5S & VWM Assessment for Safe and Vibrant Workplace

Guidelines 2021-22
Total QualityManagement 1
ChangeAuthorization

Document Number TQM//TPM/5S/01

Overall Process Owner TQM, TSLPL

Process Change Authorization TQM, TSLPL

To be ReviewedBy TQM, TSLPL

Periodicity of Review of this Document 1 year / As andwhen required

VersionControl History

Ver. Date Revision Details Prepared by Authorized by

0.0 14.07.2021 First Version Sanjay Sharma Dr. T Bhaskar

PREPARED BY APPROVED BY
Name Sanjay Sharma Dr. T Bhaskar

Designation Divisional Manager-TQM General Manager –QA,QC, TG, TQM & NPD
Date

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Contents
A. Introduction 3
B. Background 5
C. Purpose of Guideline 6
D. Assessment Process 6-9
1. Ownership 6
2. Scope 6
3. Governance Mechanism 7-8
4. Assessment Criteria 9
5. Assessment Area
9
E. AssessmentTeams
9-11
F. Rewards & Recognitions
11
G. SuggestionsforImproving5S & VWM
11-12
H. Annexures
12

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 A. Introduction
‘5S’ is a system for organizing spaces in such a way that work can be performed efficiently, effectively and safely. This system focuses on
putting everything where it belongs and keeping the workplace clean, which makes it easier for people to do their jobs without wasting
time or risking injury. Visual Workplace Management (VWM) is a great enabler for good deployment of 5S. It helps in better communication,
identification of abnormalities and for things to be returned to their proper storage area after use. Few of the benefits of implementing ‘5S &
VWM’ are as follows:
• Clean, Safe and Vibrant workplace
• Reduced inventory
• Easier to fetch things
• Reduced search time
• Fewer misunderstanding with respect to instructions

BM-Clean & Marked Pathway

LKP-Lub Store SBM-M/C Shop

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BF-1 Pump House- Visualization WRM-TG Grinding- 3S activity
BM-CNC- Visualization

B. Background
TSLPL had recognised the importance of 5S and VWM early and had instituted a process of evaluating its deployment. It helped in overall
improvement of the look and feel of the shop floors. As the maturity of deployment grew, the requirement of frequent evaluation decreased.
However, in the last few years, it has been observed that emphasis on 5S & VWM has reduced in some areas. Several of the safety related
incidents in recent years have happened due to ‘Slip-Trip-Fall (STF)’, ‘Human-Machine interface’ or ‘Moving machinery’ related hazards, which
could have been avoided by better deployment of 5S & VWM practices. To address this concern, a quarterly ‘5S & Visual Workplace
Management Assessment’ process is being initiated across TSLPL. The process will be managed jointly by the TQM and Safety departments
under the aegis of Plant level SHE review committees.

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C. Purpose ofGuideline
This guideline has been prepared to standardise the process of assessing deployment
of 5S & VWM. It will also help the departments in deploying 5S & VWM effectively in their workplaces.

D. AssessmentProcess

1. Ownership
The assessments will be conducted jointly by TQM and Safety departments under the aegis of Plant Level SHE review committees.

2. Scope
The assessment process is being deployed in all manufacturing units & Services functions of all locations of TSLPL. The detailed list of
Assessment Units and the departments included in each assessment unit has been appended in the Annexure 1.

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3. Governance Mechanism

Plant Level SHE Review Committees

TQM & Safety Department Planning & Support
Reviewing
Bodies

DIC Divisional Improvement In-charge

+ Coordination at
Divisional Safety Professional Divisional Level

Role
AIC SGA/TPM Coordinator
+
Coordination at
Departmental Safety Professional Departmental Level

Assessment Departments
Unit Apex Level Function Reward & Recognitions

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Role &Responsibilities of DifferentAgencies
Agency
Plant Level SHE review committees
DIC
AIC
TQM & Safety Department
Divisional Improvement In-charges and
Divisional Safety Professionals
SGA/ TPM Coordinators and Departmental
Safety Professionals
Reward & Recognition Committee
Role
• Provide guidance to TQM and Safety department on formulation of guidelines and assessment criteria
• Review of the progress of the departments on 5S and VWM
• Acting on issues escalated from DIC
• Communication of guidelines to AIC
• Acting on audit findings applicable for the entire division
• Acting on issues escalated fromAIC
• Reviewing the audit findings and directing the respective
department to take necessary actions against OFIs
• Reviewing the action plan and timeline for Corrective action
• Reviewing the progress of action against plan
• Preparation of Check list / guidelines / SOP as required
• Scheduling audit plans
• Training and facilitation on implementation of 5S and VWM
• Monitoring assessment compliance
• Circulation of feedback to departments
• Coordinating between assessors and assessees
• Presentation of the divisional level report to DIC
• Facilitating departmental assessment
• Presentation of the findings in AIC
• Compliance to action plan on assessment finding
• Annual Reward & Recognition
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4. AssessmentCriteria Training of 5S & VWM trainer & employee
The assessment criteria cover following aspects: • Development of 5S trainer at department level for 100% coverage of all
❑Sorting (1S) employees
❑Systematizing (2S) • Providing training by departmental 5S trainer in their respective area and cover all
❑Shining (3S) employees, training pack should be provided by TQM
• Finalization of Audit team as per the criteria defined
❑Basic Machine Condition
• Training of Accessors by TSL TQM team
❑Compliance to Safety Standards

