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5S EVALUATION SHEET

5S EVALUATION SHEET

1st S: Sort through/sort out

Eliminate what is unneeded and decide what is needed INITIAL SITUATION FIRST IMPROVEMENTS DEVELOPMENT INTEGRATED SYSTEM EXCELLENCE

NO DISTINCTION BETWEEN NEEDED ELIMINATION OF UNNEEDED ITEMS IS IN UNNEEDED AND NEEDED ITEMS HAVE CLEAR LOCATION FOR ALL NEEDED LOCATIONS FOR ALL NEEDED ITEMS
Check item Question AND UNNEEDED PROGRESS BEEN SEPARATED ITEMS ARE CLEAR AND VISUAL

Is the workplace cluttered with Unneeded raw materials, packaging The necessary quantities of materials, All locations for finished products, materials,
Large quantities of finished products and There are no unneeded drums or pallets in
Unneeded pallets / boxes / raw unnecessary pallets, raw materials, materials, inventory and finished products packaging or pallets have been defined. The packaging materials, are visually indicated.
raw materials are stored in the work area the work and storage areas. All products,
materials / consumables / finished drums, inventory or finished products? have been eliminated from the workplace. areas for boxes, pallets and finished Minimum and maximum levels have been
and in corridors instead of being stored in consumables and materials have specific
1. products in the workplace Are there any obsolete products in the The work area only includes materials used products around the machines or in the work defined, with a visual system for
the warehouse or in a specific area. There locations defined on the basis of a 5S flow
workplace? Have chemicals and on a daily basis. Corridors and safety exits area are defined. Dangerous products and replenishment. An area for tagged products
are pallets, drums, packaging materials in map (which identifies the best locations to
consumables been sorted according to are clear. Chemical products, scrap consumables have been sorted according to (with no clearly defined usage) has been
the work areas and in corridors. Safety e reduce motion waste), and they are kept in
their use and their nature? materials and their n clearly

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Unneeded tools, jigs and accessories lie Tools/items on shelves, in cupboards have No unneeded items can be found in the Only tools and items used regularly for
There are only the needed tools in the
Are there any unneeded tools, jigs, dies, about in the workplace, in drawers, on been partly sorted and put away, and workplace: the items with no specific daily/shift production can be found in the
workplace: a list has been established.
Unneeded tools, jigs, support material moulds or accessories (wrenches, machines, drums, or on the worktables. tagging of unneeded items is in progress. location are clearly identified for action. workplace: their locations are clearly
There are only clearly identified items in
2. or accessories scrapers, gloves...) in the work area? Is it Shelves and cupboards are filled with Machine tooling is put away in specific Machine toolings and jigs have been sorted marked, together with necessary quantities.
cupboards or on shelves. There are no more
possible to distinguish between needed useless tools and other old items. Machine spaces. There are still a few non-defined out and put away in a specific place. Cupboards have been completely cleared of
personal toolboxes, except for specific uses.
and unneeded items? tools are put away in a jumble. Some tools tools or items on cupboards, machines or Screws, electric and mechanical pieces are useless items. There are no tools in
The tagging process is carried out every tim
are in perso about. being sorte personal l

1 2 3-4 5 6

All machines in the area have a specific use, All equipment in the work area has a specific
All equipment in the area has a specific use.
There is some unused equipment in the and all unneeded items have been removed. use and a clear location. Forklift trucks have
Are there any unused machines or other Unneeded machines have been removed. They have defined locations and their
Unneeded machine or other workplace, in the aisles or in the storage Forklift trucks have a defined location. specific allocated spaces everywhere they
3. equipment in the workplace? (worktables, There are still a couple of unused or very names are displayed. All forklift trucks have
equipment areas. Forklift trucks have no specific Sporadically used machines/equipment are are used. All machines or equipment used
shelving, packing machine, etc). rarely used equipment in the workplace. a clearly defined location in every area
locations. put away in a specific location. The machine sporadically have a specific location, well
where they can be used.
and protection guards have been identifi indicated, and anybody can get them

