tools are easy to return to their

designated locations

Dirt and stains on machines are removed

immediately


-






-





5S is well maintained and upgraded through

creative activities

checkpoints



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5

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7

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10

2










Passages and operation areas are clearly

indicated and separated by distinct lines



Areas difficult to clean are cleanedperiodically









Jigs and tools are easy to return to their

designated locations

Dirt and stains on machines are removed

immediately


-






-





5S is well maintained and upgraded through

creative activities

checkpoints



135

1

2

3

4

5

6

PHASE PREPARATION PENETRATION AND ADVANCEMENTSTEP

SUPER 5S PROGRESS CHART FOR TWO-YEAR MASTER IMPLEMENTATION PLAN

MONTH

MAINTENANCE AND UPGRADING

Preparations* Understanding philosophy and benefits of Super 5S by CEO* CEO s visit to Super 5S model companies* CEO s commitment to Super 5S implementation

* Organize Super 5S Working Committee* Appoint Super 5S facilitators* Train Super 5S facilitators and practitioners

CEO s Official Announcement

* CEO officially announces implementation of Super 5S for 2 years

* CEO explains objectives of Super 5S program to all colleagues* Publicize Super 5S organization and assignments by area* Promote Super 5S with banners, posters and newsletters* Organize basic Super 5S training programs for all colleagues

Big Cleaning by All Colleagues* Organize a full-day of Big Cleaning Day twice a year

* Organize small groups who are responsible for assignments in dividedareas of the company s premises.

* Provide enough cleaning tools and materials* Implement a company-wide big cleaning for one day* Big cleaning includes the elimination of unnecessary items and wastes

Initial Seiri* Establish a Disposal Standard for unnecessary items* Organize a full-day of Seiri activity twice a year

* Everyone concentrates to identify and stratify unnecessary items forelimination* Unnecessary items that cost a lot should be evaluated so as to preventthe occurrence of such waste

Daily Seiri, Seiton and Seiso* Seiri: Throw away things that are not needed and not being used* Seiton: Improve locations and methods for storing things so that

searching time is minimized* Seiso: Set up a daily cleaning schedule for the creation of a healthy andcomfortable workplace

* Motivate colleagues to come up with creative improvements

Periodic Audits on Super 5S* Establish a Super 5S evaluation and incentive plan

* Conduct a Super 5S audit regularly by auditors* Organize a Super 5S inter-departmental competition for upgrading* Award groups and individuals for their contributions

* Organize study tours to other companies doing Super 5S* Organize Super 5S inter-company competition to sustain the program

SUPER S PROGRAMS

FROM / / TO / /

Super 5S is for Everyone

Documents

super 5s inter

super 5s activities

increased competitiveness quality

discard unnecessary items

removed immediately things

5s level achieved

closing times jigs

items assign items