5. AssessmentArea
The assessment will cover all locations/ geographical areas of the department Assessment Steps
under assessment such as : • Preparation of Audit Plan & Schedule
❑ On and around the Plant/ Building and Office Area • Mock Audit in selected department
❑ Shop floor • Starting of formal audit by 5S & VWM accessors
❑ Equipment
❑ Auxiliary (Pits / Basements / Cellars, Control Rooms, Hydraulic rooms
etc.)

The detailed assessment criteria are appended in Annexure 2.

E. AssessmentTeams
Assessment teams have been formed based on the criteria approved by the
‘Plant Level SHE review committees. Each team includes a Mentor, Leader,
Convener and Members. The list of assessment teams for FY22 is appended in
Annexure 1.
Audit Report
• Each assessment teams will conduct quarterly assessments for a
group of departments and share their feedback as per annexure-4
with the concerned departmental heads.

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 Criteria for each category of members is as follows:

Mentor
• Should be a E1 level officer
Leader
• Should be an E2 / M1 level officer
Convener
• Should be a member from TQM or Safety department
Members
• Subject Experts – TQM / SGA / TPM coordinators, Safety Professionals, Divisional Improvement In-charges, Trained Internal Auditors of the
Quality Management Systems.
• Changes Agents from Shop floors - MASS Leaders, Leaders, High Value suggester, Safety Supervisors or Workmen etc. having good understanding
of the subject.
• Union Representatives having good understanding of the subject.
• Any members of assessment team (including Mentor, Leader and Convener) should not belong to the AIC/ department being assessed.

Role of Mentors:
The assessment team members would seek the guidance and support of Mentors on the following matters:
• Planning and conducting assessments and discussing the outcomes
• Finalization of audit reports and circulation of result to departments
• Resolving any dispute/conflict with the assessesdepartment

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Note:
• Each assessment team will have 8-10 members (including Leader and Convenor)
• List of assessors will be revisited every year
• One assessment team will assess a group of departments having similar nature (like – IM, SM, Mills, DRI, CPP, Service functions etc.)
• Same assessment team will assess one department in all 4 quarters of an assessment cycle
• Post assessment, the team will share detailed report to the department as per the standard report format (attached as Annexure-4) along with the
scoresheet.

F. Rewards andRecognitions
There will two categories of rewards:
❑ Best 2 departments in every group:
✓ The average of scores obtained by a department in Quarterly assessments will be considered for this award.
❑ Best of the Best department in the company:
✓ The top-most department from every group will be assessed by a high- level committee chaired by Sr GM SHE&S
❑ The performance of the departments in the assessments will also be given weightage for deciding awards for SHE Excellence.
❑ A department will automatically disqualify for the award if there is any fatality or red risk incident in the department in the year under
consideration or before the award function
❑ The winners will be recognized during the company Annual Recognition Function.

G. SuggestionsforImproving5S&VWM
Department should endeavour to deploy 5S & VWM in all the areas and sections. A prescriptive checklist has been appended as Annexure 3 which
may be referred for the same.

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H. Annexures

Annexure-1: Assessment Teams & AssessmentUnits

Annexure-2: 5S & VWM AuditCriteria

Annexure-3: Prescriptive checklistfordeploying5S & VWM in the departments

Annexure-4: Assessment Report Format

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 Annexure-1: AssessmentTeams & AssessmentUnits - Gamharia

Assessment Units Department Assessment Team

MBF Leader : Mr. Manish Jain. Convener : Mr. Sanjeev Kumar (Safety)
Coke Plant
Members : 1) Mr. Soumya Mukharjee (SMS)
Pellet Plant 2) Mr. Dinesh Pradhan (WRM)
3) Mr. Arup Kumar (Shared Services)
Iron Making, Agglomerate, Utility Sinter Plant 4) Mr. Animesh Parashar (Admn)
& Power DRI 5) Mr. Prabhat Kumar (Utility)
6) Mr. Swadesh Sarangi (Environment)
CPP
IBMD Union Representative : Mr. Rajkumar Pradhan