1 2 3-4 5 6

Are there any unneeded or obsolete The workplace (workstation/monitoring All unneeded papers, documents and files All procedures and notes are up-to-date and
Instructions on the desks or workstation are Only the documents necessary for daily
instructions, procedures, memos, room) contains documents/files that are have been discarded, and the necessary forms/instructions are related to current
Unneeded documentation, visual not all related to current work. A few old production activities and process monitoring
4 drawings or visual displays in the file unneeded or that have been kept in the documents have been sorted depending on work. A location has been defined for the
displays, books, drawings memos. Drawers are still full of papers and can be found in the workplace, in specific
cabinets, on the workstation and on the wrong place (old calendars, memos, files, how frequently they are used. Teams have support documentation necessary for all
each team runs its own document system. and visually indicated locations.
walls? drawings, catalogues…). standardized their documents. operators.

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(*) PPE: Personal protection Yellow tagging for undefined items -


Suggested methodologies:
equipment Tagging list and action plan.

Saint-Gobain HPM Sector


28/06/05 Productivity Group Europe
2nd S: Set in order

Define a specific location for every item needed INITIAL SITUATION FIRST IMPROVEMENTS DEVELOPMENT INTEGRATED SYSTEM EXCELLENCE

WORKPLACE ORGANIZATION IS IN LOCATIONS ARE BEING VISUALLY A VISUAL CONTROL SYSTEM IS BEING
Check item Question LACK OF ORGANIZATION AND ORDER
PROGRESS IDENTIFIED IMPLEMENTED
A VISUALLY ORGANIZED WORKPLACE

All units, lines and machines are identified


Are production units, workshops, There are no (or very limited) visual with a name or a number that is clearly There are visual markings for all equipment, All equipment, their functioning conditions,
Identification of production units Production units, machine names, as well as
machines, piping, production lines and indications of the names of the production indicated and visible from a distance. silos, supplying inlets, and a system has and the safety conditions that are to be
1. ,piping, machines, running condition process types, are indicated. All machine
processes clearly identified and visually units, nature of processes, areas, names or Machines and workstations are well-lit. been implemented to identify when they are respected are clearly marked with a visual
and flow guards are in place,
displayed? numbers of lines and machines. Piping contents and direction of flow have functioning. control system.
been identified.

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Tools have a defined location, with a clear


A list of the necessary tools is displayed at
Are accessories, jigs and tools arranged The locations for the tools necessary to the labeling and color codes. Tooling, machine Tools are actually in the right place, and
Tools have a defined location, but they are every workstation. Equipment accessories
Organization of tools, jigs, support and ordered rationally, in order that they workstation are not visible. Tools have no accessories and jigs are organized they are visible at once. Tools locations are
not always in that location. Fixtures, toolings are well-defined. Codes and colors indicate
2. materials and machine accessories. can be easily taken and returned into allocated space. Machines tooling and according to size and frequency of use. The visually controlled, with clear and legible
and machine accessories are stored in where they are to be put away. A standard
Location for PPE* and safety material place, depending on how often and where fixtures are in a jumble in dark, unidentified tools necessary in each point of use have markings of their dimensions or conditions
specific areas. for arranging tools and accessories has
they are used? areas. been supplied and have a specific location, for use.
been created and is displayed.
cle

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Are there any markings to clearly identify Storage areas, pedestrian areas, exits, Storage areas, pedestrian areas, aisles and Materials, packaging and finished products
Delimitation of floor areas, aisles, There are no signs to indicate floor areas, Storage areas, pedestrian areas and
floor areas, aisles, walkways, scrap and safety issues and passageways are passageways are well indicated. locations, as well as flow directions and
storage areas for materials and passageways and pedestrian areas. Areas passageways are visualized or painted with
storage spaces? Are there labels identified, but not respected. Markings are Passageways are clear. All storage is hazardous areas, can be identified at a
finished products. Location and for storage and scrap, safety issues are not specific colors. All storage are carried out in
3. indicating all items location and their not always clear, or there are a few location carried-out as indicated. Forklift trucks glance.
supplies of items in shelves/on indicated or have disappeared. The labels the areas indicated. Passageways are clear,
quantities on shelves? Are PPE* and indicators, but they are not always respected locations are identified. Items in cupboards A list of contents is displayed on all
storage racks (consumables, bottles, indicating locations in cupboards or shelves and dangerous areas as well as forklift
safety materials arranged rationally and or not precise enough. PPE* have a specific or on racks are well-identified, marked and cupboards and shelves. A visual system has
rolls, tapes, etc). are nonexistent, spoiled or cannot be r trucks, ramps paths can be identified at a g
easily-accessible? l labeled. M been set up for the replenishment of the

