What is 5S?

"5S" is the abbreviation of the five words Seiri, Seiton, Seiso, Seikeetsu and Shitsuke. Because the first letter of the Roman pinyin of these five words in Japanese is "S", they are called "5S" for short. Activities with the content of sorting, rectifying, cleaning, cleaning and literacy are carried out, which are called "5S" activities.

The "5S" activity originated in Japan and is widely implemented in Japanese companies. It is equivalent to the civilized production activities carried out by Chinese companies. The object of "5S" activities is the "environment" of the site. It comprehensively considers the overall environment of the production site and formulates practical plans and measures to achieve standardized management.

In recent years, with the entry of more and more Japanese, Hong Kong and Taiwanese companies, "5S management" has gradually been understood by the Chinese people and has blossomed in some domestic companies.

The purpose of implementing 5S

Remarkable results have been achieved in improving the production site environment, increasing production efficiency, ensuring product quality, creating a corporate management atmosphere, and creating a good corporate culture:

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Enhance the corporate image and create a neat and clean working environment to make customers confident; due to word-of-mouth spread, they will become the objects of learning

Enhance employees' sense of belonging and everyone becomes well-educated; employees learn from the little things around them Get a sense of accomplishment from changes; be easy to show love and patience to your work

Improving efficiency. Place items in an orderly manner, so you don’t have to spend time looking for them; have a good working mood.

Guaranteeing quality: Employees develop a culture of being particular about work, and quality is naturally guaranteed; machine and equipment failures are reduced.

Reduce waste. Reduce waste in the place, saving space and time.

Consulting project goals

To enable enterprise employees to master the knowledge and implementation requirements of 5S;

To guide enterprises to implement 5S in relevant links and achieve the expected results;

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Guide enterprises to complete the construction of 5S related systems, so that enterprises have the ability to carry out 5S on their own.

Consulting implementation steps

Investigation of the current situation of the enterprise;

Training of 5S related concepts and knowledge;

Developing relevant 5S systems;

Promote 5S systems and activities;

Guide the implementation, promotion and supervision of 5S;

Publish project results and improve 5S related systems;

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Project summary.

5S Implementation Manual

Preface

People all have ideals.

The ideal of employees in an enterprise is to have a good working environment and a harmonious management atmosphere. 5S creates a safe, comfortable and bright working environment and enhances the true, kind and beautiful qualities of employees, thereby shaping a good image of the company and realizing the common dream.

In order to cooperate with the widespread 5S movement in the factory, the "Employee 5S Activity Manual" has been specially compiled. The manual introduces the definition, purpose, effectiveness, implementation essentials and significance of 5S in a relatively detailed manner, which is instructive. . To this end, we sincerely hope that all employees will study this manual diligently, understand it, practice it regularly, and continue to standardize their daily work step by step and persevere, so as to promote 5S activities to become "formalized---actual---habitual" Evolution, laying a solid foundation for the steady development of the factory.

1. What is 5S

5S is the five items of SEIRI, SEITON, SEISO, SETKETSU and SHITSUKE. The Roman pinyin of all numbers begins with "S", abbreviated as 5S. In factories that have not implemented 5S, you can easily feel the mess in the workplace. For example, the floor is covered with garbage, oil stains or chips, which will form a dirty layer over time. Parts and boxes are randomly placed, and cranes or trolleys are used. Navigate in tight spaces.

Another example is that the latest equipment that was finally introduced was not maintained, and after a few months, it turned into a defective machine. It was not known where to put the tools, fixtures, measuring instruments, etc., which showed that A dirty and messy scene. Employees seemed to be lax in their work, and the prescribed matters were only followed in the first two or three days. To change the face of such a factory, implementing 5S activities is most suitable.

2. The definition and purpose of 5S

1S-Organization

Definition: Distinguish between necessary and unnecessary things. In the workplace, except for things that are needed, everything is Do not place them

Purpose: to free up "space" and put it to good use

2S-Organization

Definition: The required things are placed neatly according to the prescribed position and method. Clear quantities and clear markings

Purpose: Not to waste "time" looking for things

3S-Cleaning

Definition: Remove dirt in the workplace and prevent contamination The occurrence of Institutionalize and standardize the practice and maintain its results

Purpose: To maintain the results through institutionalization

5S-Literacy

Definition: Cultivate civilized and polite habits and follow regulations Act and develop good working habits

Purpose: to improve "human quality" and become a person who is serious about any work

3. The effectiveness of 5S

The five major functions of 5S can be summarized as:

The five Ss, namely: Sales, saving, safety, standardization, satisfaction

1. 5S is the best salesman (Sales) ?It is praised by customers as a clean and tidy factory. If you have confidence in such a factory, you are willing to place orders and spread the word. Many people will come to the factory to visit and learn?.A clean and clear environment will make everyone want to work in such a factory

2. 5S is Saving. It reduces the waste of many unnecessary materials and tools, reduces the waste of "searching", and saves a lot of precious time. It can reduce working hours and improve efficiency

3. 5S guarantees safety (Safety)? A broad and bright workplace with a wide field of vision, where the flow of goods is clear at a glance? Comply with accumulation restrictions, and dangerous places are clear at a glance? The aisles are clear and will not cause clutter and affect the smoothness of work

4. 5S is the promoter of standardization (Standardization)? The principle of "3 fixed" and "3 elements" regulates on-site operations? Everyone performs tasks correctly and in accordance with regulations? Stable procedures bring stable quality and stable costs

5. 5S forms a satisfactory workplace (Satisfaction)? A bright and clean workplace? Employees have a sense of accomplishment by making improvements by themselves? An atmosphere that can create an atmosphere for all on-site personnel to improve

IV , Implementation steps (omitted)

5. Implementation essentials

(1) Organized implementation essentials:

1. Conduct a comprehensive inspection of the workplace (scope), Including visible and invisible items

2. Establish the criteria for judging [necessary] and [unnecessary]

3. Removal of unnecessary items

4. Investigate the frequency of use of necessary items and determine daily usage

5. Daily self-examination

Waste caused by not sorting

1. Waste of space

2. The waste of using scaffolding or cabinets

3. The waste of parts or products that become old and unusable

4. The storage space becomes narrow

5. The waste of managing even unnecessary things

6. The waste of time spent on inventory management or inventory

(2) Essentials for the implementation of rectification

1. The finishing work in the previous step must be implemented

2. The required items must be placed in a clear place

3. Place them neatly and orderly

4. Floor marking and positioning

5. Marking of places and items

6. Develop waste disposal methods

Key points:

● The result of the reorganization should be a state where everyone can immediately take out what they need

● It should be seen from the perspective of newcomers and other people in the workplace, so that it is easier to put things where. To be clear

Correct

● Find a way to make the item available for immediate use

● In addition, it should be easy to return to its original position after use, so that you can know immediately if there is no reply or misplacement

(3) Cleaning implementation essentials:

1. Establish cleaning responsibility areas (indoor and outdoor)

2. Start a company-wide cleaning

3. Clean every place

4. Investigate sources of pollution and eliminate or isolate them

Establish cleaning standards as standards

● Cleaning is to use The workplace should be free of garbage and dirt. Although it has been sorted and tidied, and the things you need can be obtained immediately, the things taken out must be in a state that can be used normally. Achieving such a state is the first purpose of cleaning, especially when the current emphasis is on the manufacturing of high-quality, high-value-added products, and contamination by garbage or dust is not allowed to cause product defects.

(4) Cleaning implementation essentials:

1. Implement the first 3S work

2. Establish the benchmark for visual management

3. Formulate 5S implementation methods

4. Formulate audit methods

5. Formulate reward and punishment systems and strengthen implementation

6. Senior supervisors often take the lead in inspections, Drive all employees to pay attention to 5S activities.

● Once a 5S activity starts, it cannot become ambiguous midway. If it cannot be implemented to the end, another stain will be formed, and this stain will also create a conservative and rigid atmosphere in the company. [Everything our company does is done halfway] [It won’t succeed anyway], [Just deal with it]

●To break this conservative and rigid phenomenon, we can only spend more time to correct it.

(5) Essentials for promoting literacy

1. Develop identification standards for clothing, armbands, work caps, etc.

2. Develop relevant company rules and regulations

3. Formulate etiquette codes

4. Education and training

5. Promote various incentive activities

6. Comply with rules and regulations

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7. Routine greetings and polite exercises

6. Check points:

1. Are there any items of unknown purpose?

2. Yes There are no items with unknown contents

3. Are there any idle containers or cartons?

4. Are there any unnecessary items?

5. Are there any materials under the conveyor belt? Are there any items placed under the shelves?

6. Are there any personal belongings placed randomly?

7. Are there any items placed on the passage?

8. Are the items placed parallel or at right angles to the passage? 9. Are there any deformed packaging materials such as packaging boxes? 10. Are there any damages to the packaging boxes (damaged containers)? p>

