SEIRI - 1st S (Sorting out)

Sl.no Description Max.Marks

1 Floor Area of Departments
a) All floor Clean 5
b)Disposal of Scrap items,Old samples,records etc 5
c) Unwanted items keeping over m/c,window,wall etc. 5
2 Insides and Top of all Tool box, Shelf,trolleys,drawers etc free from unwanted
5
material
3 Walls are free of old posters, calendar, pictures checklists etc. 5
4 Displays, graph boards, standard Size Boards are free of old Notices
a) No old papers. 5
b) Removal with date marking 5
c) Person responsible marked. 5
5 Items are stored based on the usage frequency 5
6 Any unwanted materials kept long period within the dept 5
7 a) Review and disposal of Red tag materials and follow up 5
b) Value yard follow up. 5
8 Disposal of defective handling equipments Crates,bobbins etc 5
9 Disposal of wastes at correct intervals 5
10 Disposal of unused materials like damaged parts downgraded lots, llnd quality 5
materials
11 Red Tag area marked 5
12 Red tag check list and register availability 5
13 Availability of Disposal strategy/Disposal Plan 5
11 Seiri disposal strategy adoption 10

Total 100
Marks Awarded Remarks
 SEITON - 2nd S (Set in Order)
Sl.no Description
1 Direction indication for all Fecilities

a) Alley way marking

b) ID for machines,Plant room, Waste Room etc.,

2 All machines have identified with lables (Colour code boards)

3 All equipment, tools, files, etc are arranged according to usage frequency

a) Trolley's/Mock drill for fire/ Tools traceabilty/ crates area marking

b) Machine Handling equipment placing area marking
c) Machine tools list, Files list display for easy traceability
d) Every thing in its place with marking
4 X, Y alighnment for placement of all equipments, tables, trolleys, notices, fire
extinguisher, pipe lines etc

a) All Posters,paintings, charts, photographs

b) All Trolleys,cupboards,machine etc.
5 Visual displays for defects and rework
a) Marking to prevent mix up
b) Marking for do not switch on
6 Alley way marked for all areas with yellow line

a) Entrance, Exit lines, Emergency Exit with clean ID

b) Door Opening lines

c) Marking of machine moving parts (OHTC)

7 Areas for rejects, waste, garbage with ID

8 ID for lighting, fans, A/C

9 All pipe lines, wires, cables, etc are neat and straight in all depts

10 Colour coding is used effectively for easy ID in all depts.

11 Good orderliness to find any items, files, tools, documents

12 Any system to trace out a Staff,technician

13 Any materials with out id (like rework,damages etc)

14 ID for regu;ar usage items like bobbins,cops, cones etc

15 ID for usable waste and salable waste

Total
rder)
Max.Marks Marks Awarded Remarks

5
5

5
5
5
5

3
3

3
3

5
 5

100
 SEISO - 3rd S (Cleaning)
Sl.no Description
1 Cleaning Responsibilty chart and schedules are displayed

2 Cleanliness of machines and maintain at high level always

3 Waste bin strategy followed in all depts
a) Bin waste disposal with interval
b) Marking for all bins
4 Equipments, Tools, furniture are maintained at a high level of cleanliness
Clean Machines
Maintenance schedules
Cleaning checklist evidence

5 Cleanliness of the following

Floor
Wall
Windows
Doors
Pipe Lines
Systems

Racks
Displays

6 Usage of cleaning Tools are evident

a) Evident of appropriate tool in place in all depts
b) Checklist of tools maintained

7 5 minutes 5s in all dept with checklist

8 Problem Recording and follow up after 5 min 5 S

Total
g)
Max.Marks Marks Awarded Remarks
10

10
10

15

15

20

10

10

100
 SEIRI - 4th S (Standardise)
Sl.no Description
1 Standardisation of 5 S Procedures

Standard size boards and displays in all depts

Pipe line colour
Section wise file differentiation etc

2 Rules and Reguation display and follow up of checklist

3 All alley ways and gang ways have standard size and colour

4 All lables and notices are standardised

5 Fire extinguishers are clearly maked and placed

1. indication for Type
2.Easy accessible
3.Visible from any place in the dept
4.Checked at appropriate intervals
6 Pipes, Cables Etc,as per colour code according to the standard

7 Standard warning signs for the following

a) Prohibition signs
b) Must do signs
c) Danger signs
d Safe way signs

8 Standard Visual Management is evident

Fire Pipe lines, Safety awareness

9 System Do's and Don'ts displays in depts

10 Innovative visual control methods are implemented

Total
se)
Max.Marks Marks Awarded Remarks
15

15

10

10

10

10

10

10

100
 SEIRI - 5th S (Standardise)
Sl.no Description
1 5 S understanding of Leader / Co ordinator

a) General awarenesas
b) Involvement

2 5 S Understanding of members and workers in particular zone

3 5 S in daily activity for team (sustaining )

a) 5 min 5s cleaning in dept effectively
b) Follow up and action to be verified

4 Internal Audit Once in a Month

a) Reprts to be verified
b) Follow up and action to be verified

5 Training Programme/ meeting

a) Evidence of Traning for existing/new workers

b) Evidence of follow up (evaluation)