1 2 3-4 5 6

Presence of the necessary documents All necessary documents (SHE* documents, SHE* documents and job instructions are Job instructions, batch forms, order forms, Instructions, standard operating procedures
All SHE* documents and other documents
in the production unit and at the Are all documents essential to the activity batch forms, quality forms, etc) cannot be well organized and visible, and specific quality forms and other documents (specific and safety instructions can be identified at a
4 have an allocated space and are available
workstation (SHE* documents, job well-arranged and clearly identified? found on the workstation, or they are in a spaces with color codes corresponding to operating procedures) are visually marked, glance on each workstation, and globally in
on the workstation
forms, work instructions, etc) jumble and difficult to identify and read. the nature of documents have been defined. codified with well-defined sequences. all areas of the workplace.

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(*) PPE: Personal protection
Suggested methodologies: 5S flow map
equipment

(*) SHE: Safety, Human, Environment Color codes / addresses codes

Photos

Saint-Gobain HPM Sector


28/06/05 Productivity Group Europe
3rd S: Shine and sweep

Keep the workplace clean and eliminate abnormalities INITIAL SITUATION FIRST IMPROVEMENTS DEVELOPMENT INTEGRATED SYSTEM EXCELLENCE

CONDITIONS FOR A CLEAN


CLEANING AND INSPECTING BECOME A CLEANING AND INSPECTING ARE PART
Check item Question ENVIRONMENT NOT CLEAN CLEANLINESS IS IN PROGRESS ENVIRONMENT ARE BEING
HABIT OF THE CULTURE
ESTABLISHED

Cleaning tools, materials and equipment are


The necessary tools (shovel, clothes, There are clearly defined and visualized
clearly identified in well-defined areas: their
brushes), products (detergents) and Cleaning tools and materials have been Cleaning tools, materials and equipment are locations for cleaning instruments, materials
Cleaning tools, materials and Are cleaning tools, equipment materials list has been established in every production
1. equipment (vacuum cleaners) for everyday identified, they have been allocated a space, available and they have a specific allocated and equipment, with available material
equipment available, accessible and adapted? unit and the operators in charge of their
cleaning are not all available or in a good but they are not all in that space. space. everywhere it is needed, in different points of
maintenance and replenishment are
state, or they have no defined location. the workplace. All addresses are marked.
indicated.

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Machines are not very clean: all overflows, Machines are moderately clean: there are Machines are quite clean, and hard-to-reach
Workstations, machines are dirty: there are leaks and dust are not under control. still cables, PPE and areas difficult to reach. Workstations , machines and piping are areas have been removed or adjusted.
Cleanliness of workstations, Are machines, workstations, piping,
overflows, swarm, leakages, dust, Workstations (drawers, cupboards, shelves) Workstations are clean. clean. equipment, machine accessories, Workstations are perfectly clean, there are
machines, equipment, accessories cabinets, shelves clean? Have
2. fingerprints. Dirt and contamination sources are not completely clean. Some The main contamination sources are tools and racks are clean. no fingerprint or dust. All contamination
and piping. Elimination of sources for contamination and dirt causes (leaks,
are not treated: there are oil leaks, dust and contamination sources are identified with identified with tags and they are being All identified contamination sources are sources are being improved. Some
dirt and contamination dust) been identified and treated?
overflows. tags. Some of them have been treated or improved or a team is analyzing the being improved or are planned to be. improvements projects are still going on and
are being treated problem. are displa

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Floors and all the workplace areas are


Floors and passageways are rather clean, perfectly clean and markings are in a very
Floors are dirty; there is dust, oil and product Floors are quite clean, even nearby or under
Are floors, aisles and scraps, scrap areas but floors in the work areas are dirty, soiled Floors are clean, bin/scraps areas and good condition. A team is responsible for
3. Cleanliness of floors and scrap areas stains. Containers and bins are dirty and machines and piping, and in all work and
clean? with oil and dust. Containers and bins are containers are clean and emptied regularly. every area in the plant. Responsibilities are
they sometimes overflow. storage areas.
emptied regularly. defined for control of cleaning and extraction
systems.