Material Handling Department

SMS Leader : Mr. Subhankar Pal. Convener : Mr. Amit Kumar (Safety)
Limekiln Members : 1) Mr. Bhupendra Mishra (MBF)
BM 2) Mr. Chandrashekhar Sahu (SP)
3) Mr. Shaukat A Khan (DRI)
Steel, Mills, Utility, Shared SBM 4) Mr. Sanjeev Ranjan (HR)
Services. QA WRM 5) Mr. Vijay Mutalik (IBMD)
6) Mr. Kishor Pramanik (Environment)
Utility, Water, Gasses & Oxygen Plant
Central Electrical / Mechanical Maint. Union Representative : Mr. Ajay Das

Quality Assurance

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 Annexure-1: AssessmentTeams & AssessmentUnits - Gamharia

Assessment Units Department Assessment Team

Safety, Health & Environment
Security & Fire
HR, Admn, Training Institute
Finance & Accounts
IT Department
Service Functions
GM Office Building
MD office Building
Leader : Mr. Sidharth Roy Convener : Mr. Sanjay Sharma (TQM)
Members : 1) Mr. Sanjeev Kumar (BM)
2) Mr. P Senthil (CPP)
3) Mr. Hemant Sahu (COP)
4) Mr. P Patil (Pellet)
5) Mr. Sandeep Kumar (LKP)
6) Mr Soumya Nath (Environment)
Union Representative : Law kumar

Corporate Office
Engg & Project
Purchase & Stores
QC, TG, TQM

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 Annexure-1: Assessment Units & Assessment Teams – Joda

Assessment Units Department Assessment Team (From Vijay-II Mines)

Leader : Mr. Debashish Mukherjee Convener : Mr. Anuprasad Pal (Safety)

DRI Operations
Members : 1) Mr. Hemant Panda
2) Mr. Jay Kant Jha
CPP
3) Mr. Saroj Rout
4) Mr. Dulal Chandra Sardar
Mechanical Maintenance
5) Mr. Sanjay Mondal
6) Mr. Ramendra Kumar (Environment)
Electrical Maintenance
Operation & Maintenance

E&I

QA & PC

Civil Maintenance

Logistics

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 Annexure-1: Assessment Units & Assessment Teams – Joda

Assessment Units Department Assessment Team

HRM Leader : Santosh Kumar Das Convener : Abhilash Rout (Safety)

Members : 1) Prashant Sahu
Security
2) Manish Jain
Finance & Accounts 3) Nishi Kanta Sahoo
4) D. D. Mishra
Legal Services
5) P.K Rout Roy
CSR, Corp & Communications 6) Rishabh N. Singh

Service Functions 7) A K Sahu (TPM)

Internal Audit
8) Basu Sanyal- (Associates-Under Union category)
ITS 9) Barada P. Behera- (Associates-Under Union category)

Marketing & Sales,

Procurement, Purchase & Store

Office of Sr. GM

Safety, Health & Environment

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 Annexure-1: Assessment Units & Assessment Teams – Vijay-II Mines

Assessment Units Department Assessment Team (From Joda)

Leader : R K Manchanda Convener : A B Haque (Safety)

Sandvik Plant 1 & 2
Members : 1)P K Nanda
2) N. N. Giri
Fintac 540 & 570 Screen Plant 3) Manisha Mishra
4)Sanjay Das
B S Mining Equipment Garage & Rest 5)Parimal Malakar
Shelter
6)Deepak Mishra
Operations, Maintenance & 7)A K Panigrahi (Environment)
Service Functions New Office Complex
8) Sanjay Mohanty (Associates-Under Union category)
9) Rajesh Saha (Associates-Under Union category)
Old Office Complex & Store

Security Gate

Bokhna Plant

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Annexure-2: 5S & VWM AuditCriteria (1/5)

5S & VWM Audit Criteria F/TQM/24

Name of the Department -
Sections Assessed -
Assesses Present -
Date of Assessment -
Name of AIC -
Name of Assessors - Mentor: Team Leader: Team Members:
Scoring Rules for each criteria elements - Poor (20%), Fair (40%), Satisfactory (60%), Good (80%), Excellent (100%)
Areas to be covered during Assessment: Plant/ Building and Office Area, Shop floor, Equipment & Auxiliary Locations
Criteria Element Score
Criteria Check Areas Criteria Requirements Criteria elements
Score Score Obtained
Only the necessary items are present in the work area. No unnecessary and unidentified
item is lying here & there. 6
Sorting

