How to implement 5S management in automobile maintenance service enterprises?

Implementation policy: standardize the site and existing materials to improve the quality of employees in an all-round way.

Implementation goal: visitors or superiors do not need to make any preparations.

Second, the unified logo

During normal working hours or on-duty hours, all employees should wear work marks made by the company, wear work clothes and work shoes reasonably and keep their clothes clean and tidy once they enter the company's factory. The requirements are as follows:

1, the work sign is uniformly worn above the left chest.

2. Work signs should be kept clean for a long time.

3. Work clothes should be uniformly worn, such as a coat that covers the pants.

4. Work clothes, shoes, etc. You must wash or wipe it at least once a week, usually with dirty ones. You must wear clean work clothes and shoes when you go to work every Monday.

Third, polite language and address.

All employees of the company should use the civilized and polite language and address stipulated by the company in the workplace.

1. The civilized and polite terms uniformly stipulated by the company are as follows:

Hello, welcome, please drink water, please sit down, please sign, please check out, take care, thank you, and welcome to visit next time.

2. The unified polite expressions within the company are as follows:

Monitor, manager and assistant.

Other names: master.

Four, monitor, dispatcher management responsibilities

1. Cooperate with the company's policies, fully support and implement 5S management, carry out the instructions of superiors with good quality and quantity on time, earnestly perform the post responsibilities, abide by various rules and regulations, and actively participate in various meetings, study and training activities;

2. Participate in the company and be responsible for the promotion, introduction and improvement of the company's 5S management, and feed back all relevant information in time;

3. Plan the arrangement and positioning of 5S management area, and be responsible for arrangement, positioning and identification;

4, roll call and clothing appearance inspection before going to work, safety inspection before coming off work;

5. Assign 5S management responsibilities to subordinates, such as arranging cleaning in turn and earnestly performing employees' 5S management responsibilities;

6. Supervise and guide subordinates to perform 5S management responsibilities, and conduct regular maintenance and cleaning inspection of the managed areas;

7. Be familiar with this specification and train subordinates, help them overcome 5S obstacles and difficulties, and be responsible for 5S management training and technical guidance for new employees;

8. Be responsible for the evaluation and scoring of 5S on-site management of subordinates;

9 to participate in the formulation of this specification and the improvement and improvement of evaluation scores;

10. Strictly implement all other relevant provisions in this specification and act as required.

Verb (abbreviation for verb) Employee management responsibilities

1, own working environment, tools, equipment, responsibility area, etc. Must be constantly sorted out and rectified, and all items should be placed in the specified position according to the specified requirements;

2, unnecessary items should be dealt with immediately, shall not occupy the workspace;

3, the channel must always keep clean and smooth;

4. Temporary removed spare parts and other items must be placed in the designated location according to 5S management requirements;

5. Fire extinguishers, switchboards, switch boxes, motors, etc. Always keep it clean;

6. All articles and equipment should be placed correctly and safely, and the larger and heavier ones should be stacked on the lower floor;

7. Paper scraps, material scraps, waste materials, etc. Should be concentrated in the trash can;

8. Regularly clean the management responsibility area as required to keep it clean;

9. Carry out the instructions of the superior in quality and quantity on time, earnestly perform the post responsibilities, abide by various rules and regulations, and actively participate in various meetings and training activities;

10. Strictly implement all other relevant provisions in this specification and act as required.

Management scope, responsibilities and requirements of intransitive verbs

(a), to class as a unit, to determine the management area and clear responsibilities and specific requirements.

1. area: the management area uniformly divided by the company for each class.

2. Responsibilities: Manage the maintenance, maintenance and environmental sanitation of equipment and facilities in the area.

3. Requirements: clean the floor of the health responsibility area before going to work every morning and afternoon, clean the floor of the health responsibility area and wipe all kinds of equipment, facilities, tools, pipes, lines and window sills before going off work every afternoon, clean the walls and windows every Friday, and clean up the dirt such as cigarette butts and scraps of paper at any time. Always keep the floor, walls, windowsills, windows and all kinds of equipment, facilities, pipelines, lines, etc. clean. Clean and tidy, without water, oil, dust and garbage. When you get off work, lock the doors and windows, the tool cart and cut off the power supply.