11. Are tools, fixtures, measuring instruments, etc. placed in the designated locations?

12. Are they easy to move?

13. Are there any objects placed behind or on the shelf?

14. Are the items in the shelves and storage boxes placed according to the marked items?

15. Are the dangerous goods clearly marked, and are the fire extinguishers regularly inspected?

16. Are there scattered parts at the operator’s feet

17. Are the same parts scattered in several different places

18. Around the operator Are there more than necessary items (tools, parts, etc.)?

19. Are parts kept everywhere in the factory?

7. Classification criteria of "must" and "no" for sorting Example

(1) Requirements

1. Normal equipment, machines or electrical devices

2. Ancillary equipment (sliding table, workbench, material rack)

3. Trolleys, carts, stackers

4. Tools in normal use

5. Normal work chairs and benches

6. Consumable supplies that still have use value

7. Raw materials, semi-finished products, and finished products

8. Scrap materials that still have use value

9. Pads, plastic frames, dust-proof supplies

10. Trash cans and garbage bags in use

11. Samples in use

12. Office supplies and stationery

13. Cleaning supplies in use

14. Posters and billboards for beautification

15. Posters and billboards for activities in progress

16. Useful manuscripts, magazines, reports

17. Others (personal items)

(2) No

1. Floor

A. Waste paper, dust, debris, cigarette butts

B. Oil stains

C. Equipment, fixtures, molds that are no longer in use

D. Office supplies no longer used, trash cans

E. Broken backing boards, cartons, rags, broken baskets

F. Dead materials or Expired samples

2. Table or cabinet

A. Worn books, newspapers

B. Broken chair cushions

C. Old Old useless reports and ledgers

D. Worn tools, leftover materials, samples

3. On the wall

A. Spider webs

B. Expired posters, reading newspapers

C. Useless proposal boxes, card boxes, hangers

D. Outdated calendars, slogans

E. Damaged clock

4. Hanging

A. Expired work instructions on the workbench

B. Wiring no longer used Piping

C. Old ceiling fans that are no longer in use

D. Manual fixtures that cannot be used

E. Department signs before the change

8. Employees’ 5S activities

Responsibilities:

1. Your working environment must be constantly sorted and reorganized, and items, materials and information must not be left randomly.

2. Unused items must be disposed of immediately and must not be left unused. Occupying working space

3. Access must always be kept clean and unobstructed

4. Objects, tools and documents must be placed in specified places

5. Fire extinguishers, The areas around switchboards, switch boxes, motors, air conditioners, etc. must be kept clean at all times

6. Objects and equipment must be carefully placed, correctly placed, and safely placed, and larger and heavier items should be piled on the lower level

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7. The tools, equipment and responsible areas must be sorted out

8. Paper scraps, cloth scraps, material scraps, etc. must be concentrated in designated places

9. Keep cleaning and keeping clean. 10. Pay attention to the instructions of superiors and cooperate with them.

9. Responsibilities of cadres in 5S activities:

1. Cooperate with company policies and fully support and implement 5S

2. Participate in external 5S education and training , absorb 5S skills

3. Study books related to 5S activities and collect a wide range of information

4. Promote 5S within the department and participate in the company's 5S promotional activities

5 . Organize and position the work areas within the planning department

6. Comprehensively organize, position and mark the work areas according to the company's 5S schedule

7. Assist subordinates Overcome the obstacles and difficulties of 5S

8. Familiarize yourself with the company's [5S sports competition implementation method] and explain it to subordinates

9. Participate in the company's scoring work when necessary

10. Improvement and representation of 5S scoring shortcomings

11. Supervise subordinates to perform regular cleaning inspections

12. Roll call and clothing appearance inspection after work, and before get off work Safety inspection and assurance.

10. 5S Checklist (Office Area)

1. Do you throw away unnecessary things? (Drawers, cupboards, cabinets, shelves, books, files, files, charts, stationery, wall slogans, posters, billboards)

2. Will the floor and table look messy?

3. Whether the trash can is too full

4. Office equipment will not be stained with dirt and dust

5. Are desks, file racks, and pathways separated by lines? ?

6. Clean the desktop after get off work

7. Are there any filing rules?

8. Are they classified according to filing rules?

9. Are documents etc. positioned (color, marked)?

10. Necessary documents can be easily taken out and placed in file cabinets, and whether the person responsible for management is clear

11. There are no corners in the office Spider webs

12. There is no dust on the desktop or cabinets

13. There are no expired notices on the bulletin board

14. Is the water dispenser clean

15. Whether the pipeline wiring is messy, and the telephone lines and power cords are properly fixed

16. Whether the drawers are messy

17. The garbage can be cleaned after work

18. Are private belongings neatly placed in one place?

19. Newspapers are arranged neatly on the newspaper rack

20. Are they dressed in accordance with the regulations

21. Turn off the power of the equipment at noon and after get off work

22. The office equipment should be kept in normal condition at all times and there are no faults

23. The bonsai placed should not be dead or yellow

24. Is there a personnel movement registration column?

25. Are there rules for document circulation?

26. When the person concerned is not present, when receiving a call, does the person respond with "leave"? 27. Positioning and furnishing of conference room items