All the necessary and identified items have a unique identification name/tag on it. 3
12

Plant/ Building and Only necessary and identified

office area, Shop materials are present at the Waste bins are available and clearly marked at the point of generation & there is an
floor, Equipment & site earmarked scrap disposal area which is evacuated on regular basis. 2
auxiliary locations
Standard process for eliminating unnecessary items exist and are being followed 1
Storage locations for all the necessary & identified items are clearly defined and marked (
including their required quantity) 2
Identified and necessary items are arranged, divided, and clearly labelled in their
designated locations and are easily accessible. 5
Plant/ Building Location for keeping the
Systematizing

identified materials are All necessary and identified items are properly protected to avoid deterioration 2
12

and office area,

Shop floor, clearly defined & marked
and all the materials are Storage and stacking of materials is always neat and placed at right angles. All the material
Equipment & 2
auxiliary locations arranged, divided and clearly stacks are aligned and not in danger of falling over.
labelled Spares, tools, materials, and products are not left to sit directly on the floor. Large items are
positioned on the floor in clearly marked areas. 1

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 Annexure-2: 5S & VWM AuditCriteria (2/5)
Criteria Element Score
Criteria Check Areas Criteria Requirements Criteria elements
Score Score Obtained
Working floors are absolutely dry and clean (The entire floor is swept properly to make it
Shining (Cleaning)

free from dust, water and oil spillages etc.) 4

Plant/ Building Neat and clean Storage containers, shelving and storage areas are clean and damage free 2
10

and office area, atmosphere is maintained

All available tools/tackles, Machines and related items are kept clean, well maintained 2
Shop floor, all across the
and damage free
Equipment & departments.
auxiliary locations Cleaning frequency for the area is well defined and followed ( ask for documents) 2
Company's/ Division's/ Department's Goals, Polies, Objectives etc. are displayed in the
prominent locations inside the shop floor so that everybody can see these. 1
Names of Building, Floor/Section, Office, equipment, Control room, Panel room, toilets,
drinking water etc. are clearly displayed. 2

Direction boards are there in the main entrance, all intersection and corridors. 2
Entry & exit points are displayed. Hazards of the area, precautions to be taken and PPE
required are displayed at each relevant entry /exit point. 3
Visual Workplace Management

Plant/ Building Good level of visual Layout of the floor is displayed at each Entry/ exit point indicating all amenities, Pathway
and office area, display is maintained all directions, Location of First Aid Box, Stretcher, safety devices etc. 2
Shop floor, across all areas Location of Emergency assembly point is clearly marked and Emergency contact numbers
22

Equipment & displayed at prominent locations. 2

auxiliary locations
Evacuation plan & rescue arrangement in case of emergency is displayed at a prominent
location. 1
Appropriate safety signage are displayed near its point of application e.g. 'unauthorized
access prohibited', 'Dos and Don'ts of the jobs' etc. 2
Proper identification mark on all the electrical panels/Switches, pipelines, Valves, gauges,
motor direction etc. 3
All the equipment control related indicators (e.g. oil level, pressure etc) and inspection
points are displayed near the equipment. 2
Communication boards are up to date and contains safety, ethics related
communications along with departmental performance, good jobs doneetc. 2

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 Annexure-2: 5S & VWM AuditCriteria (3/5)

Criteria Element Score

Criteria Check Areas Criteria Requirements Criteria elements
Score Score Obtained

All Pathways and Gangways are clearly marked and are free from any type of
obstructions 3

Illumination at all the working places is sufficient as per the defined protocols 2

Stairs are not slippery and standard handrails are installed at the required places 3

No potholes, uneven surface, extruded metallic pieces in the working floors. 3

Plant/ Building Safer Workplace with clear Area for keeping hazardous materials is clearly defined and marked 2
and office area, visibility of safety devices
Shop floor, and equipment Safety and emergency equipment are unobstructed and stored in an obvious, easy to locate
Safety & legal related requirements

manner. Safety devices are clearly marked and highly visible. 2

25

Equipment &
auxiliary locations
Walls / structures are not damaged/corroded and are properly white washed / painted. 2

All drains are well covered, there is no spillage from any drain. 2

Last date & Due date of testing and inspection are mentioned on the items where ever it is
applicable e.g. EOT crane, Vessels, tools and tackles etc. 2

First aid boxes are displayed at accessible places with descriptions written on it 2

Statutory requirements like guarding of rotating parts of machineries, No open electrical

hazards etc. are also complied where ever it is applicable 2

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 Annexure-2: 5S & VWM AuditCriteria (4/5)

Criteria Element Score

Criteria Check Areas Criteria Requirements Criteria elements
Score Score Obtained

Drinking water tap in proper / clean location & No spillage of water in the surrounding 1
area.
Amenities, Ergonomics and Environment

All the toilets are clean and there is a fixed cleaning frequency. All accessories (wash basin, 1
urinals, pots) are in proper condition.

