5s guidelines

7/28/2019 5s Guidelines

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XX CELLGUIDELINES FOR STANARDIZING AND SUSTAINING 5S

SORT(Do we need this?)

SET(Do we have a good place for this?)

SHINE(Is it in the designated place, labeled and clean?)

STANDARIZE(Is there a written procedure for this?)

SUSTAIN(Are we auditing and maintaining the written standard?)

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TABLE OF CONTENTS

GENERAL Pages 3-4

General Guidelines

Area Division

Daily Activities

Weekly Activities

Audits

Floor Taping

Floors, Wall, Aisles, Ceilings

MAIN CELL Pages 5 - 6

Cell Operation Areas

Kanban and Queue Locations

Supermarket

SFGI and SFGI Overflow

Communication Areas

TECHNICIAN AREA Page 7

Troubleshooting and Repair

Troubleshooting Test Fixture Storage

Tool and Misc. Equipment Storage

ADMIN AND MATERIAL SUPPORT Pages 8-10

Desk Areas

Quarantine

Staging area

Reject Area

SECTIONS TO BE DEVELOPED N/A

Annex

NPI cell

Appendix: Page 11 Floor Taping Guidelines

5S Operator Daily Check Sheet

5S Audit Sheet - General

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XX CELL - GENERAL

The guidelines for 5S in each area of the Signal Sources cell will be maintained

in a clearly labeled binder at the cell leader bench.

Any employee may suggest updates to the documentation.

Cell leaders and managers are responsible for maintaining updates. Only the

current approved version will be stored in the binder and this will be the onlyauthorized copy for setting the 5S expectations within the area.

The Signal Sources area of responsibility is divided into separate locations for thepurposes of conducting 5S activities. These areas are:

1. The Cell Operation area (cell proper). It includes the Supermarket as well asoperations on the main route from board test though shipping. Also includedare the communication (stand-up) areas, shift report and SQDC/QDIL boardcontent.

2. Troubleshooting and Repairarea. This includes technician benches and thestorage locations within this area. Also included is test fixture storage, andboard repair benches.

3. Administration Areas: This includes manager, cell lead and material handlerdesks as well as the staging, quarantine and rejects storage areas controlledand managed by these individuals.

4. Annex and NPI lab:

DAILY ACTIVITIES:Each operator, technician, material handler and manager will conduct a 5S audit oftheir individual work area at the end of each shift. All tools will be verified and leftin the appropriate positions. Work surfaces will be clean. Floors will be free ofdebris. Any unnecessary items will be removed. Trashcans will be emptied.Calibration dates will be verified.

WEEKLY ACTIVITIES:All employees will participate in weekly audits and corrections to findings duringthe audits.

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AUDITS:Audits will be conducted by each shift on a weekly basis at the end of the shift.Results will be posted on the SQDC/QDIL board. Outside audits will beconducted at least once per quarter by an individual who has been trained to do sofrom any other group or support function.

FLOOR TAPING:Refer to the reference sheet titled Level 3: Visual Controls Floor Taping at theend of this document.

FLOORS:Floors are to be kept free of debris. Normal scuff marks are the responsibility ofthe weekly cleaning service but any lack of service should be called to theattention of the cell manager and the site manager for Washington Group.

WALLS and VERTICAL SURFACES:Building walls and cubicle may be used as approved by managers to display

information, posters and pictures relevant to our business, events or currentinformation.

AISLES:Aisle ways will be kept clear at all times even if a manager has authorizedtemporary overflow. Trip hazards and obstacles to safe exit from the area are tobe avoided at all times.

CEILNGS:Ceiling tiles should be free of obvious stains, breaks or holes. Burned out bulbsshould be brought to the attention of Washington Group for maintenance. Notethat some areas have bulbs removed with management approval

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XX MAIN CELL

CELL OPERATION AREAS

Each work bench will use shadow boards for tools or have taped out space for

items that belong on horizontal surfaces.

Benches and PCs should be regularly cleaned. Cords and cables should be neatly dressed or stored and off the floor.

Work Instructions are posted on the company web site and will be open and

used for each build sequence.

Clipboards will be hanging at each station for displaying current waivers and

bench inventory sheets)

Kanban disciplines are TBD.

Only necessary items are to be present. Necessary items are to be clearly

labeled. All necessary items present and in their proper location at end of shift.

All equipment has current calibration dates.

No trip hazards At no time should food items be found within the ESD protected cell area.

The stand up area should be free of chairs, instruments and material other than

what is needed for show-and-tell.

KANBAN AND QUEUE LOCATIONS

TBD

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SUPERMARKET:

Flow Racks should be clean, labeled and orderly.

All part locations for storage are to be marked on both the front and back of

flow racks.

All individual boxes and totes are to be labeled with the current part numbers

(no use of xx suffix). Water skipper carts are to be left in taped out locations except when in use.

Personal notes, etc. are allowed on the work surface of the cart or pc location

during the shift but must be removed at the end of each shift.

SFGI and SFGI OVERFLOW: Instruments will be placed on the approved storage racks/locations in an orderly

fashion.