(2), warehouse keeper, buyer

1, area: warehouse.

2. Responsibilities: Maintenance of spare parts and raw materials, environmental sanitation.

3. Requirements: same as above.

(3), take turns on duty personnel

1. area: customer lounge.

2. Responsibilities: Maintain facilities and environmental sanitation.

3. Requirements: Clean the floor before going to work every afternoon and before going to bed every night, wipe all facilities and windowsills before going to bed every night, and scrub the windows once a week. Keep the floor, facilities, walls, windowsills and windows clean and tidy.

Seven, the distinction between necessary items and unnecessary items and the placement of necessary items.

(a), maintenance workshop and equipment library

1, the necessary items are as follows:

Hoists, locators, electric welding machines, gas welding machines, oxygen cylinders, shearing machines, tool carts, maintenance tools, tool boxes, bench drills, vises, grinders, fire extinguisher box, fire extinguishers, jacks, waste oil pumps, air pumps, pressure-bearing equipment, chargers, exhaust gas testers, suitcases, shoe racks, towel racks, various working platforms, cleaning and sanitary appliances, etc.

2. In principle, all the above-mentioned necessary items should be marked, positioned and clearly marked, except the elevator and locator. All equipment, facilities and tools that need to be moved during the operation, such as tool carts, tool boxes, electric welding machines, gas welding machines and jacks, must be put back in place immediately after the operation is completed.

(2) Customer lounge

1, the necessary items are as follows:

Air conditioners, televisions, TV cabinets, drinking fountains, office desks and chairs, square cabinets, telephones, long wooden sofas, single wooden sofas, wooden coffee tables, filing cabinets, fire extinguishers, blackboards, cleaning and sanitary appliances, etc.

2. All the above necessary items are positioned and placed (no need to cross). Under normal circumstances, keep the position unchanged and cannot move.

(3), warehouse and waste warehouse

1, the necessary items are as follows:

A. Special tools, expensive equipment, instruments and meters, all newly purchased spare parts and other articles and appliances, such as sanitary appliances;

B, all removed spare parts that are damaged to varying degrees but can be repaired or have other use values (put in the waste warehouse);

2, put the principle is as follows:

A. Everything that can be put on the shelves should be put on the shelves. First, it should be divided into major categories, such as common oil products, engines and chassis, and different types of accessories should be placed separately;

B, similar accessories are placed by different manufacturers;

C, similar accessories of the same manufacturer are placed according to different specifications and models.

3, the principle of dealing with damaged spare parts

A spare parts that can be repaired, as spare parts for internal vehicle maintenance, should be repaired in time. Spare parts should be placed in the specified area after classification and clearly marked.

B spare parts that can't be repaired but have other use value should be classified and placed in the designated area, and clearly marked.

C spare parts that can't be repaired and have no other use value should be recycled regularly on time.

Eight, clean up unnecessary items

Except for the required items specified, all the above places are unnecessary items. If necessary equipment and facilities or other necessary items need to be used are added, they should be included in the management scope of essential items in time, and the placement position should be determined and clearly marked.

All unnecessary items must be cleaned up in time to keep the site efficient, clean and orderly. Waste products with recycling value can be sold as waste products, and waste products without recycling value can be discarded as garbage.

Nine, work card measuring tools and other necessary items management

(1) Equipment and maintenance of work card measuring tools

1. The equipment, purchase and distribution of work card measuring tools shall be approved by the deputy production manager.

2, the new distribution, loss, intentional damage to the implementation of bad compensation or purchase.

3. Commonly used work card measuring tools shall be registered by the warehouse keeper. The warehouse keeper should improve the procedures for receiving, regular maintenance and timely maintenance.

4. Precision and heavy truck measuring tools shall be used and kept in accordance with regulations.

(2) Management of special tools

1. The warehouse manager is responsible for the storage, lending and recovery of special tools.

2. The borrowed special tools must be properly kept and returned in time, and shall not be damaged or lost, and shall not be illegally used outside the special function, so as to avoid unnecessary losses.