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The planned cleaning activities are carried


The workplace is divided into areas, and
out according to schedule. Working clothes
Cleaning programs are nonexistent, not teams are responsible for them. The
Is cleanliness a usual team concern? Is Cleaning programs are displayed. They are The cleaning activities planned at the are clean. Cleanliness criteria are on display
4 Cleanliness behaviors and rules regular or not applied; weekly cleaning has planned cleaning activities are carried out
cleaning an ongoing team activity? not always completed for lack of time. workstation are adhered to. on every machines. Changing-rooms,
not been done; clothes are dirty. according to the programs. Working clothes
similarly to all the workplaces, are quite
are clean.
clean and well-kept.

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Suggested methodologies: Red tags - Cleaning program - Photo showing a cleaning standard - Map of the setting with divided areas

Saint-Gobain HPM Sector


28/06/05 Productivity Group Europe
4th S: Standardize

Create a visually managed workplace INITIAL SITUATION FIRST IMPROVEMENTS DEVELOPMENT INTEGRATED SYSTEM EXCELLENCE

Check item Question LACK OF STANDARDS A FEW STANDARDS ARE ESTABLISHED STANDARDS ARE BEING DEVELOPED A VISUAL CONTROL SYSTEM IS IN PLACE ALL SITUATIONS ARE UNDER CONTROL

Tools are marked with defined color codes: A visual system has been defined for tools,
Standard colors have been defined for floor locations are identified according to color equipment and accessories organization
Are there existing standards and a shared Colors, coding systems for tools , jigs and
Visual standards for marking, Marking rules and color codes are not markings (raw materials, finished products, standards and to an established codification and management. A reference book has
1 coding system for areas, tools ,pipes and pipes have been defined and are
signboarding and tools management clearly defined for the site. bins, etc) and are implemented in all system. Moulds, fixtures and machine been created with all the standard operating
equipment markings? implemented.
workplaces. accessories are marked out with defined procedures for cleaning and organization of
codes. moulds, dies and jig storage, et).

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The standards to avoid dirt have been


defined by teams and displayed where dirty
Each team manages its own cleaning
Have cleaning routines, Orderliness There are no cleanliness standards. There are a few cleaning rules or operations take place. Cleaning and Cleanliness and cleaning standards are
schedule and inspections, has a checklist of
2 Orderliness and cleaning standards standards and inspection routines been Cleaning and inspection programs are instructions for some workstations, but they inspection routines, as well as cleanliness displayed and integrated into daily team
specific control points, and all areas are
visually standardized? neither visible nor clearly formalized. are incomplete. criteria, are displayed. All disposal recipients activities.
clean and under control.
have been identified, and all discarded
mater

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Some rules are formalized, operators are Instructions are clear and visually indicated Quality parameters and standard operating
Are production rules operating Operating rules and procedures are not
trained and work according to habits. There on all workstations: production and process procedures are displayed at each The process is defined by clear, visual
procedures and safety standards, clear clear; the process is uncertain or it results
Production operating procedures, are instruction and quality forms at the parameters (weight, pressure, temperature) workstation. standards which are adhered to. Process
and accessible? Are there dangerous from a habit. There are no traces of quality
3 safety and quality standards workstation. are visually indicated. Visual standards for hazardous activities are malfunctions will be seen at a glance.
activities in the workplace that have not forms or specific instructions. There are no
safety instructions are displayed where All rules for dangerous activities have been clearly displayed where hazardous Mistake-proofing systems are developed to
been defined and visualized by a appropriate and visualized safety rules for
hazardous actions take place. Displays and standardized and displayed where operations take place, and they are adhered prevent dangerous operations.
standard? hazardous operations. No visible saf
visual controls of safety condit operations take plac to.