Sufficient working bench and sitting stool are available to perform job in good ergo posture 1
Plant/ Building All basic amenities are
and office area, present and well
All working areas are ventilated, free from dust/ fumes in order to give comfort to the 1
Shop floor & maintained. Manual lifting
people.
10

auxiliary locations of heavy materials and

repetitive work by Manual and repetitive lifting of heavy parts/spares/tools do not takes place and
employees are discouraged. Appropriate equipment/tools provided for the current work activity 2

Parking place for employees vehicles is available with clear cut demarcation and no
unauthorised parking is permitted in the area 2

Greenery is well maintained around the area 2

Machine/ Equipment are free from any type of contamination (dirt, dust, grime, rubbish, 3
sludge etc.)
The basic working condition
Basic Machine

of equipment is well There are no loose/unnecessary/excess wirings/pipelines on and around the equipment
conditions

2
Equipment maintained and the machine
9

is completely free from any There are no excess lubrication oil, hydraulic oil, pneumatic, water etc. on and around the 2
kind of contamination equipment.

Critical points for daily O&M checks are clearly defined & marked and Operators are aware 2
about the daily checks

Total Score (100)

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 Annexure-2: 5S & VWM AuditCriteria (5/5)
Qualitative feedback
Best Practices & Strengths OFIs

Scoring Rules

Rating Scale Weightage Conditions

Poor 20% No evidence of implementation at the required areas

Fair 40% Some evidence but major gaps at all the required areas

Satisfactory 60% Implemented and conforming in more than 2/3rd of the areas where applicable

Good 80% Established and conforming in most areas, Only a few minor gaps remains

Excellent 100% Excellent conformance with substantial improvement activities & employee involvement

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Annexure-3: Prescriptive checklistfordeploying 5S & VWMin the departments (1/6)

SN Area/ Aspect Checklist

I On and around the Plant/ Building & Office Area

1.Designated Parking place with “its name written on it”.

I.A Parking
2.Clear-cut demarcation in the parking place for Type of vehicles, Permanent Employees/ visitors.

1.In and around area is quite green.

I.B Greenery / Aesthetics 2.Trees and lawns are kept in highly good condition.
3.Flowerpots are painted and there is no spillage/leakage of water/mud from it

1.The area is free from any type of dirt/dust.

I.C Overall cleanliness, ventilation, light 2.There is a fixed cleaning frequency for the area.
3.There is proper ventilation and lighting arrangement in the offices.

Sorting / removal of all unnecessary items. 1.There is an earmarked scrap disposal area
I.D
2.No unidentified item is lying here & there.

I.E Name & address of all required items 1.All fixed items have a unique name upon it.
2.All movable items have a name and proper address.

I.F Customers corner / park 1.Customer Corner/Park displaying the main products.
2.List of main customers, their profile etc.

1.Name of the shift office / store prominently displayed

2.All sub-stations are clearly identifiable.
Stores area, administration & shift office.
I.G 3.There are not any unidentified items kept inside.
4.In stores there are there are clear indications for the inventory level, the min. and max level
5.There is not any mixing of items.
6.There are proper arrangements of light and ventilation.

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Annexure-3: Prescriptive checklistfordeploying 5S & VWMin the departments (2/6)

SN Area/ Aspect Checklist

I On and around the Plant/ Building & Office Area

1.Building / plant name is clearly written on it.

2.Lay out of ‘that’ floor is there near the lift / staircase.
3.Direction boards are there in the main entrance, all intersection and corridors.
4.Companies Goal, Policies, Objectives are displayed in the prominent locations.
5.Name plates are there at every door
6.All the pipelines are painted in designed colours with direction of flow on them.
I.H Visual workplace management. 7.All files / folders are readily identified with short retrieval time.
8.Entry and Exit points are clearly mentioned.
9.Layout of the plant is there near the entrance.
10.Main activity board placed at the entrance showing the process flow charts details of the ongoing activities,
Organization structure etc.
11.Display of photograph of prize winner / any job well done in the main activity board.