3, after use, to scrub clean. For boxed special tools, oil residue and other sundries shall not be carried in the box. For some special equipment (such as disassembly-free cleaning machine and exhaust gas tester), the wires and pipes should be arranged and wiped clean according to the regulations after use.

(iii) Management of maintenance tools

1, all maintenance tools are configured in principle according to the principle that two people * * * are equipped with one set. Each set of tools is put in a tool cart, and the squad leader of each class designates the keeper and defines the responsibilities. The person in charge of storage should urge the team members to put the tools back in the tool cart immediately after using them, put them in order and lock them.

2, tools should be strictly classified. Different types of tools should be separated by lines (or other separation methods). In principle, tools of the same category should be placed in order of size and length.

3. Before operation, decide whether to use the tool cart according to the difficulty of maintenance. Simple maintenance or remote maintenance can be operated by toolbox, and difficult and complicated maintenance must be operated by tool cart.

4. After the operation, you need to use tools to remove the female washer of the screwdriver and other smaller parts. To clean it up, it should be placed in the designated area above the tool car in an orderly manner, not on the ground or on the car. Tool carts must be placed parallel or at right angles to the passage, and the placement position should be determined from the angle of easy operation. When working under the car, the tool cart must be placed under the car to prevent accidents.

5. Before coming off work, the tool carts and tools should be sorted and wiped clean to keep them clean.

6. If the tool box is used for operation, the tools to be used should be confirmed in advance, prepared and placed neatly, and the smaller parts such as the screwdriver washer that has been removed should also be placed neatly in the tool box or parts box. In principle, the placement method is the same as that of the tool cart.

(4) Management of other necessary projects

1, broom, mop, dustpan and other cleaning tools, as well as automobile protection articles such as automobile protection cloth, seat cover, foot pad and steering wheel handle cover, whose equipment, procurement and distribution shall be approved by the deputy production manager.

2, the new distribution, loss, intentional damage to the implementation of bad compensation or purchase. Automobile protective articles, rags, etc. Should be stacked neatly in the tool cart, cleaned once a week, usually washed with dirt.

3. The warehouse keeper should keep proper inventory, issue the purchase plan in time, ensure the supply, and improve the purchase application procedures.

X. Work site specifications

1. Operators must use labor protection articles correctly.

2, working platform, pad, bracket, etc. Must be strong, load-bearing items shall not be overweight.

3. In principle, the disassembled components and large pieces should be cleaned and put in a large tray. It is not allowed to be placed directly on the ground. Cover those left for a long time to prevent dust from falling.

4. When disassembling the oil tank and oil-water storage parts, catch the leakage with the oil basin to prevent the oil-water from falling to the ground or the sink.

5, lifting operations, there must be a specialist care, in order to prevent accidents.

6. When working outside the car, you must use protective cloth correctly, and you are not allowed to enter the car.

7. When working in the car, use the seat cover, foot pad and steering wheel handle cover correctly.

Smoking, spitting and eating food with skin are strictly prohibited in the factory.

XI。 Operating process specification

For the maintenance process, the company implements kanban management. The specific requirements are as follows:

1, all employees must follow the process and must not violate it.

2. All employees must be very familiar with the specific operation methods of the whole process.

Twelve. quality management

(A), quality management organization

Under the leadership of the manager, the deputy manager is responsible for quality management and concurrently serves as the chief quality inspector. Each class has 1 quality inspector, who is also the monitor.

(2), quality requirements

1. The repaired vehicle must meet the requirements of the repair technical standard (GB3798-83).

2, overhaul vehicles must reach the mileage. Ensure the technical condition of the vehicle within six thousand kilometers or three months after delivery.

(3), quality inspection procedures

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2. After the parts are processed, repaired, assembled and adjusted, they shall be inspected by the quality inspector. The next working procedure can only be carried out after passing the inspection, and the unqualified parts must be reworked.

3, after the completion of vehicle maintenance, the first inspection by the main personnel. After the self-inspection, the auxiliary maintenance personnel carry out mutual inspection, and then hand over the car keys to the monitor, and the quality inspector (that is, the monitor) carries out inspection. If it meets the quality standards, the inspection sheet will be filled in and signed, and then the test run will be arranged. After the trial operation, it is confirmed that there is no problem, and the vehicle keys can only be released after being handed over to the dispatcher. If necessary, it must be submitted to the chief quality inspector for re-inspection.