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The management of consumables/ various Teams have a checklist that they can refer
There are no standards for the management Systems have been set up with warehouses
Are there standards for the management kinds of products is under the responsibility to for a regular checking of reorder levels.
Consumables, supplies and raw of consumables, cleaning products and Minimum and maximum quantities for or suppliers (FIFO, Kanban system) for the
4 and supplying of consumables and raw of teams operators: a visual standard allows Checklists are displayed and integrated into
materials management materials in the workplace. There are products used regularly have been defined. regular replenishment of products necessary
materials? to see at a glance when products need teams routines, and replenishment
occasional stock shortage situations. to the teams, and they are fully respected.
resupplying. standards are fully respected.

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Saint-Gobain HPM Sector


28/06/05 Productivity Group Europe
5th S: Sustain

Sustain improvements and make further company wide


INITIAL SITUATION FIRST IMPROVEMENTS DEVELOPMENT INTEGRATED SYSTEM EXCELLENCE
improvements

INTENSIVE CONTINUOUS
CONTINUOUS IMPROVEMENT A CONTINUOUS IMPROVEMENT
Check item Question NO REGULAR 5S ACTIVITY REGULAR 5S ACTIVITIES ARE STARTING
ACTIVITIES ARE BEING DEPLOYED CULTURE IS ESTABLISHED
IMPROVEMENT ACTIVITIES ALL OVER
THE PLANT

The 5S are not integrated into the activity.


The Steering Committee has started audits
Is there a formal 5S program with No formal program . Management is not
and performance meetings, but they are not The Steering Committee audits are part of Steering Committee audit programs and
1. 5S project with management management commitment? Is the 5S aware of the benefits. The Steering The Steering Committee audits are
carried out regularly. 5S achievements are the reporting system and teams priorities are results for all production units and all the
1 commitment and a Steering vision shared in the plant? Are targets Committee members do not carry out any scheduled on a regular basis in the
amongst the managerial staff priorities and regularly defined with the managerial staff teams priorities are displayed in a place
Committee clearly communicated? Are there an audit audits. The nature and the objectives of the workshops. 5S are part of team activities.
they are followed during workshop meetings. and the Steering Committee. shared by all personnel
system and a reporting system in place? 5S project are not displayed and known by
everyone.

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All workshop operators have been trained in


A large part of workshop operators have Everyone takes part in the 5S activities and Each team is responsible for an area in the
5S. Each team is responsible for an area,
All workshop operators have not been been trained to the 5S, the 5S team activity each team is responsible for an area. Some workplace. The activity board is a regular
Have all operators been trained to the 5S and a meeting point with an activity board
trained to the 5S and there is no evidence of board is set up, but regular team activities time is allocated to the 5S activities. Team and systematic meeting for the team;
5S training and team activities. and is there a continuous 5S team activity has been set up. Regular meetings and
2. team activity. have not started yet. All documents are not members photos are displayed on activity documents are up-to-date. There is a 5S
Audits and follow-up all over the plant, with a regular audit plan teams are developing.
up-to-date. Some audits have been boards together with team action plans. coordinator in each team. The planning of
clearly defined for all the teams?
scheduled, but they are irregular, and the team audits as well as all the elements of
Audits are made by the whole team,
last Audits are made regularly and lead to im the te
supervisors and operators, as

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All identified issues are subject to A process for the treatment of abnormalities
Several improvement ideas have been put
Have improvement suggestions, projects A couple of recent improvement ideas and a improvement projects and displayed on (problem solving methodology) and the
forward, they are recent and well displayed
Ideas for improvement, problems and action plans been structured and There are no recent improvement couple of issues have been targeted for an activity boards. Abnormalities are subject to follow-up of improvement ideas has been
3. on the team activity board. Meetings aimed
solving and action projects visually displayed, and are they visible to suggestions, or visible action projects. improvement project and are displayed in a clear improvement process. Action plans set up. Teams have set up a very efficient
at solving some particular issues have been
everyone? the workshop. are shared out between team members and and shared organization for problem
scheduled.
displayed on the team activity board. analysis and action plans follow-up.

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The workplace performance indicators are


There are a few performance indicators, but displayed and up-to-date. The results for 5S The performance indicators are followed by
There is no displayed indicator of the
Is everyone informed of the workplace they are not up-to-date, they are still too audits and indicators related to the teams and the 5S action plans progress All teams develop their own action projects,
4 Performance indicators production unit performance and of the 5S
past and present achievements? global or do not reflect correctly the improvements due to the 5S are displayed are being related to a process indicator and process and performance indicators.
progress.
production unit performance. on the activity board or in the production to a financial indicator.
unit.