II Shop floor

1.The entire shop floor is swept properly to make it free from dirt / dust.
II.A Overall cleanliness, ventilation, light
2.Proper arrangement is provided for ventilation and light
II.B Unidentified items 1.All items in the shop floor have a unique identification name on it.
2.All unnecessary items are removed from the shop floor.
Floor condition (slippery / dangerous) 1.Shop floor is free from any type of contamination / slippage.
II.C
2.No potholes, uneven surface, extruded metallic pieces in the shop floor.
1.Scrap / Dustbins are kept near the point of generation.
II.D Proper scrap bins without any mixing 2.Separate scrap bins for separate items. There are on any mixing.
3.On floor, the address of the scrape bin is marked.
II.E Drinking water tap 1.Drinking water tap in proper / clean location.
2.No spillage of water in the surrounding area.

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Annexure-3: Prescriptive checklistfordeploying 5S & VWMin the departments (3/6)

SN Area/ Aspect Checklist

1.Plan available to show where fire hydrants/extinguishers are locates.

II.F Fire hydrants/ extinguishers 2.Display of fire fighting equipment with their proper description and method of use.
3.There is regular audit of all fire equipment. Audit date displayed on the equipment.

1.Defined areas for hazardous materials.

2.Display of Fist Aid box in easily accessible place with the details of its contents and the name of the first aiders on it. Last audit date of First aid
box is mentioned.
II.G Safety related
3.Mirror at all the blind curves (both inside and outside of the plant).
4.Display of appropriate safety signs near its point of application.
5.Display of safety instructions for the contractors and periodic checking of their awareness.

1.All the gangway / passages marked with straight line.

II.H Gang ways 2.Any two lines intersect at 90 degrees.
3.No material kept on the gangways.

1.Companies Goals, Policies, Objectives etc. are displayed in the prominent locations inside the shop floor so that everybody can see these.
2.All the display boards are in simple and easy to understand language.
3.Display of key performance indicator near the equipment.
4.Display of Annual / Monthly Maintenance Calendar.
5.Display of area wise responsibility for 5-S activities.
6.Daily Performance Board is updated by operators.
II.I Visual work place management
7.Display of process parameters near the point of use.
8.A unique name for every item in the shop floor.
9.An address for the moving items.
10.Systematic arrangement of working tools.
11.Display of quality sample.
12.Define area for accepted defective output.

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Annexure-3: Prescriptive checklistfordeploying 5S & VWMin the departments (4/6)

SN Area/ Aspect Checklist

III Equipment
III.A Any type of contamination No dirt, dust, grime, rubbish, sludge, on the equipment and its surrounding
There are not any loose/unnecessary/excess lubrication, hydraulic, pneumatic, water, gases and electrical pipelines / connections.
III.B Loose/unnecessary/excess
wirings/pipelines

Unnecessary/unidentified item
III.C
on/ near equipment
III.D Operator desk/tool box
III.E Visual work place mgmt.
1.All subassemblies/items on/near the equipment have a unique identification name on it.
2.All unnecessary items are removing away from the equipment.
1.All the items in operators’ desk are marked properly.
2.There is a clear-cut location for each tool in the toolbox.
1.Oil level indicator for the levels.
2.Red, orange and green zones on gauges & meters for ‘Danger’, ‘Warning’ and 'Safe situation'.
3.Gauges of all pressure line – close to the point of use.
4.Transparent covers for the panels, belts to show direction.
5.Acrylic sheets (transparent doors wherever possible) to expose closed drives / rotation parts.
6.Installation of inspection holes on safety covers.
7.Provision of inspection window for critical moving part.
8.Sight glass, wherever used, are clean with high low points clearly marked and colour coded.
9.Details of proximity switches near the point of fixing.
10.Visual displays of valve positioning (green plant for closed valves, red for open and semi-circular knob valve for midway positions).
11.Visual display to indicate the open/ close positions of the duct damper and paint adequate range markings.
12.Visual display (paper fans / ribbon) near motor to see operation
13. Floats with doll mechanisms to show the flow of cooling water, coolant or any other fluid 14.Main lines and sub lines for all
utilities are marked with standard colours
15. Arrow signs on pipes to show the type and pressure of fluid direction of flow
16. All lubricator units – on and outside machines- have different colour to indicate different types of oils including on pouring conical flasks and
their direction of flow
17. Small windmills are used to indicate extraction fans and motors working
18. Match marks are provided on bolts and nuts.