4. When a quality repair accident occurs, the dispatcher and the class monitor responsible for the maintenance operator must report the relevant situation of repairing the vehicle to the company leader in time.

(4), maintenance quality control and related matters

1, start the engine to check the fault of the vehicle. First, check whether the fan rotates and whether there is water in the water tank.

2. When testing vehicle maintenance, first check whether the handbrake and brake are sensitive.

3. Disassembly and assembly of spare parts and automobile assembly shall be carried out in sequence. Disintegration, in principle, should be carried out from outside to inside and from left to right. Assembly shall be carried out in the reverse order of disassembly. There must be no omissions in the assembly process. If you find something missing, you must make it up during maintenance to ensure that it is complete and not missing. When screwing the screws, tools such as matching wrenches must be used, and the strength must be moderate, not too hard or too small.

4, common fault judgment and inspection order specification.

A, who come to repair the vehicle, must first be confirmed by the vice monitor maintenance difficulty, reasonable arrangement of maintenance personnel for maintenance. In principle, maintenance personnel with better skills are arranged for the more difficult maintenance tasks, and other maintenance personnel are arranged for the less difficult maintenance tasks.

B, before maintenance, must first by the monitor and deputy monitor (or monitor designated skilled workers) fault judgment, confirm whether need to replace spare parts and which parts need to be replaced. It can only be implemented after a decision is made.

5. When replacing spare parts, it is not allowed to install mismatched spare parts.

6. Take good care of all kinds of instruments and equipment. After each work, the instruments and meters should be wiped clean and the workshop should be kept clean. Maintenance, overhaul and calibration should be carried out before work every Friday. Before work every day, the elevator should be inspected and wiped clean.

7. The maintenance task in the morning shall not be delayed until the afternoon, and the maintenance task in the afternoon shall not be delayed until the next day. For the maintenance tasks that should be completed overtime at noon, evening, Saturday and Sunday, the vice squad leader and vice squad leader must arrange overtime.

(5), parts quality control and related matters

1, the buyer must strictly abide by the following provisions to ensure that the quality, quantity, specifications and models of accessories meet the specified requirements and actual needs.

A, strictly control the purchase channels to ensure the quality of accessories. It is required that counterfeit products and defective products shall not be put into storage.

B, under the condition of ensuring the quality, by comparing the prices of suppliers, choose the suppliers with high quality and low price.

C spare parts needed for internal vehicles, especially expensive spare parts, can only be purchased after being approved by the company leaders or signed by the warehouse keeper.

D, familiar with the price of all kinds of accessories, and closely cooperate with the warehouse. Newly purchased accessories must be counted and put into storage before they can be assembled and used.

E, the newly purchased accessories, bills must be consistent with the real thing. If the specifications and models do not meet the requirements or are inconsistent with the bills, they must be returned in time.

2. Related matters

Maintenance personnel go to the warehouse to receive unusual raw materials, spare parts, etc. The model, specification, name and quantity must be reported to the warehouse keeper. In order to ensure the accuracy of purchasing, the warehouse keeper must indicate the model, specification, name, quantity, etc. When making a purchase plan, two copies must be made, one for the buyer and one for future reference. For temporarily added procurement items, the warehouse keeper and the buyer must incorporate the added procurement items into their respective procurement plans. After the buyer purchases according to the plan, the maintenance personnel can collect it.

Thirteen, safety operation procedures

(a), automobile electrical operation procedures

1. When loading and unloading automobile electrical components, the power supply of the automobile must be disconnected if necessary, and the power supply cannot be disconnected if it cannot be disconnected.

2, need to start the engine to check the electrical appliances, should ensure that no one under the car and tighten the handbrake, put it in neutral.

3. When testing the battery, use a discharge fork or multimeter to test, and do not use pliers or other metal tests.

4. Strictly implement technical standards to ensure quality. Unqualified products are prohibited from leaving the factory.

(2), welding operation procedures

1, those who pass the examination without special training shall not carry out welding work.

