5S5S

TraininTrainingg

What is 5S + 1?What is 5S + 1?

A program that helps establish a clean, safe, organized workplace creating a new culture which will embrace change and ensure that

all improvements will be sustained!!!

“A Place for Everything and Everything in it’s Place”

5S TRAININGElements OF 5S

• SEIRISEIRI

• SEITONSEITON

• SEISISEISI

• SEIKETSUSEIKETSU

• SHITSUKESHITSUKE !!!!!!

The Elements of 5S + 1

• (SERI) = (SERI) = SSORTORT

• (SEITON) (SEITON) SSTRAIGHTENTRAIGHTEN

• (SEISI) = (SEISI) = SSHINEHINE

• (SEIKETSU) = (SEIKETSU) = SSTANDARDIZETANDARDIZE

• (SHITSUKE) = (SHITSUKE) = SSUSTAIN!!! USTAIN!!! (THE KEY TO (THE KEY TO SUCCESS)SUCCESS)

• + 1 + 1 SSAFETYAFETY

Purpose of 5S +1

•5S + 1 is a method to improve and sustain workplace organization

Purpose of 5S +1

•5S + 1 represents 6 disciplines for maintaining a visual and safe workplace.

Purpose of 5S +1

•Reduces clutter

Purpose of 5S +1

•Reduces the time it takes to look for tools, equipment and parts

Purpose of 5S +1

•“A place for everything and everything in its place”

Purpose of 5S +1

•Creates pride in the workplace

Elements of 5S + 1Elements of 5S + 1

• Sort– Remove all unnecessary materials and equipment

• Straighten– Make it obvious where things belong

• Shine– Clean everything, keep everything clean inside and

out• Standardize

– Establish policies and procedures to ensure5S + 1

• Sustain!!!– Training, daily activities,

• Safety (often called “6S” or “5S + 1”)– A safety commitment in all activities

A Maintenance Shop Without 5S + 1

Department 30 Shop WITHOUT 5S + 1 Training

Department 30 Shop

WITH 5S + 1 Training

SortSort

• Red Tag (tape) exercise – One-time activity to remove One-time activity to remove

or disposition clutteror disposition clutter– Identify clutter, unused Identify clutter, unused

equipment, etcequipment, etc– Use Use REDRED Duct to tag Duct to tag – Red tagged (or taped) items Red tagged (or taped) items

must be disposed of within must be disposed of within 30 days30 days

• Identify clutter and disposition

• When in doubt, throw it out

SortSort

StraightenStore Them in a

Designated Area

Straighten• Clearly Mark And Arrange

Everything Neatly So What Is Needed Can Be Easily Found

Straighten

Floor Surface

Define A Clear Boundary around Work Area (i.e. – grinding equipment, lifts, tire changing machine)

Maintenance equipment and golf cars parked in designated area with passable walkways. Floor striping.

StraightenFRAMES

A Frame Is A Specific Space Enclosed A Frame Is A Specific Space Enclosed By A Tape Line of a Certain Color By A Tape Line of a Certain Color That Identifies A Specific Item For That Identifies A Specific Item For That SpaceThat Space..

Straighten• Decide On Places For Storage

• Mark Storage Locations

• Mark Items To Be Placed In Storage For Ease Of Maintenance

StraightenFRAMESTools:“Footprint” A Storage Space For Each Tool

StraightenLabeling

Label each tool drawer to help identify and cut down time when looking for a tool.

StraightenLabels

Straighten• Clearly Mark "Danger Zones” and "Off Limits" Areas

of the maintenance facility.• Fuel Storage Area• Pesticide Storage Area• No Trespassing

Straighten Designate a location for hand tools, weed

eaters, edgers, blowers, and other small tools. All tools should be stored hung off

of the floor.

StraightenMaintenance Records, Service Tech and Partsmanuals stored neatly in central location of mechanics work area. Equipment check off

sheets located near equipment for easy access.

Straighten

Dept. 40 Dept. 30 Scheduling Board Detail Cart PostersRising Stars Battery Care Poster Preventive Maintenance Board Charging Poster

Organize Documents, Charts, and Posters

Standardize• Make the standards and 5S + 1 guidelines visual• Maintain and monitor those conditions through the use of our tools:

Dept. 40 Dept. 30

MPS/Cleanup Schedule Assembly Line MaintenanceTraining (Rising Stars) Training on Detail ProceduresPreventive Maintenance Warranty ProgramSafety Meetings

Shine

• Everything kept Clean, inside and out• Prevent dirt and contamination from recurring• Wash Equipment daily• Detail Equipment on an Semi Annual basis

– Results in• Fewer breakdowns• Greater safety• Product quality• More satisfying work environment

ShineDesignate a Time and Task For Everyone To

Engage In Cleanup Activities on a daily basis.

Shine

• Each job tasks scheduled for all areas (inside and outside) of maintenance facility with standard Start Time

• Daily work schedule implemented 365 days per

year

• Check List for Cleaning

Sustain!!!The Key to a Successful

Operation• 5S + 1 training for Dept. 30/40 Co-workers• Managing Daily Cleanup Schedule• Checklists, Standards and Procedures• Quarterly 5S + 1 Audit by GM & Supt.• BEST PRACTICES• Use Before and After Photos• Reward and Recognition Program • Co-Worker Accountability!

Safety•Emergency Shut Off Switches

•Fire Extinguishers clearly marked and properly charged

Safety

During 5S + 1 audits also review all areas During 5S + 1 audits also review all areas for safetyfor safety

First Aid Kit properly stockedFirst Aid Kit properly stocked Eye Wash Kits and Stations located Eye Wash Kits and Stations located

in all shopsin all shops

Safety

During 5S + 1 audits also review all areas During 5S + 1 audits also review all areas for safetyfor safety

Emergency Clinic Address and Map Emergency Clinic Address and Map PostedPosted

MSDS Sheets current to inventoryMSDS Sheets current to inventory

Safety

Safety Switches on Maintenance EquipmentSafety Switches on Maintenance Equipment Key ControlKey Control Parking Golf Carts in Staging AreaParking Golf Carts in Staging Area Parking Golf Carts in Storage AreaParking Golf Carts in Storage Area Protective Eye WearProtective Eye Wear Steel Toed BootsSteel Toed Boots Protective Head Gear when on Golf CourseProtective Head Gear when on Golf Course

Common Sense or the lack of!

SAFETY

When others get in a hurry sometimes SAFETY is forgotten. This is what happens when others don’t take the time to think about SAFETY.

AGC’s 5S + 1 Implementation

1. Begin reviewing your shops for 5S + 1 immediately!2. Train your Dept. 30 & 40 Maintenance Team on 5S + 1

Concept!3. Red (tag) Tape exercise (one time)!4. Brief 5S + 1 checklist or procedure for each area!5. 5S + 1 audits!

• Directors of Maintenance and Fleet Managers to perform Audit during course visits

• GM/Superintendent to perform each quarter• Results posted and reviewed with maintenance team• Action plans implemented to correct issue if necessary

AGC’S VisionA Maintenance Shop with 5S + 1

The End ResultsThe End Results

The End ResultsThe End Results

The End ResultsThe End Results

The End ResultsThe End Results

The End ResultsThe End Results

The End ResultsThe End Results