1 2 3-4 5 6

Saint-Gobain HPM Sector


28/06/05 Productivity Group Europe
OFFICE 5S CHECK LIST
OFFICE 5S CHECK LIST

1st S: Sort through/sort out Eliminate what is unneeded and decide what is needed

Check item Question 1 2 3-4 5 6


SCORE
FIRST INTEGRATED
INITIAL SITUATION DEVELOPMENT EXCELLENCE
IMPROVEMENTS SYSTEM

Are there any unneeded things (newspapers, samples,


1. Unneeded objects
various items) on shelves and in file cabinets? 0

2. Unneeded files Are there any files requiring specific archiving? 0

Are there any computer cables and wires lying about on


3. Cables and wires
the floor? 0

Are walls, machines or boards covered in unneeded


4, Walls, equipment and partitions
calendars and posters? 0

0
Total S1

Saint-Gobain - HPM Sector 28/06/2005 Productivity Group Europe


2nd S: Set in order Define a specific location for every item needed

Check item Question 1 2 3-4 5 6


FIRST INTEGRATED
INITIAL SITUATION
IMPROVEMENTS
DEVELOPMENT
SYSTEM
EXCELLENCE SCORE

Are shelves and filing cabinets identified with labels,


1. Shelves and filing cabinets
markings and visible codes? 2

Documents, files and binders Is there any indication of title, number, name of person in
2.
identification charge, and/or date on file or binders? 2

Are documents, stationery, materials well-ordered and


3. Easiness of use
easy to reach and return to their location? 1

Are the various areas, cabinets, and offices clearly


4, Areas indication
identified? 2

7
Total S2

Saint-Gobain - HPM Sector 28/06/2005 Productivity Group Europe


3rd S: Shine and sweep Keep the workplace clean and eliminate abnormalities

Check item Question 1 2 3-4 5 6


FIRST INTEGRATED
INITIAL SITUATION
IMPROVEMENTS
DEVELOPMENT
SYSTEM
EXCELLENCE SCORE

Are floors, carpets and walls clean, do paintworks need


1. Cleanliness of floors and walls re-doing? Are windows, shelves and plants regularly 0
dusted and cleaned?

Is there a specific person in charge of keeping files up-to-


2. Updating tasks
date for each subject? 0

Are wastebaskets and destroyer bins regularly emptied


3. Wastebaskets
before they overflow? 0

4, Feeling of tidiness and cleanliness Offices are clean, few documents are not filed. 0

0
Total S3

4th S: Standardize Create a visually managed workplace

Check item Question 1 2 3-4 5 6


SCORE
FIRST INTEGRATED
INITIAL SITUATION DEVELOPMENT EXCELLENCE
IMPROVEMENTS SYSTEM

The location of files, books, articles and stationary can be


1, Visualization seen at a glance. All cabinets are visually defined with 0
their contents.

Is there a procedure for dealing with confidential


2, Confidential documents and archiving
documents and archives? 0

Have team defined a shared filing system in the computer


3, Shared filing system and are the work-in-process files managed with a 0
visual system indicating progress level and things to do?

4, Stationary Are minimum supplies levels clearly indicated? 0

0
Total S4

Sustain improvements and make further company wide


5th S: Sustain improvements

Check item Question 1 2 3-4 5 6


FIRST INTEGRATED
INITIAL SITUATION
IMPROVEMENTS
DEVELOPMENT
SYSTEM
EXCELLENCE SCORE

Do team members carry out regular meetings in a


1, Meetings
specific area? 0

Are activity scheduling, departments tasks and


2. Work schedules and performance
performance indicators clear and visualized? 0

Are meetings and traveling schedules clearly visualized


3. Schedules
and displayed? 0

Have dates been set within the team for audits, and to
4, Audits and updating
update and dispose of documents? 0

0
Total S5

TOTAL SCORE 7

% of ultimate target 5.83%

Saint-Gobain - HPM Sector 28/06/2005 Productivity Group Europe

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