2, in strict accordance with the technical regulations, to ensure product quality and construction safety.

3. Before operation, you must wear work clothes, safety covers, insulating gloves and rubber shoes.

4, when welding in the car, to remove the surrounding flammable, pipeline wires are not allowed to be placed in the oil tank or oil rack; Wear protective glasses when welding and cleaning welding slag; Welding gloves must be worn when replacing covered electrode.

5. Before gas welding operation, check oxygen cylinders, acetylene cylinders and pressure gauges, and repair them in time when problems are found. Oxygen cylinders and welding and cutting guns are strictly prohibited from being contaminated with oil. The acetylene generator shall not be less than 2 meters away from the welding site.

6. When the welding gun is lit, the acetylene switch should be turned on first, and then the oxygen switch should be turned on. It is forbidden to ignite directly with a hand-held match.

7. When installing the pressure gauge, the operator should turn his head to one side instead of facing the bottle mouth. Always wear gloves when switching the power supply, and don't face the switch to prevent burns. In winter, the bottle mouth is frozen, so it should be scalded with hot water, and it is not allowed to be roasted with open fire.

8. It is forbidden to weld oil tanks, barrels and other flammable containers.

(3), grinder safety operation procedures

1. It is kept by a special person to keep the machine running normally.

2. After the new grinding wheel is installed, it must be tested at full speed. No one is allowed to stand in front of the grinding wheel when it is running.

3, bedstead must be strong, and the gap between grinding wheel shall not be greater than 3mm, grinder to install safety shield.

4. Wear protective glasses when working. It is forbidden for two people to grind on a grinding wheel at the same time. It is forbidden to grind on the side of the grinding wheel.

5. When using the grinder, it is forbidden to wrap the workpiece with cotton yarn or cloth.

6. Overweight workpieces or films, such as copper, lead and tin, are not allowed to be polished on the grinding wheel.

(4), paint safety operation procedures

1. Wear a gas mask before operation.

2. When the metal surface is filled with oily putty, it must be scraped repeatedly to prevent the putty from entering the air.

3. Oily putty is generally not used inside metal objects. After the antirust primer is painted, it can be directly sprayed or painted.

All thinners and paints are flammable and dangerous. It must be stored in a well-ventilated room with moderate temperature, and the fire source and power supply should be isolated to prevent fire caused by strong backlight.

5, according to the technical requirements for painting, painting surface should be bright, smooth, complete and uniform.

(5), car charging operation procedures

1, work clothes, acid-resistant rubber shoes and acid-resistant gloves must be worn before operation.

2, sulfuric acid, electrolyte container to ensure no leakage.

3. When adding electrolyte, slowly pour it into the battery. After standing for 20 minutes, make sure the vent hole is ventilated, and then screw on the bottle cap.

4. When welding the battery, unscrew the electric bottle cap to prevent the battery from exploding. The temperature of battery liquid shall not exceed 45℃

5. Overload operation is prohibited when charging. Charging should have good ventilation and fire prevention facilities to prevent lead poisoning.

(6), sheet metal safety operation procedures

1, before operation, the surrounding sundries must be removed, and whether the tools and equipment are complete and reliable must be checked.

2, the sledgehammer ups and downs must pay attention to the safety within the scope of the sledgehammer, and the hand holding the sledgehammer is not allowed to wear gloves to avoid the sledgehammer slipping out and hurting people.

3, homework should pay attention to coordinate homework, so as to avoid accidental injury.

4. Matters needing attention when using shearing machine:

(1). Pay attention to fastening the upper scissors and the lower scissors when starting and shutting down, and make the upper scissors and the lower scissors tilt relatively by 20゜-30゜. According to the thickness of the material, adjust the overlap amount of the upper scissors and the lateral clearance of the upper scissors, and carry out no-load test run.

(2) Before starting the machine, check the surface quality of the metal plate. If there are hard scars, electroslag and other problems, you can't cut.

(3), no overload shear, cut off the power supply after use.

5, when using chain and jack, must ensure that the top connection is firm and reliable, so as not to hurt people.

