LEVEL 1

LEVEL 1 - SORT A workplace where only necessary items are located and with all the necessary tools available. No violations can be present to receive a "YES" for any category

  • FURNITURE & EQUIPMENT - Are work benches, carts, machines, equipment, cabinets, tool boxes, shelves, jigs, structures or areas which collect clutter free of unnecessary item?

  • PPE - Are all safety gloves, arm guards, safety glasses, ear plugs, aprons, etc. in area necessary?

  • DOCUMENTS - Are unauthorized / outdated instructions, visual aids, inspection forms, work instructions, etc removed from the work area?

  • FLOOR & WALK ISLES - Are floors and workstations free of unnecessary hardware, parts, paper, cardboard, metal, pens, debris, trash, etc?

  • CLEANING EQUIPMENT - Is all cleaning equipment & supplies such as rags, mops, mop buckets, brooms, dust pans, cleaning solutions, floor mats, etc. in area necessary?

  • TOOLS, FIXTURES, GAUGES, HAND TOOLS - Are only necessary tools needed to perform workstation jobs (tools, fixtures, gauges, air wrenches, hand tools) located in the area?

  • PARTS - Are only necessary parts and part containers such as color totes, wire baskets, returnable parts or containers located in the area?

  • PERSONAL ITEMS - Have all personal items such as (lunch boxes, coats, sweat shirts, newspapers, food, magazines) been removed from the work area?

  • WORKSTATIONS - Has all trash, scrap, rework containers been emptied as needed from the area?

  • WORK IN PROCESS (WIP) - Is the active shop area free of excess inventory or parts? Only necessary parts, tools, and equipment required to perform the job are present in a reasonably clean work area.

LEVEL 2

LEVEL 2 - SET IN ORDER Work place becomes visual. Necessary items have a clearly designated location and are labeled. Workstation arranged and designed for operator's ease of use. No violations can be present to receive a "YES" for any category.

  • FURNITURE AND EQUIPMENT - Are tables, containers, stationary power tools bins, racks, carts, cabinets, stationary tool boxes, shelves, structures foot printed and labeled?

  • PERSONAL PROTECTIVE EQUIPMENT - Is emergency equipment easily identified at a glance and arranged for ease of access? Is all emergency labeled and in the designated location?

  • EMERGENCY EXITS - Are emergency exits, first-aid, electrical panels and hazardous materials appropriately identified/labeled and accessible?

  • DOCUMENTATION - Are visual aids, inspection instructions, labor and osha postings, standard work combination sheets, 5S checklist etc. in a designated labeled location?

  • FLOOR & WALK AISLES - Are floors and walk aisles clearly foot printed and labeled using proper color guidelines?

  • CLEANING EQUIPMENT - Are rags, mops, mop buckets, brooms, dust pans, cleaning solutions, etc. labeled and foot printed and in the designated location?

  • TOOLS, FIXTURES, GAUGES, HAND TOOLS - Are tools, jigs, fixtures, gauges, air wrenches etc. footprinted/labeled and in designated location?

  • PARTS - Are parts in the shop labeled with part names, and part numbers and work order number? Is shelving that part containers sit on are labeled to match part container, job or tech?

  • PERSONAL ITEMS - Are personal items such as beverages in designated and labeled location?

  • INVENTORY - Do shop supplies have standard levels indicated at work station or storage cabinet or shelf with label or by right sizing of container. And, are inventory levels marked by min/max indicators where applicable?

LEVEL 3

LEVEL 3 - SHINE Areas are clean meaning free of dust, oil, dirt etc. A checklist for maintaining cleanliness with assigned responsibilities is utilized No violations can be present to receive a "YES" for any category.

  • WORK STATIONS - Are all items on work stations in proper location and are they clean? (Personal Protective Equipment (PPE), WIP containers, tools, floors, desk, carts, jigs, rework areas, etc.?

  • MACHINES, EQUIPMENT & TOOLING - Are all equipment, work benches, baskets, bins, totes, etc. clean and in their designated location?

  • MATERIAL, SUPPLIES & PARTS STORAGE - Are all shop supplies and part containers etc. clean and in their designated location?

  • TOOL BOARDS - Are all tools etc. in the designated location on the tool boards and all tools & tool boards clean?

  • OCCASIONAL TOOL USE STORAGE - Are all items on racks, benches, carts, jigs, floors, etc. in off-line storage areas clean and in their designated locations?

  • CABINETS, SHELVING - Are cabinets, files clean and in their designated location?

  • INVENTORY STORAGE AREAS SUCH AS STAGING AREAS, MATERIAL HOLDING AREAS AND QUALITY DEFECT HOLDING AREAS - Are inventory storage areas such as staging areas, material holding areas and warranty holding areas/items clean and in their designated location?

  • INFORMATION - Is all posted information on performance boards, talk time boards, communication boards, std. work, combination sheets, current, clean and in the right location?

  • TRAINING AREA - Is the tech training area orderly, with all necessary materials and supplies?

  • SAFETY AND QUALITY RELATED CONTROLS - Have visual aids for appropriate safety and quality concerns been documented visually?

LEVEL 4

LEVEL 4 - STANDARDIZE Levels 1, 2, 3 have created "normal" and are maintained throughout the shift. Level 4 is eliminating the need for frequency No violations can be present to receive a "YES" for any category.

  • WORK SURFACES, WORK STATIONS, SUB STATIONS AND FLOORS - Have ideas or devices been installed to prevent work surfaces, work stations, sub stations and floors from becoming unorganized, messy or dirty?

  • MACHINES, EQUIPMENT, FURNITURE, TOOLING, ETC. - Have ideas or devices been installed to prevent machines, equipment, furniture, tooling, etc. from becoming unorganized, messy or dirty?

  • INVENTORIES & WIP AREAS - Have ideas or devices been implemented to prevent on-line inventories & WIP areas from becoming unorganized, messy or dirty?

  • TOOL BOARDS, SHELVING, & CABINETS - Have ideas or devices been implemented to prevent these areas from becoming unorganized, messy or dirty?

  • PERSONAL ITEMS - Have ideas or devices been implemented to prevent these areas from becoming unorganized, messy or dirty?

LEVEL 5

LEVEL 5 - SUSTAIN Sustaining 5S levels 1-4 No violations can be present to receive a "YES" for any category.

  • Have 5S audits been completed per weekly for 3 straight months?

  • Have posted counter measures been completed on time?

  • VISUAL CONTROL - Can all unnecessary items be distinguished at a glance?

  • Can all employees clearly articulate the 5S objectives of the area?

END

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