6 Innovative and new ideas in 5 S activities

7 5 S Progess monthly review

a) Team/zone meeting agenda
b) Team/Zone meeting minutes
c) Follow up of meeing points
d) Attendance maintained

8 Orderliness,cleanliness of team gallery and zone corner areas

9 5 S awareness Dispalys
a) 5 S Posters at work place/depts
b) 5 S Cards for workers

10 Corporate Social Responsibility

Total
se)
Max.Marks Marks Awarded Remarks
10

10

10

10

10

10

10

10

10

10

100
Sl.NO Description Marking Details Size if any
1 File Marking
a ) Type of use
1.Most frequently used Green Sticker Size
2.Less Frequently used Blue 2"*0.5"
3.Confidential Red

2 Dept file visual id

Office Books Sticker Size
Marketing A man with Suitcase 2"*2"
Sales A ma talking phone
Despatch Moving lorry with Container
Cashier Ruoee note
HRD Team of peaple teaching
Security Police security
Packing Pallet
Stores Rack with materials
Cotton Dept Cotton flower
QAD Q symbal
Maintenance Spanner
Spinning Vops
Sizing Beam
Weaving Loom Side view
Warehouse Storage cloth bundle
Electrical Lighting symbol
Hostal Dormitory Cots
Mess Fork with Spoon
Civil Masonery Bowl with Spoon
Transport Lorry without body

3 Painting colours
Compound Outside
Compound Inside
Factory Outside
Factory Doors
Factory Window
Office Outside
Office Oudoors
Pillors
Fire extinguishers
Fire extinguisher ID ABC type
Fire extinguisher ID Hydrant
Humidification Plant
Supply air diffuser
Trench Grill

4 Pipe Line Colour

Fire Red
Water Dark Green
Compressor Pipe Sku Blue
Material Ivory
Microdust Light Blue
Waste Water Pale Green
Hot water Brown
Diesel Pipe line Yellow
Gas Pipe line Gold
Remarks Sl.NO Description
5 General
Gate Colour
Pasted on Top of the file Company Name & Board Display
Display Board / Displays

6 Line Marking
Alley Ways
Pasted on Bottom of the file Furniture/Equipments

7 Man Holes
Water Tank
Cable Trench
Pneumatic air line Trench
Exhaust Trench
Ladders
Drainage/Septic Tank

8 Others
Ramp
Trolley Place
Do not Store area
Moving area
Safety Guard
Emergency Exit

9 Tools Colour
Blow Room Card
Lapformer Comber
Drawing Simplex
Spinning
Autoconer
Vortex
Power house
Sizing
Weaving
Garden/Civil

10 Gear Wheels and Pullies

Blow Room
All other dept

11 Process Waste Bin colour

Sliver waste
Pneumafil waste
Roving waste
Lap Waste
Contamination
Hard Waste
Plastic waste
Iron Waste
Problem Cops
Damaged empties
Dust Bin
Marking Details Size if any Remarks Sl.NO
12

Font Size, Colour,Back ground colour

Font Size, Colour,Back ground colour

3" width Yellow Colour

1.5" width Yellow Colour

Green/White Zebra 13
Red/White Zebra
Sky Blue/White Zebra
Yellow/White Zebra
Yellow/Black Zebra
White/Black

14
Yellow
Sku Blue/White
Post box Red/white
Yellow intermittent line
Yellow / Black
Red Back ground white letter

15
Ivory
Orange
Lemon Yellow
Green
Tools Natural Colour
Blue
Red
Purple
Blue
Mild Buff

Sky Blue
As like Tools colour

Green
Blue
Orange
Yellow
Black
Grey
Violet
Dark Brown
Dark blue
Plain - Natural
Red
Description Marking Details Size if anyRemarks
General Waste Colour Code
Oil Waste Black
Sweeping Waste Red
Paper Waste Ivory
Scrap Waste Dark Brown
Food Waste Green
Plastic Waste Rose
Electrical Waste Silver
Damaged Glass Yellow.

Lighting ID
Light L Violet
Fan F Green
Plug P Red
Air Conditioner (A/C) Blue
Exhaust Fan (EX) Brown

Arrow Line Marking Tail width/Height

Pipe Line Size
1.300 mm to 500 mm 50mm
2.100mm to 250 mm 25mm
3.50mm to 75 mm 12mm
4.Below 50mm 8mm

Lubricants Oil container Colour

Max Amocam 220 Oil Light Green
Mak 15W/40 Oil Orange
To list such Oils and give Container colours