6. Clean up the site in time.

Fourteen Group management

The vice monitor of each class and the dispatcher form a cooperative group. Related matters are as follows:

1. The company has two general managers and two responsible persons. The general manager concurrently serves as the deputy production manager, and the person in charge is appointed by the company.

The person in charge should lead and manage the team. Team members should obey the leadership and arrangement, and actively assist the person in charge to do the relevant work.

3. The main task of this team is to find and solve the problems existing in site management and daily management in time, so as to ensure the continuous and normal development of 5S management activities, such as recycling wastes regularly, proposing suggestions on the purchase, storage and distribution of temporary materials such as cleaning appliances and necessary gadgets, and reporting them to the deputy production manager for approval and implementation, managing the fixed-point placement of equipment and facilities, and alternately cleaning and classifying equipment warehouses and waste warehouses. Regularly check the quantity and damage of grouped tools, supplement normal wear and tear, compensate for loss and man-made damage, carry out various reasonable improvement activities on site management, temporarily adjust and match various operators to ensure the optimal distribution of various operation tasks, and conduct collective consultation on various complex and difficult maintenance tasks to ensure maintenance quality. , and other related matters.

Fifteen. Specialized technical training

Every Thursday at noon (12: 30- 13: 30), the company organizes technical training for all employees. The training of teachers and the content are determined according to the actual situation.

Sixteen. Management training

Every Friday at noon (12: 30- 13: 30), the company organizes the team leader and the vice squad leader to hold a 5S management meeting for all staff. The contents of the meeting are as follows:

The vice squad leaders of each class will make a comprehensive review of this week's implementation in turn according to the provisions and requirements of this Code, sum up experience and draw lessons. And announce the deduction of each employee this week.

Seventeen, comprehensive evaluation method and reward and punishment system

This specification implements comprehensive management assessment, and adopts monthly percentage system, as follows:

1, check the responsible person

The assistant manager and assistant are responsible for the assessment of the monitor and dispatcher. The assessment of maintenance personnel shall be the responsibility of the class and vice squad leader. The dispatcher shall be responsible for the buyer's inspection.

2. Evaluation content

All provisions of this specification and the company management system.

3. Scoring method

According to this specification and the provisions of the company's management system, check and evaluate item by item. In case of failure to perform management duties or violation of regulations, the party concerned will be deducted 1 point, and the vice monitor and his subordinates will be deducted 1 point for each missed inspection. If subordinates are found and the vice squad leader is present, the vice squad leader and his subordinates will be deducted 1 point. The dispatcher's evaluation of the buyer is the same as before.

All staff in each shift will be deducted 5 points, and the corresponding deduction will be 1 point. Once a day, the person in charge of evaluation must make relevant records. The deduction table shall be kept by the dispatcher in a unified way. The person in charge of the assessment of each class and the dispatcher shall record the assessment of the day, and accurately register the deduction points in the deduction table at the dispatcher before coming off work on the same day. Before the 5th day of the following month, the dispatcher will submit the assessment deduction form to the deputy manager or assistant, and then submit it to the financial accounting.

4, each class rewards and punishments

If the assessment score of the current month is lower than 100, the benefit salary of the class will be paid in proportion according to the assessment score. The calculation method is as follows:

Benefit salary = benefit salary calculated according to working hours × (assessment score/100)

5. Individual rewards and punishments

First, the welfare wages withheld by each class shall be accounted for by the finance department to the employees of each class according to the proportion of points deducted by the employees of each class, and deducted from the welfare wages.

B, monthly assessment 100 points, according to the assessment scores, personal benefit wages will be paid in proportion. The calculation method is as follows:

Benefit salary = individual benefit salary calculated according to class benefit salary and relevant regulations × (assessment score/100)

C. The accumulated amount of personal welfare wages withheld by each class in the current month shall be uniformly and evenly distributed to other employees in the class by the Finance Department.

D, vice monitor of subordinate assessment list, mainly according to whether serious and responsible, whether strict assessment as the basis of rewards and punishments, according to the assessment scores in proportion to monitor subsidies. The calculation method is as follows:

Actual subsidy = designated monitoring subsidy × (assessment score/100)

E, vice monitor, dispatcher's daily assessment and rewards and punishments with other employees.