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XX Cell TECHNICIAN AREA

TROUBLESHOOTING AND REPAIRTechnician bench tops and shelves are for tools, equipment and referencematerial to be shared by bench partners. Items on the bench top and shelves willbe neatly organized and clearly labeled. The only items to be stored at the benchare those items which are used frequently throughout the week.

Items used less frequently than on a weekly basis but are still needed for currentwork activities will be stored in the storage cabinet. All items in this cabinet willhave a designated and neatly labeled location for storage.

The top bench drawer should contain shadow boards for tools. The bottom drawer

will contain neatly stored and organized reference material such as personalcopies of schematics or personal notes and other reference materials.

TROUBLESHOOTING TEST FIXTURE STORAGE:

Each fixture is to be labeled with name or part number.

Fixtures are to be stored in designated locations or taped out floor locations

when not in use.

As fixtures are needed they are moved to a work bench. They are to be

returned to storage at the end of the shift or when finished working with them.

TOOL and MISC EQUIPMENT STORAGE:Items infrequently used and shared by technicians will be kept in a storage cabinetadjacent to the test fixture storage. Items in the cabinet will be neatly labeled andstored.

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XX CellADMINISTRATIVE AND MATERIAL SUPPORT AREAS

The purpose for these standards is two-fold:1. Desk areas should be kept visually appropriate for tours, important customers

and other visitors.2. In the event of an unplanned absence, the desk area should be organized andlabeled well enough to allow a person with general knowledge of the role totake over with a minimum of difficulty in understanding what stage varioustasks were left in and where necessary records are stored.

ADMINISTRATIVE DESK AREAS:

Administrative desk areas should be neat, well-organized and free of clutter at

the end of each work shift.

Nothing shall extend above the height of higher cube walls.

Work surfaces shall be clean of stains and debris.

Drink and food items and containers should be properly stored away in the

break area, personal lockers or designated drawer space at the end of eachshift.

No appliances (coffee pots, microwaves, refrigerators, etc.)

Desks which are not shared with others are allowed personal items so long as

they do not impede on required workspace if others need to use the desk.

Personal items should be appropriate to a business environment.

Floors should be clear of items other than trash can, one recycle box and

personal heaters or fans approved by managers.

Miscellaneous supplies should be neatly stored in pencil and desk drawers. Only currently active work should exist on the desktop.

Cabinet surfaces should not be used for desktop overflow but may be labeled

and used for appropriate holding space for work.

Drawers, cabinets and work in progress should be labeled well enough for

others to step in during an absence.

Reference material posted on interior walls should be current and necessary.

All parts and assemblies temporarily at a desk will be properly protected. They

will be re-located to their proper storage locations before the end of the shift.Exceptions are allowed only for overnight attention and communication to the

next days shift.

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QUARANTINE:The quarantine area is used to temporarily store material or instruments beingevaluated or with some kind of problem causing it need to be kept apart fromsupermarket inventory. Items kept in this area must be labeled with the followinginformation:

What it is

Why it is in quarantine

Who is responsible or owns the items/problem

Date the item went into quarantine and if known, how long it is expected to be

stored there.

Items in the area should be reviewed at least on a monthly basis to be sure theydo not linger for long periods of time without action.

STAGING AREA:Items in the staging area are instruments staged for work activities that are not

part of the cell daily rate or are waiting for some support activity. Examples are: Code 5 warehouse returns

Waiting for rework

Production Hold.

As items move into the staging area the white board will be updated with thefollowing information:

Date in

Who is responsible

Reason for the item being in the staging area What needs to happen for it to move out and/or expected date for it to move

out

As items leave the staging area they should be erased from the white board sothat the white board is always up-to-date with the current content of the stagingarea. This area should be audited as part of the end of shift clean up activitieseach work day.

This is not a location for storing parts or collecting unnecessary items.

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REJECT AREA:

Reject parts must be clearly labeled and should be found in only one of three

areas:

1. Cell lead desk tops have clearly marked bins for parts coming off the line asmaterial needing to be rejected. Cell leaders print the appropriate tags and doall necessary quality record entries. This work should generally be completedbefore leaving for the day.

2. Once rejects have been appropriately labeled and transacted by the cell lead,they are moved to the black bins on the reject carts adjacent to the stagingarea. Material Handlers process these items on a daily basis by transactingthem in Oracle. As they do so, the material is moved to the orange bins for anengineering review prior to having the parts scrapped. Engineers will make the

final determinations as to whether these parts can be used as is, returned tovendors or discarded as scrap.3. Cell lead benches also have separate bins for returning reject parts to each

shift cell leader when the reject tags have not been properly filled out. Thisensures the correct individual gets the appropriate feedback for correctiveaction in the future. These bins are not to be used to deposit reject parts forany other reason.

No part should linger in any one location for more than two business days.Exceptions should be brought to the shift managers attention so that additionalhelp can be called for as needed. Rejecting parts in a timely manner ensures wecan keep appropriate inventory levels and have knowledge about leading edgequality problems.

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APPENDIX

Floor Taping Guidelines.Page 12

5S Operator Daily CheckList.Page 13

5S Audit Sheet GeneralPage 14

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