28. Is the work attitude good (whether there is chatting, joking, reading novels, dozing, eating) )

29. Etiquette for receiving guests

11. 5S checklist (on-site)

1. Place items on site (such as raw materials, finished products , semi-finished products, remaining materials, garbage, etc. are cleaned regularly, distinguishing those that are used and those that are not used)

2. Correct use and cleaning of material racks, mold racks, tool racks, etc.

3 , Desktops and drawers should be cleaned regularly

4. Materials, scraps, remaining materials, etc. should be placed clearly

5. Correct use and placement of molds, fixtures, measuring instruments, tools, etc. Tidy

6. No unnecessary items or tools are placed on the machine or are not placed securely

7. Data and items that are not immediately needed or expired (for example: more than three days) Put them in the cabinet for management or disposal

8. Place tea cups, personal belongings and clothing in fixed locations

9. Regularly record and place information, maintenance cards, and inspection sheets in the correct locations

10. Positioning and placement of trolleys, small trailers, loading trucks, molding trucks, etc.

11. Placement and positioning of plastic baskets, iron boxes, cartons and other transport boxes and barrels

12. Positioning and labeling of lubricants, cutting oils, detergents and other supplies

13. Divide the workplace and add the name of the place

14. Consumables ( Such as rags, gloves, brooms, etc.) positioning and quantitative management

15. Materials in processing, materials to be inspected, finished products, semi-finished products, etc. are stacked neatly

16. Channels and walkways are maintained It must be smooth and no objects (such as wires, trolleys) may be placed or pressed in the passage.

17. All production tools, fixtures, parts and other positioning furnishings

18. Delineate the location Place unqualified products, damaged products and infrequently used items

19. Inflammable items such as oily rags should be positioned and isolated as much as possible

20. Pack up and position items that are not currently used for production or in the short term

21. When individuals leave their work stations, items should be placed neatly

22. Protective materials and warning signs should be added to the power supply system

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>23. Clean and tidy up before leaving get off work

24. Remove garbage, paper scraps, cigarette butts, plastic bags, rags

25. Clean and wipe machines, equipment, workbenches, doors, Window

26. Clean up waste materials, leftover materials, dead materials, etc. at any time

27. Remove oil stains on the ground and in the working area

28. Trash cans, inside and outside the barrel Clean up

29. Clean up cobwebs

30. Keep the working environment tidy and clean at all times

31. Items that have not been used for a long time (such as more than one month), Cover materials and equipment to prevent dust

32. Cleaning of floors, doors, windows, and walls

33. Repair of peeling paint on walls or peeling paint on the floor

34. Observe work schedules (not be late, leave early, and be absent without excuse)

35. Is the work attitude good (whether there is chatting, joking, leaving work, sitting, reading novels, dozing, eating) things)

36. Wear neat clothes, no slippers

37. Cadres can supervise subordinates, and subordinates can work spontaneously

38. When using public property, Be able to return to the correct place and keep it clean (such as using the toilet)

39. Clean and tidy up before stopping work

40. Follow the factory's regulations and do not violate factory regulations

The "5S" activities commonly carried out by Japanese companies are an important part and effective method to strengthen on-site management and create a good labor environment. The so-called 5S means sorting, rectifying, sweeping, cleansing, and quality. Because the Japanese romaji pinyin of these five words all begin with "S", they are referred to as "5S".

Organization (SEIRI): Separate what is needed on site from what is not needed, and get rid of unnecessary things. Such as removing unnecessary equipment, pipelines, tools, models and personal belongings.

Organization (SEITON): Place the things to be used separately according to the frequency of use, so that commonly used things can be taken out promptly and accurately, and kept in a state that can be used immediately when necessary and everyone can understand it. state. Such as signs of places and passages, signs of placed items and their managers, etc.

Cleaning (SEISO): Remove dirt, garbage, and stains from the site, clean and inspect frequently, form a system, and adopt countermeasures to eliminate dirt. Such as completely improving equipment leakage, oil leakage, air leakage, and easy falling dust.

Cleaning (SEIKETSU): Keep the enterprise, site, post, and equipment clean at all times, and maintain environmental hygiene. For example, conduct regular health and safety inspections, take measures to prevent pollution, noise and vibration, and make the site brighter.

Quality (SHITSUKE): Strengthen self-cultivation, beautify body and mind, and achieve beauty in mind and behavior. Everyone should develop good habits and consciously abide by and implement various rules, regulations and standards.