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Annexure-3: Prescriptive checklistfordeploying 5S & VWMin the departments (5/6)

SN Area/ Aspect Checklist

III Equipment
15. Stickers for inspection (ear, hand, eye etc.)
16. Provision of ladders for visual inspection at heights.
17. Make up shadow boards for tools and spares so that the correct location of every item is immediately apparent. 22.voltage / current limit
indicators using flickering lights and alarms.
III.E Visual workplace mgmt. 23.Vibration toys to note abnormal vibration.
24.Temperature sensing tape / thermal paint on motors reduction gears to check for overheating.
25.Assign and display code number for processes, equipment, major sub assemblies, jigs, and tools

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Annexure-3: Prescriptive checklistfordeploying 5S & VWMin the departments (6/6)

SN Area/ Aspect Checklist

IV Auxiliary
1.All Pits / basements / cellar are absolutely dry and clean
IV.A Pits / basement / cellar 2.There is proper lightening arrangement in all Pits / basements / cellars.
3.Stairs are not slippery.

1.There is not any unidentified / unnecessary item kept in the control room
IV.B Panels / control room 2.Electrical switchboards / panels are clean with a clear-cut cleaning schedule.
3.Data sheet for each electrical switch board / panels is available near it..

Drainage systems all over 1.All drains are well covered

IV.C 2.There is no spillage from any drain.
the plant/ shop floor
3.There is a cleaning frequency for drains to avoid any foul smell

1.All items are properly protected to avoid deterioration

IV.D Tool room 2.Actual users are aware of the list and list and use it confidently.
3.List details are being applied i.e. inventory levels, location and cleaning and sorting at the frequency mentioned by the person responsible.

1.All the toilets are clean and there is a fixed cleaning frequency.
IV.E Toilets
2.Toilet doors and other accessories (wash basin, urinals, pots) are in proper condition.

IV.F Walls 1.The walls are not broken

2.Walls clean with properly white washed / painted.

1.Proper identification marks on all electrical switches / panels

2.Name the control room / tool room is written clearly on it so that it can be seen from a distance
IV.G Visuals work place 3.In tool room visual management is made to minimize the retrieval time.
management 4.On toilet doors, proper visual sign is displayed to recognise whether for ladies or gents.
5.There are not any unnecessary painting / posters any where
6.All notice boards are relevant and updated regularly.

TQM
 5S & VWM Assessment
Report –
<Name of the department>

29
TQM
 5S & Visual Workplace Management Assessment
Name of the Department:

Section(s) Assessed:
Assesses Present:
Date of Assessment:

Assessors:
Mentor:
Leader:
Members:

Aggregate Score:

TQM 30
Sorting - Score

Criteria Criteria Element Score

Criteria Check Areas Criteria elements
Score Requirements Score Obtained
No unnecessary or unidentified item is lying
8
anywhere
Plant/ Building All the necessary items have a unique identification
5
and office Only necessary name/ tag on it.
area, Shop and identified Waste bins are available and clearly marked. There
Sorting

floor, materials are are earmarked scrap disposal areas which are
20

5
Equipment & present at the evacuated on regular basis. There are no mix-up in
auxiliary site bins.
locations There is a standard process for identifying and
eliminating unnecessary items and it is being 2
followed.

TQM 31
Sorting - Observations
Pic. 1 Pic. 2

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

Observation: Observation:

Pic. 3 Pic. 4

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

If required, additional pages
can be added
Observation: Observation:

TQM 32
Systematising - Score
Score
Criteria Check Criteria Element
Criteria Criteria elements Obtain
Score Areas Requirements Score
ed
There are clearly defined and marked storage locations for all the necessary &
4
identified items (like spares, tools, products, consumables, stationeries etc.)
Identified and necessary items are arranged, labelled and kept in their
4
designated locations and are easily accessible.
There is no mix up of materials or items 2

Plant/ All necessary and identified items are properly protected to avoid deterioration 2
Building Storage and stacking of materials is safe and maintained as per relevant
Systematizing

and office Place for standards so that the retrieval of material is easy and there is no danger of 2
area, Shop everything and falling over
20

floor, everything at Spares, tools, materials, and products are not directly kept on the floor. Large
Equipment its place 2
items are kept on the floor in clearly marked areas.
& auxiliary Names of the Building, Floor/Section, Office, Equipments, Control room, Panel
locations 1
room, toilets, drinking water facility etc. are clearly displayed.
Direction board/ signages are there at the main entrance, intersections and
1
corridors.
Layout of the floor is displayed at entry/ exit points (with current location
1
mentioned)
Parking place for the vehicles of employees/visitors is available with clear
1
identification. No unauthorized parking.
TQM 33
Systematising - Observations
Pic. 1 Pic. 2

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

Observation: Observation:

Pic. 3 Pic. 4

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

If required, additional pages
can be added
Observation: Observation:

TQM 34
Shining - Score
Criteria
Criteria Element Score
Criteria Check Areas Requirement Criteria elements
Score Score Obtained
s
Working floors are clean and dry, free from dust, water
6
and oil spillages etc.
Storage areas, shelves and containers are clean and
5
damage free
Shining (Cleaning)

Plant/ Building Neat and

and office area, clean All available tools/tackles, machines and related items are
Shop floor, atmosphere kept clean, well maintained and damage free. Machines/
5
20

Equipment & is maintained Equipments are free from any type of contamination such
auxiliary all across the as dirt, dust, grime, spillage, rubbish, sludge etc.
locations department Drinking water area is clean and there is no spillage of
2
water in the surrounding area
All the toilets are clean and there is a fixed cleaning
frequency. All accessories (wash basin, urinals, pots etc.) 2
are in proper condition.

TQM 35
Shining - Observations
Pic. 1 Pic. 2

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

Observation: Observation:

Pic. 3 Pic. 4

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

If required, additional pages
can be added
Observation: Observation:

TQM 36
Basic Machine conditions - Score
Criteria Check Element Score
Criteria Criteria Requirements Criteria elements
Score Areas Score Obtained
There are no loose, unnecessary or excess wirings
3
or pipelines on and around the equipment
There is adequate lubrication at relevant places.
Basic Machine conditions

Applied lubricant is clean and there is no spillage 2

The basic condition of on machine or surrounding area.
equipment is well Nuts and Bolts are well maintained (No Slackness/
maintained and the Missing/ Crushed/ Corroded). Inspection windows 2
Equipment
15

machine is free from are marked, clear and not damaged.

any kind of
contamination Relevant markings on all the electrical
panels/Switches, pipelines, valves, gauges, 5
motors, nuts & bolts (match marking) etc.
Equipment control related markings (Operation
and Maintenance related) are displayed on or near 3
the equipment

TQM 37
Basic Machine Conditions - Observations
Pic. 1 Pic. 2

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

Observation: Observation:

Pic. 3 Pic. 4

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

If required, additional pages
can be added
Observation: Observation:

TQM 38
 Compliance to Safety Standards - Score
Criteria Check Criteria Element Score
Criteria Criteria elements
Score Areas Requirements Score Obtained
No potholes, uneven surface, extruded metallic pieces on the working floors. 3
Stairs are not slippery and standard handrails are installed at the required places 3
All drains are well covered, there is no spillage from any drain. 2
All pathways and gangways are clearly marked and are free from any type of
2
Plant/ obstructions
Compliance to Safety Standards

Building Illumination at all the working places is sufficient 2

and Emergency equipment are stored in an unobstructed, easy to locate manner. 2
Safe Walls / structures are not damaged/corroded and are properly white washed / painted. 2
office
Workplace
area, All conveyors and rotating parts of the machines are guarded 2
with clear
Shop Working areas are well ventilated and free from dust/ fumes 1
25

visibility of
floor, Area for keeping hazardous materials is clearly defined and marked 1
safety devices
Equipme Last date & due date of testing and inspection are mentioned on the items, where ever
and equipment 1
nt & applicable e.g. EOT crane, Vessels, tools and tackles, fire extinguishers etc.
auxiliary First aid boxes are kept at accessible places with descriptions and name of first aiders
1
locations written on them
Fire extinguishers are available at easily accessible places 1
Hazards of the area, precautions to be taken and PPE required are displayed at each
1
relevant entry /exit point. Emergency contact numbers displayed at prominent locations.
Appropriate safety signage are displayed near its point of application e.g. 'unauthorized
1
access prohibited', 'Dos and Don'ts of the jobs' etc.
TQM 39
Compliance to Safety Standards - Observations
Pic. 1 Pic. 2

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

Observation: Observation:

Pic. 3 Pic. 4

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

If required, additional pages
can be added
Observation: Observation:

TQM 40
Best Practices Observed (if any)
Pic. 1 Pic. 2

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

Remark: Remark:

Pic. 3 Pic. 4

Date: DD/MM/YY Location: Date: DD/MM/YY Location:

If required, additional pages
can be added
Remark: Remark:

TQM 41
Qualitative Feedback

Qualitative feedback
Best Practices & Strengths (if any): OFIs (Apart from what has been captured in
observations):
Examples:
• Kaizens for standardising 1S/ 2S/ 3S Examples:
• OPLs displayed at relevant places • Lack of awareness on 5S & VWM
• Best out of waste • Anything which couldn’t be captured through pics.
• Special practice(s) having good impact on 5S
or VWM

TQM 42
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(for internal circulationonly)

TQM